REPAIR MANUAL 2012 | ammo 125 Duke EU 125 Duke DE 200 Duke EU Art. no. 3206127enINTRODUCTION 1 ‘ad this repair manual carefully and thorovarly be work 1 vehicle will only be able te meet the denands placed on it the saecitied service 1h 's performed regulerly and properly We reserve to ake changes inthe i ing this Tan We shall no prow de @ descr pt or of gereral workstop methods. likew se, safety rules that apply in @ workshop are not specif ed here Ie is assumed that :he rep work wll be perfored by 2 fully rained mechanic G sp erica reasons, :o adept ular medel without prcr netce, KTM accepts no lability for delivery misprints ard ocher erors, The models portrayed partly contain spe ape of supply Al specications are con-bind ng, KTM Spert motor tions, arices,colrs,f these fo local craitens, 25 well as to sop preduct en ofp apt ons, deviat ens from illustrations and descriptions, as wel hat does not belorg tothe ly reserves the right to med fy or delete tech 12 KTW-Sport moter All ighss reserved Rearodul owner 180 9001112 100 6062) ding to the in fen Austra tothe maximu Issued by: TOY Wt KTM-Sportotoreycle AG 30 Matlighofen, AustraTABLE OF CONTENTS 1 MEANS OF 2EPRESENTATION 6 Li Symbdls used 6 1 6 2 8 7 2.1 Repair Manual 7 22 Safety adi ce 7 23 sk and sym ? 2a 7 3. IMPORTANT NOTES 8 2.1 Guarantee, warrenty s 32 nd euxilary substances, 8 33 fe parts, accessories 5s 24 Fours 8 4 SERIAL NUMBERS: 8 al ss cumberitype 8 42 Key number 9 43 Engine rumber 8 5 MOTORCYCLE 10 Raising the motorcycle with the rear wheel 2 ereyele aff of the rear wheel cle with the front whee! Taking the metoreyce aff of tre front wheel stand) le with the work stand le from the work stand Starting. Starting the metercycle to make checks 6 FORK, TRIPLE CLAMP 6.1 Clearing the dust boos ofthe fork legs. 6.2 ReTovrg fork less 63 Installing she for Disassembling the fork legs Checking the fork les, Assembling the frk Removing the loner =r ple elemp Inscalling the lower a Check rg the steer Adjust ng the sca 7 MANOLEBAR, CONTROL TL Checking the pay in 7.2 Adjusting tre play 7.3 Checking he clute 7A Adjustiog the clutel 8 SHOCK ABSORBER, SWINGARM 82 Ie oad 8 “4 8 8 9 9.1 Removing the exraus: manifold Inscalling he exaust ~anifold Remewrg the main silencer Insualling he main silen 10 Ala FILTER 0.1 Removirg the air iter 10.2 Installing she a filter. ANK, SEAT, TRIM Opening the Fle 2 Closing tre filler cap 3. Remov ng the seat A Meurting the sea 5 Removing the 8 9 Moursing the p Removing the fuel tark cover Insvalirg te fuel t2rk Removing the fuel tank alg the fuel tark Removing the fron: spoiler Ft rg font spies Chang re the fuel fer L117. Replecirg the fuel pump WHEELS 12] Check ng the Ure alr pressure 12.2 Checking the tre congit on 123 Checking the brake discs. 24 Hon whee 12.4.1 Removing the font wheel 12.4.2 Irsalling the frort whee 2.43 Removing *he brake dsc ofthe front brake 12.44 _ Installing the brake d's of the front brake 12.5 Rear whee! 12.5.1 Removing the rear whee! 2.5.2 Iestalling the reat wheel 1253 2 he on rear brake 12.54 Installing the brake dsc of the rear brake 12.5.5 Checking the crain tersion 12.5.6 — Adjusting the chain tension 12.5.7 Check ng the che n, rear sprockel, 2nd engine sprocket 22.58 leaning th 125.9 Grecking the rar Pub rubber dampers WIRING HARNFSS, BATTERY. 18.1. Remouing the battery 18.2 _Instalirg the battery 133 Disconnecting the negat ve cable of the battery 18.4 Reconnecting the regative cable of the a 18.5. Rechargng the battery 135 Checking the charging voltage 137 1g the fuses of irividual sumers BRAKE SYSTEM 14, ching the fror: brake lin gs 14.2 Changrg the front brake linings 14.3 Checking the brake fluid level ofthe font 14.4 Adding frort brake flu 14.5 Changing the front brake fluid 14.5 Checking the rear brake ln nas 4.7 Changirg the reer brake linings 24.8 Checking the tr of foo: brake lever 14.9 Adjusting the free cravel of the foot brake fluid levelTABLE OF CONTENTS rear brake fluid 2 ing the rer brake uid 73 15. LIGHTING SYSTEM, INSTRUMENTS 75 8.1 Setting kilometers er miles 78 Ajesting the shift speed RPM L re Adjesting tne shi speed RPM 2 78 Setsing the time 76 Reselting the service interval display 76 Checkirg the headlight seting. 6 Adjusting the headliar: range " CChenging the parking light bul, 78, CChenging the Peadiigh: bulb 9 16 ENGINE 8 16.1 Removing the erg al 16.2 Installing he engine Ba 16.3. Dsessemblirg tre engine a9 163.1 Preparat ons (128 Duke) 88 16.3.2 Drainrg the engine 0! (126 Duke) ao 1633 hain securing au de (128 59 16.3.4 Removing the vale cover (126 Duke) 90 16.3.5 Removing the soark plug 90 263.6 Removing the clutch 0 16.3.7 Setting the engine to ignition top deed n 163.8 a1 16.3.9 Removing the tim ng chain tens one Duke} i the carshatt (1 the ing the pistor (126 Qube ing the water pump wheel (125, Removing the rotor (125 Duke) Removing the starter drive (128 Duke) he balancer sraf drive wheel 9a Removing the alterrator cover (126 Duke)... $5 96 ke) ing the gear posto ser (125 ing he spacer (125 Duke) Removing shee Removing the prim Removing the oil ump (2 Removing the shift staf (125 Removing the sift drum loca Duke} 200 Removing the lacking Rerevin Duke} Removing the shift als (126 Dekel Removing the shift drum (125 Duke} Removing the sift forks (125 Duke} Removing the transriss.on shatts ( Duke} Removing the balarcer shaft (125 Duke) Removing the crankshaf: (28 Duke) Preparat ors (200 Duke) re the engine o! (200 Duke) ing the chain securing guide (200, ye cover (200 Duke)... 104 3 he spark plug (200 Quke) 104 ing the vivich cover (200 Duke) ..... 104 16.3.40 Setting tre engine to ignition top deed ccerzer (200 Duke) Rerroving he starter motor (200 Duke Rerrov ng she iming chain tensioner (260 Duke} 163.43 Rerozing the camshaf: (200 Duke} 16.3.44 Removing the cylinder head (200 Duke} 16.345 Removing the pistor (200 Duke} 163.46 Removing the water pump wheel (200, Duke} 08 163.47 Removng the alleraser cover (200 Duke} 26.348. Reroving the rotor (200 Du 16.349 Reroving the slarer drve (200 Duke}... 120 163.50 Removing the balancer staf: drive wheel (200 Duke} no Rerroving the gear position sensor (200 uke} Re he epacer (200 Duke} 1 Removing the clu:ch Removing the pr rary gear ( ‘ovng the cil purnp (200 Dul Reroving he left ergire Duke} Rerraving the shift rails (200 Duke) ‘oung the shift crum (200 Duke) Rerroving the shift forks (200 Duke) Removing the ransriss.en shafts (200 Duke) 116 Removing the bslancer shaft (200 Duke)... 117 Removing the crarkshaft (200 Dukeb...... 117 k on ind dual parts ur? Work or the left section of the ergre 82 (200 uy 1642 1643 : 164e 19 645 16.4.6 ranging the 16.4.7 hanging the balancer shaft Dukel 1648 Charging re Duke} 16.49 Work or theo Checking :h Duke)... 124 oslinder (125 164.13 Gheckingimeasuring tne pistor Duke} 125 16.4.14 Crecking the 9 ston‘eyl rder re. cleararce (-25 Juke). 126 16.4.1 Grecking the oil pump (125 Duked 126TABLE OF CONTENTS Mont 2 cooeahcht bear na (204 ° 16.524 16.438 Werk onthe cylinder nead (200 Deke) 16.439. Crecking th jr head (200 Duke)... 144 164.40 Creckinglmeasuring the cylinder (200 Duke} 144 16.4.1 Checking the Duke} 148 164.42. heckingimeasuring tne pister (200 Duk 145 6.443. Checking the p stonleyl cder mourting clearance (200 Duke} 146 16.533 16.444 Checking the 01 pump (200 Duke) 146 1653 164.45 Checking the ell pressure regulator value (200 Dike} 146 16.535 164.46 Checking the clutch (200 Duke) up 6.5.36 16.441 Preassembling the clutch {200 Dy 148 l653r 16.448 Check ng the shift echanism (200 Duke} 149 16.538 164.89 senbling the shit sheft (200 Duke)... 160 165.39 Disassembling the main shaft (200 16.540 Duke} ip541 Dismantling zhe countershatt (200 Duke). recking the transmiss.on (200 Duke. Assenbl rg the "ain shaft (200 Duke) Assembling the counters 10 Duke 16.4.89 Checking she s ming essembly (260 Duke} 6645 Chang ng the ator (200 Duke) 165.46 6.4.57 Checking the electric starter deve (200 16.547 Duke} 16.548 16.4.58 Checking the reewee! (200 Duke) 165.49 lestalling tre sh ft forks (125 uke) lestalling the sh ft drum (225 Duke) lestallng tne shit ails (12 Duked ling the left 92 (125 lestalling the ail iter (128 Duke) lestalling the lacking lever (125 Duke) lestalling tre sh ft drum locating (128 Duke} lestalling the shift shaft (£25 Qube} lestalling tne oil amp (228 Duke) lestalling the primary gear (125 Duke), lestalling the clutch cage (228 Duke) (128 Duke} lestalling the gear pos “on sensor (125 Duke} Iestalling the balancer shaft deve wheel (128 Duke} Iestallig the starter dive (125 Duke) lestallng tne rotor (125 Duke) lestallng tne alternator cover (128 Duke) lstalling te water pump cover (125 Duke} ng the pston (225 Dekel lestalling the cylinder head (225 Duke) lestalling the i528 Duked lestallng tre t rng chain tens cner (125 Duke} Adjusting the val Iestalling the st lestalling the clutch cover ( lestalling the sparkplug (125 Iestalling the valve cover ( Iestalling the lestallng ire balancer shaft (200 Duke) lestalling the trarsmission Duke} lestalling tne shi forks (209 Duke} lestallng the shit: drum (200 Duked lestalling the shif: rails (200 Dul Iestalling the left engine case (200 Duke} lesta ithe ol ficer (200 Duke) the lacking lever (200 Duke) ing the shift drum locating (200 lestalling tre sh ft sraft (200 Duke} lestalling te oil pump (200 Duke lestalling the primary gear (200 Duke} lestalling the clu:ch cage (200 Duke) lestalling tne spacer (200 Duke)TABLE OF CONTENTS 5 26.5.50 Installing the gear pos ion sensor (200 23 stone 212 che a0 232 Storage 2:2 lrsaling te balancer shat deve wheal 23.2 reoarng lor vse alter storage 212 (200 bu 24 SERVICE SCHEDU: 2 trstal 24.. Servce sted 2 Irstalg the rot (200 Duke 26. WIRING DIAGRAM 2a Install g the altemator 25.1 Page Lof8 2a Irstaling he water pump 252 Pate 2018 2 Duke) ; 253 Pape 30f8 2 Urstaling the pista (200 Duke) 25.4 Page 40h 8 2 trstalrg the eylincer read (200 Duke) 285 aye 508 2 ee 2 tre 7 25.6 608 224 rs ap DBP Pate 70 2 258 Pape Bol 8 26 SUBSTANCES Crecki leararce (200 Duke)... 188 Ausra ce 200 uke) «1882 aupiLnay SUBSTANCES Irstal the clutch cover (200 Duke) 1gg 28. SPECIAL TOOLS Italo the sat lg 200 Dae ze Sianoanos ist (200 Duke ° Ital the chen searing aide 200 bute) 230 Italie i seeen 200 De). 180 Reroung the egne ror the engre sen sand 000 ule 17 SHIFT MEGHAN 17. Adising te sit er 18 WATER PUP, COOLiNe sVSTEM Draining he celert Fingeedg ie cog en is tere and alan eel» 198 Cesk te cat 5 19 Lueelention sisrew SI aie o Chek re ene pessice o Chang ng the angire ol ard il fer, clear ng the ol creer 19.5 Addog engine il 20. IGNITION SYSTEM 20.1 Alternator - checking the stator wrcing 21 TESHNICAL nr 21. 125 Duke 212 200 duke 21.3 Engine tolerance, wear | mits LBL 125 due 2132 200 duke 21.4 Engine tightening torques. DLS Capec ties 2181 Engrecil 2182 oi 218 216 21? sen, 218 sak 21.10 Shock absorber 2 tighten og tora 207 22.0) ROTEGTIVE TREATMENT 22.1 Cleaning the ratrcyele 222 Checks and mainerance steps for winter ion 21 MEANS OF REPRESENTATION 6 AA Symbols used The meaning of specific synbols 's described below, lon (eg ofa work siep or foncsony an unexpected rt ion fe.g. of 2 werk step er a furctior) Pa Ingicates a page relererce (rrore informa cn is provided on the specified page) Indicates information with mare details cr tps Incicates the result ofa testing step. wi Derotes a voltage measurement w Denotes a curent measurement The typographical formats used in this deeu'nent are expleinad below Proprietary name Teerates 3 propre nae Name® Identifies 2 protected name, Brand Identifies @ trademark2 SAFETY ADVICE 7 2A Repair Manual Read this Repair Manual cavelully and thoroveiy before begin rg work, It contairs useful infermation and tins hat wil help you reper ard ma ntain your veh cle This ‘ranval essumres thatthe necess 1y spec al KTM tools and KTM workplace are workshop equ amet ate avalable A numberof sefety instructions need to be flawed to operate the vehicle safely. Therefore, read this anual carefully. The setety instruct ors are hgrlighed vthe cext and are refered :9 atthe relevant passages. = Info The vehicle has varous formation and watrirg labels 2t prominer: locations. Do not rerneve infermaticnl they are missing, you of others may rt recogrize dangers and 7ay therefore be injred. Danger Identifies a danger that will media janine labels. It od iveriably lead to fatal or ser'ous permanent injury i Warning Identifies a danger at is kely to lead #0 fatal o serious injury if the appropriate mesures ar not Saker. ao Identifies a danger that ay lead to minor injuries if the appropriate nessures are not Note Idersiies a danger thet will ead‘ considerable machine and “aterial damage ifthe appropriate measures are nat ‘aken, Warning Iersifies a danger at wl lead to environ rental damage i he appropriate meesures are not ‘aken. ‘Special tools are necessary for certain tasks. The tools are not cor‘ained in the vehicle but can be erdered under the number in peren- theses. & 2: beerng puller (15112017000) Durirg assembly, con-reusable parts (e.g sell-locking screws and nuts, seals and sel rings, O-ings, pins, lock washers) must be faciurer instructions for use “ust be falloned. them for damage and wear, Change damaged or warn pars, ofthe ‘ter dszssembly, clear she pars tate ob ler you complete tre repair or service nork she ooeratng3 IMPORTANT NOTES 8 BL Guarantee, warranty The work prescrited inthe service schedule must be cetried out by an authorized KTM workshop orly ard confirmed in the customer's service record and nm “heKTM dealer.net ctreraise all warrarsy clams will be vows. Ne warrarty claims car be corsidered for camage result ng fron "manipulations ardor alterations to the veh cle Additional nfermation on the guarantee or watran'y ard she procedures invclued car be four inthe sere ce record Warning Environmental hazard Improper handling of fuel isa darger isthe env ronment ‘= De notallow fuel to get into the ground water, the ground, o the sewage system Use the operating and aviilary substances (suchas fuel ard lube canis} as specif ed in the manual Only use spare pars and accessories approved arclor recommended ty KTM, KTM accepts no lablity fr o:her produe's ard ary result na damage or loss The current KTM PowerParts for your vehicle can be fourd on the KTM website Incernatonal KTM Website: htpwww.ktr.com The figures cantzined in the marual may depict special equipment In the ircerest of clary, some components may be shown d sessembled ar may nat ‘semi the comporer lo perform the activly in queston, Please fallow the stu4 — SERIAL NUMBERS 8 irber @ is tayped on the right ofthe steering hes @ ison she right of the Trae behind the steering hes The Hey rumber @. | =—=—0 = Info | ANI DH You need the key rumber to order pla be found ar the KEYCODECARD. se hey. Keog the KEYCODECARD in = e075 The engine number @ is stav)ped or the left side sprocke! f the engine under the engine5 MOTORCYCLE 10 ‘5.1 Raising the motoreyele withthe rearwheel stand Note Danger of damage The parked vehicle = Always place the veticle on a firn and ev ‘Adapter Rear wheel stand (6202905 = Stand the motorcycle upright, a adapters, an It the 2505513011 p. 285) 400) (Fp. 235) he wreel star wh the link frk ane the Note Danger of damage The parked vehicle may roll anay or fall over place the veticle on a firm and even surface. = Secure tre motoreycle aga st 1 — Rerrove the rear wheel stand and lear the veh cle or the side stand @, e 4 pert of the wheel Note Danger of damage The parked vehicle may toll anay or fall over, = _Always place she vehicle on a firm and even surface Preparatory work = Rase the m Condition = le withthe rear wheel stand. (Fp. 20} ove cap ©.5 MOTORCYCLE 1" 8 gear ‘0 54 Note Danger of damage The parke = Always place the vel Taking the motorcycle off of the front wheel stand vehicle may rll anay or fll 0 en sur cnafirna = Mount ea 5.5 Raising the motorcycle with the work stand Note Danger of damage The parke vehicle may roll anay or fall oer Always place the vehicle ana firm and even surface fhe veh ele = Mourt spec al tool @ on she right s Tard Ooe2oSSOOO > p 2ET5 MOTORCYCLE 12 = Mourt s cial tool @ on the left side of the veticle Wark stara (25200500001 (% p. 236) sition the motoreycle upright, elign the specal tool ard reise the motorcycle o1ae10 Note Danger of damage The parked vehicle may roll anay or fall over - Al a firm and even surface. place the vec! = Secure the motorcycle aga rst falling over = Remove special tool @ Danger Danger of poisoning Extaust gases are nic ard irralirg them oray result n unconscieusress ardor death tres suf ve exhaust exracton system = Wren running he engine, aluays rake ventlatin, and do nat stator run the engire in an enclesed space witha are my om Danger of accidents If the vehicle's operated with a d scharged battery o without a batter, electrer'c components ard sete equipment may be demened = Never operate the vehicle with 2 discharged battery or w thout 2 battery Note Engine failure Unf lieve airhas a negative effec he sence life ofthe engre. = Never ride the vehicle without an air Fler since dust and wit can get into the engine ard resull in inoreased weer, Note Engine failure High ergire spe n cole eng a negative effect on the service life ofthe engi. = Always wer up at lw engine s5 MOTORCYCLE OQ} ® 0732-10 13 Sion thew Turn the er ‘wich tothe position ©. ‘Sw tch on the ignition by turning the ignition key 1% Alter you swtch on the ignitan, you two seconds. The furcton test ofthe combinal on instrument Shift gear te neutral 1 The green idling speed indicator lame Nig Press the elec er buiten@. 1d, and move up all the way. he position ©. fel pup working oral ural mf Info De not press the electric s nation rstrumert is fin When ster’ eg, OO NOT} slang procedure, fuel and the engire Press te starter for @ maxim of before ty 8 een the function est ofthe combi T you open the tnotle dering the d by the eng re managerert gysien nds, Wait fora least § seconds = ransmiss on is in nevital or tor seg fine sie stands ld a lease the clutch, the engine stops, Danger Danger of poisoning Extavsi eahaust usress ardor death ye ventlation, and do nt run the engive in an enclosed tater for a maximum of 8 seconds, Wal for @ OQ} ® eoo7e2.20 Turn the en he ignition by turnrg the ignition key zo the position ©. Press the electric starter button ®. = Info Do not open the title6 — FORK, TRIPLE CLAMP 4 6.1 Gleaning the dust hoots ofthe forklegs A Push dus: baot @ of both fork les cow wards, Info Bo The ous les from the fork tubes. Over Lime, dirt can penetrate behird the dust boats, If this drt is not recoved, the oil Sea's ber nd can start to leak A Waring Danger af ancidents Reduced brah brake disc = Always keep she brake discs free af ol and grees, an he cleaner niien necessary = Clean and oll the dust boots and innar fork tube of bath fork le Taw = Press the dus: boots back into tre normal os = Remove excess cil ToT spray p22) Preparatory work = Rase the otoceycle withthe work stand, (@ p. 11) = Tie the rear of th denn, = Dismount the fer: fender, (© p. 47) Main wark = Reniove seraus @ = Press back the brak Vent brake d se, Pull she retully ore side = Info fr when the brake cal er has been renow De not pull the had b 1s © ered sorew ©. = Unsoren screw @ abavt sk urns and press your hand or the sera whee! sp ndle out ofthe ade clamp, Remove screw -—@ Warning Danger of accidents. Resuced uraking ds sen by camaged brake the wheel Gown ic suet 2 way that the brake diss are the wh Take the front wheel out of ole binder and heng the wheel speed sersr to are sd,6 — FORK, TRIPLE CLAMP 18 = Loosen soraws @. Rernove the fork legs from the bottom iy ne Danger of accidents Mocificatons tothe suspens en sett ngs can seriously alter the vehicle's ride behavior = Following modifications ride slowly a Ft :o get the feel of the new ri Main wark = Push the fo the tople clamps. = Align the fork egs in the required pes ior using the fork rings = Tighter screw @, eli Sa nS TING FD J] - Fully tgnter screns @. Guideline Seren, bation ple Garp Te Position che wheel speed sersor. Mount and t ghter screws ©. ieline Fe ie ann Bee6 FORK, TRIPLE CLAMP = Mour ‘a pressure point The brake = Fullytighten screw @. deli sleigh 16 Spindle = Lift the front fork, postion tard srt the wreel spindle, deli Mont weal sp ale ne 25 Nm (8.4 tot = Position the treke cal pers ard check thatthe brake linings a weeily = Mourt screws @ bu do rot tighten ted until the brake linings are in contact wth Tron brave cal Tote 243 1 Fxation of ad the rear of 1 motoreycle fre the front brake ard com legs siaighten. = Tiahten screws @ Guideline Screw, Fak sub rr rT Te 64 Finishing wark = Intell Front fender p. 47) Disassembling the fork legs operat ors are the s Jn both fork eps Condition he fork lags have been remrved, a of the lo ak leg in the Clampre sand TOLOSH™ p24 POLED6 — FORK, TRIPLE CLAMP Empty the Devaeh the Info Unclamp ark il wth the fork tut, outer tube from the iprer tube ne inner tube, Drain the ol we the screw cap6 — FORK, TRIPLE CLAMP 18 ring ®. Info The lock ring rer can be appl 2018 = Remove seal ring @ Remove support ring @. h ust fall out af tube ona a n board Y Sire bushing ® 1 - i pois:s.20 6.5 Checking the fork legs Condition he fork lags have a 20186.6 — FORK, TRIPLE CLAMP 19 Charge the fork Measure the run-aut of the inner tube Measure the outside diameter of the inver tube in several places Exernal diameter f iver tube 975, 48.005 wm (1 69193 16981) ry + WF the measured value ig less than the specified value Ru-out of nner ube ©020 nm EOOOTI NT Cha ge the fork leg 2cKs50 op k the euter tude for damane. It Garrage ' found: Change the fork leg, = Gheck the surface of the slicing bushings. IF the dark layer @ is worn = Charge the fork Ifthe measured velue is greater tran the specif ed valve fork eg Preparatory work = Creck the fork lees. (7 p. 18) Main wark =" Clamp in the inner ‘ube with the axe clam Guideline P Use soi js Grease and slide or dust boo a Tobrean TST Info We always charge tne dust boot, ook Install the dust boot with the sean werd I rg, ard support rig. wlip ard spring exparder Fac re down6 FORK, TRIPLE CLAMP Slide on lock ring @, de or seal ring @. 20 Lobrean SLD = Info Mount w ch the sealing ip f2cirg down and the oper s de facing up. Slide on suppor: ring ©. Sand the edges of s ding bushing @ w th 600- drive (SO TPSOBOGOOI I p. 2407 = Renove wasrer ®, Remove steer ng head bearing ®. = Re ce the lower tr clamp with t lamp Main wark = Ob s, check for damage, ard - th the steering stem = Mourt washer @ with the cut-out facing dossnsard Alternative 1 Arew steering head bearing is used. = Mount and tighten the nut ®, Guideline Mat, searing Pe Nm (37 Itt) Case nul wach G01 750501 OF Altomnatve 2 The steering head bearing is used again = fount and tighten the nut ®, greet ¥ Sm GFA6 — FORK, TRIPLE CLAMP 2 Caste nul ore mop aa) = Positir the upper tr ple clamp wh the handlebar sher but do not Lighten it ye. Tie BON (38.4 bor TINn BIE = Plug r conrectors @ ard @, = Plug r conrecters ® and ®.6 — FORK, TRIPLE CLAMP 25 Fold the headligh ask up. = Mourt and sighen Guideline ‘Sereu_ hezdlaht mask We Tne A Mount expanding rivets ® on tot Testall te fork (pl Using a pleste he Tighten screw ®, er tap lightly en the upper triple elem to evo strain Guideline ‘Screw, top Seerng heed G2Nm (38.4 bor 1) Tighten sa Guideline Seren, op wiple damp cE Tele AT Finishing work =. Check thatthe wiring Ireedor of moven = Check ng head bearing lay. (* p. 25) dt pL a ine Danger of accidents Uns ile handlieg from = Adjust the steering Feed bearing play withcut del. = Remove the matoreycle from the werk Info th play 1 the steering head bearing, the bea Proparatory work = Raise the motorcycle with the werk Main wark = Move the handlebar to che sira ght hes ot ron the ciection af trax abe he steering head bear t = Adjust tre play of the steering nese bear ng. (Fp. 26) Move the hardletar to and fo over the artire ove easy over the ene Seer iceable,6 — FORK, TRIPLE CLAMP 26 click positions are naiceable = Adjust the play of the steerng nese bear ng. (Fp. 26) = Check the steering heed bearing and change if necessary Finishing work = Rerrove the motoreyele from the work stand. ¢% p. 1 Preparatory work ~ Raise the “otoreycle withthe work stand. (Fp. 11) Main wark sen serous @, = Loosen serew @ = Tighter nut © withthe special tool until there ro play inthe s ing, Ke Ser ng Fed bearing (501: OOOH p. 240) = Using plastic hammer, tap lightly er the upper triple clamp to = Tighter screw @. Guideline ‘Screw, top Seerng heed CON 8.4 tof ty = Tighter sew @. Guideline Seren, led m7 cE Finishing work = Check the steering heed bearing play. ( p. 251 e the motoreycle from the work stand. ¢® p. 12}7 HANDLEBAR, CONTROLS 2 ‘TA Checking the playinthe twatle cable = Check the throttle gr p for smeoth operation — Move the handlebar tothe ss gh-ahead pusition, Move she th wards and forwards to ascer y the thratle cable wearin Troe cable play Sn ommia02 a e throttle = Adjust the play in the throttle le play does not mee: sp ble. (p27) Danger 200392.10 Danger of poisoning Exhau in urcenseiousness andor des*h = When runring the engine, alvays make sure there is sufficient verve ton, anc do nt startorrun tre engine in an enclosed space w thout an effect ve extaus: extract on svster, — Siar he engine and let ¢run idle, Move the handlebar to ard fro over the entire steering ra The idle speed must More the handlebar to the straighter Push beck le sen tek nut @ = Agius the play she thot cable ty tring adjusting scren ©. videtine rote cable ley asa O12 027 = Tiahten lock @. = Side on sleeve the clutch lever for smooth operation, = Move the hardlebar tothe sa ght-ahe: ascertain the clutch Clutch lever play Td mm 04, O12 in) + Wthecluteh lever = Adjust the clutch cal position. Lightly pull the cluteh lever ions Note Clutch damage If there is no pley on the cl the clutch will beg ta sip = When operating the motoreyele, always check the clutch Fever play = Move the Pardlebar fo and fo over ing range The eloch lever pl ‘Ua nol charge + [the clutch lever play changes = Check the rout ng of the clut7 HANDLEBAR, CONTROLS 28 e Pust tack s nut @. Adjust the play in the cluch level @ by turning adjusting sciew ©.8 SHOCK ABSORBER, SWINGARM 29 8.1 Adjusting the spring preload of the shock absorber Warning. By sangerotaccitents ovat on he susgonson se res can serusy ae side bebavion = Following modifications ride slowly at frst :o get the feel of the new ride bet Info The spring preload defines the in Jal situation of the spring process on the shock atsorber The best spring preload seting ig ach eved when its set for tre neigh of the r der and that of ary bageage and a passenger, thus ersuring 21 Geal compromise between aneuverabil'y ard stabil y — Ture adjusting rng @ to adjust the spring preload. Guideline ‘Spring preload Slander Fall payload Bclicks Hi conch (TTO6SH p. 2417 = Info The spring preload can be set to 20 different postions Preparatory work = Raise the rotor Main nat = Re le with the work stand. (© p. 11) Info Proveet the link fork 2 Ersure thatthe chain and brake | re re na tachments from = Renove fiting @ — Lift the link fork ar sake out the shock absorber @ toward the rear Main wark = Lifs the link fork snd position sheck abseroer @ = Mourt fiting © but do rot tighter ye Guideline Fiting, bottom shock absorber TOE sw (33.2 bot ft)8 SHOCK ABSORBER, SWINGARM 30 = Lift the link fork = Mount and tighten screw . Guideline ‘Screw top shock absorber WoL 25 ONT (35.5 tet = Tighter Pting ®. Guideline iting, bolton shock a WOK 25 Wm (33.2 tot ft) Finishing work = Rerrove the motoreyele from the work stand. (& pL Condition The shock absorber has been removed = Clamp the stack aasorber in the vise usrg soft jaws for pretect en. = Note the position of tre spring preload = Looser adjusting ring @ Hook wrench (11065106 p. 241) = Clamp the stack absorber inte the special too ‘Spring cornpressor (TLAOBOS) I p 242) = Info Use the ring of she special tool with the smallest poss ble inside @ameter. IL mustbe pressed d rectly arto the spring, = Sonpresthe re = Rereve spring eta rer®, = Release te spring Reravet = Remove the spire 85 Instalingthe spring = Mout the spring shack absorber from the spec al tool A The ight col of the spring atthe bottom. Clap the shock absorber into the special tool ‘Spring compressor (ILAOSOS) (ep 2A2) = Info Use the ring of she special tool with the sna must be pressed d actly ara the sper 9. 7 The open eres oppeste the Release she spring. Remave the skack absorker fom the spee’al tel. = Clamp the stack aasarber in the vise using soft jaws for protect on, lest possible inside Gamer, It Mount sori8 SHOCK ABSORBER, SWINGARM 3 Alternative 1 ‘= Tersion tre spring ‘othe prescribed pesitior by turing the adjusting rg ieline Spring preload Sianda Full Hook wrench (TT Altemative 2 i ne Danger of a cushy alte we 29 EXHAUST 32 my ne Danger of buns The ice is driven hot components or forward slighly ‘ove the cable binder, expose the corrector @ of the lambda probe, and = Reove lambada sensor ®, = Remove te culs ©.33 ve tre exhaust man fold toward th frort sition the exhaust manifold nt nuts @ but da ot tighten hem ye Guideline Tit, exvaust Nange (128 Duke} 1 ZN (262 bor it, exhaust any 18 Onna 1 ZN (6.2 or 5 ‘Mount and tighten lamb Guideline Tair Wigs Lubre: Plug in connector @. Secure the cable with the cable pincers,9 EXHAUST a4 Nut, reciator We ERIERAEG) Proparatory work wen = Remove the front spe le Mai = Ri = Remove © Info Bde not mse coward the bottom,9 EXHAUST 35 Main ark =. Position the main slencer = Mount end vighten screw @. Guideline ‘Serou, Tain STeneer ua 2am AT eT = Mount and tighten screw @ with the ‘Séerew main slencer = Mount and tight Guideline ew © with the washers ‘Serou an Sener rg SLR Finishing wark = Fithe front spoler (p46) = Irstal the exhaust manifold. OF p. 310 AIR FILTER 36 1O.4__-Removingthe aifite Note Engine failure Unf lied intake air has @ negative effec: 0 ehicle without an air flr since dust and wit can get into the engine ard resull in inoreased weer he service life af the engi. Proparatory work riferrove the passenger seat. p. 38) = Remove the se Main wark =. Renove st = Pull the air ft tothe sde = Revove ar titer @. =. Clean the air filter box Main mark Pesivon ar flier @, Mount air fter bax tid Info Moke sure he air iter box Id seated comectly, = Moor Guideline air flte bow i tighten screws EN a Tata Finishing work = Mourt tne seat (© p, 38) = Mourt the passenger seat. p. 38)11. FUEL TANK, SEAT, TRIM 3 Danger Fire hazard Fuel s ghly flanirable es or burning cigarettes, and always snitch off tre orgie frst, Be careful that no miparenis, Clear up spilt fuel mrmeciatey scage ifthe ark severed, Si fuel s spilt, especially = Fuel nthe fuel tank Warning Danger of poisoning Fuel spo'sorevs and 2 health hazard — Avoid contact between fuel and skin, ees and clothing. 90 not inhale ately wth water and contact a doctor, Wash affected skin areas mired tacts doctor mmediztely, Change cletrirg that fas come inta carta to regulations and heep it out of tre reach of ds when warm and c he notes or refueling Warning Environmental hazard. I proper handling of fuel is und water, the ground, of the sew ger te the environment em = De not allow fuel to get ito the a = Lift she cover @ of the Tiller cap and inser the ign ian key in the Note Danger of damage Ignition key breskeze sh dow on the filler cap = To the pressure off of the igrtion key tion keys must be replaced = Turn the ignition bey 90° clockwise = Open the Filer cap, = Remove the grtion bey, Warning Fire hazard. Fuel s highly lanmadle, po soraus ard harmful te your health = When closing the filer clothing that came in came contact fuel using soap and water the filler cap. = Push down the Filer cap until the lock engages. Preparatory work = Remove the passenger seat. (7p. 28) Main wark = Reniove seraus @, = Raise the rear of the seat, pull towards the rear, and renow it uowards11. FUEL TANK, SEAT, TRIM 38 11.4 Mounting the seat Main wark =. Flech seat recesses ® 2 = Mourt ard tighten screws 2s @ and loner at the ue Nas Finishing wark = Mourt the passenger seat. 1% p, 38) 11.5 Removing the passenger seat 11.6 Mounting the passenger seat 16 @ on the subframe, ard lower it rte place Warning Danger of accidents. The p from the anchoring if tis not mounted conectly = Alter ne check that i is locked correctly ay pulling u - heck th ns 11.7 Removing the fuel tank cover Danger Fre hazard Fue = Never tes, and always snitch off the engine fist. Be careful the fuel s spil up spilt fuel mediately. = Fuel nth warm ard can escape ifthe tark overt he nates or refueling11. FUEL TANK, SEAT, TRIM 39 Warning Danger of poisoning Fuel s po'sorevs and 2 health haard = Avoid contact between fuel and skin, eyes and clothing, Do rot inhale fuel vapors. If fuel ges into youre ately with water and contact @ docter. Wash affected shin areas med ‘ely wth scap ard water, If felis swallow Cra tact with fuel. Stoe fue in 2 suitable car ster a es, rinse immed facta docior mediately. Crange clotirg that has cone to regulations and heep it out of tre reach of Warning Environmental hazard. Iproper handling of felis @darger to the eneonmert = De not allow fuel to get to the ground water, the ground, oF the sewage sytem, Preparatory work = Remove the passenger seat. (% p, 28) Remove the seat. (€ p. 37) Create the tool (special screw) Four ordinary serevs are needed = Curl sere © to length @, Tena ® a0 nm 1167 = Cute slot nto the top end of she screw, ind dually and replace therm with a spe 01d distorting the fue lark. and tighten spec e. ier another special screw @.11 FUEL TANK, SEAT, TRIM 40 = Remove screw ®. Mount and tighter anather special screw @, = Open the filler cap. p 37) = Renove filer cap ©, Fy — Remove screws © with the washers — Renove seraus ©, = Remove screws @, = Remove cap @ fram the compensating tank — Renove seraus ©,11. FUEL TANK, SEAT, TRIM a Lift the fuel zank cover. = Detach the side c oF beth sides = Push back pose clamp ® = Pulloff she ven: hose = Remove the fuel tank cover = Close the fuel tank with 2 su table plug Danger Fie hazard Fuel s ghly llavwrable fe ergire first, Be careful that no Up spilt fuel me escape ifthe tank s overt 2 he nates or refueling Warning Danger of poisoning Fuel + po sorces and @ health hacer — Avoid contact between fuel and skin, ees and clothing. 90 not inhale ately wth mater and contact a doctor, Wash al lect doctor mmediazely, Crange clo to regulstions and keep it out of tre swallowed, com riser according Warning Environmental hazard. Ieproper handling of fuel is = De net allow fuel tc get ito the ground Main wark =. Remove the slug11. FUEL TANK, SEAT, TRIM 2 Position the fuel tank cover Attach the side cover on both sides = Mourt ane sighten screws @, Guideline Reva nr Sores, Chassis We sna eT — Mourt filer cap © ce then with serene @. a serons © inciv dually and 1 Info HL stways replace the serews rd vidually, or the fuel tank wil di il the screws, be possible 9 0 Thm BTL11. FUEL TANK, SEAT, TRIM “3 = Mount plug@ = Mourt ane sighten screws @ with the washer. Guideline ‘Screw foal tk We TINn eID = Mourt ane sighten screws: Guideline ‘Sereu, fal anki Me in (8.7 AD = Mourt and sighien screws. Guideline ‘Screw, ont seat Dine NG SAT Finishing wark = Mourt tne seat, (* p, 38) = Mourt the passenger sest. IF p. 38) Danger Fire hazard Fuel 9 ghly flavwrable = Never refuel the vetile n fees spilt, csp =r flmes or bucring cigarettes, and elways sm ally on hot veh cle compocents, Clean up spill fuel rmmeiately ff tre engine first. Be = Fual rhe fuel tank expards wher ifthe ark soverfled, See she nates or refueling. Warning Danger of poisoning Fuel po soreus and 5, rinse immedi: aly wth sosp ard water I uel is swallow with fuel, Slow feel in 2 Warning Environmental hazard proper handling of fuel is a darger to the env ronmart = De not alow Fuel to get ito the ground water, the ground, or the sewepe system, Preparatory work — "Remove the passenger seat. (* p, 28) = Remove she seat. (Fp. 37) = Remeve the fuel tank co (9. 38)11. FUEL TANK, SEAT, TRIM 4 Main nark = Renove screws @, = Toke off the holder ©. = Detach eo Dezzeh the fuel line with 2 suitable tool = Push ba Pol off the and rerove the fuel tark11. FUEL TANK, SEAT, TRIM 45 Danger Fire hazard Fuel s ghly flanirable - hi g fuel s pil cle comparents, Clean up spilt fuel rrmecively. = Fuel inthe fuel tank expargs wher warm and can escape ifthe tark ‘ overfilled, See Warning TA vance cf poisoning. Fuels posorausan Sh hazard = Avoid contact between fuel ang skin, eyes and eleshing. 90 ately wth water and contact a doctor, Wash alfecied skin areas tacts doctor mmedizcely, Change cletrirg th has come inta cart to regulations and keep it out of the resch of ch laren. Warning Environmental hazard. [proper hand! = De not alow fuel to get ito th environment of fuel isa darger to und water, the ground, or the som, Main wark = Connee the fue = Pesiton hose clarp @, Remove tool ©, Plug in con ition the fuel tank on the haluer @,11. FUEL TANK, SEAT, TRIM 46 Mourt ane sighten serens @, w tighten sorens @, Guideline EFL conch ui wa Tm BAT Finishing work = Irstal he fuel tank cover. (% p. 41) = Mourt tne seat. (© p, 38) onger seat. (Fp, 38)11. FUEL TANK, SEAT, TRIM a = Mount We tighten screws Guideline Reran rg se ei, NESS i DONT TAIT = Higher screw @, Guideline Reman rg screws, chasse ne DONA aI A Remove sorews @, Remove the front fender Positios the font ferder. Maur Guideline tighten sex ‘Screw front fender Me TIN (G1 FR) Danger Fre hazard Fue mes or burning cigarettes, and always svitch ol snporens. Clear up spilt fuel mrmeciately ‘ds wher warm ard can escape ifthe tark ‘overfill, S fe ergire first, Be careul that no = Fuel in the fuel tank he notes or refueling Warning Danger of poisoning Fuel s po'sarous and = healt — Avoid contact between fuel and skin, eyes and clothing, Do rot inhale fuel v2 ately wth mater and contact 2 doctor. Wash affected shin areas mired tact doctor mmediztely, Crange cloth that has cone into carta lo regulations and keep il out of the reach of cil acer pors, I fuel gets into your eyes, rinse immedi wth scap ard water. If fel 1s swall with fue, Sto fe! i Condition The fuel ‘ank s completely full. Ersure thal the battery vllage does he gnsior sch The diagnostics tools connected drop below11. FUEL TANK, SEAT, TRIM Sout Derzeh the fi Push back Fos re with 2 suiteble tol 1p @ er pull eff the fuel ire Mourt spec al tool @, 48 Pressure testing 0 som Tp 228) Mourt spee al teal © with nozzle ea Testing fox Guideline Minima TOMe5 US eh Sw teh the ignition rol unit"Motranik Bosc Press "Continue Select "Actuator test "Please entr the passwort" Press "Continue" Solect Fuel pump relay function test Press "Contin! Te che KT dagr wth "Continue" Guideline the information page and he actuator test Mex doalion ot acum test [3mm vel pressure wah the filler ca ro hen the fuel pump ac © bar 36 >If the specification is nat rezched: nthe fille cap. (7 p. 37) = Check the tank air vert system, (Check the fuel pressure withthe filler cap open, Foal press When the fuel pump is active Ifthe spes fication snot reached = Check tat the fuel lie el = Change the fuel fe: (p43) = Replace the fuel pun. (© p. jop he "Function test of fue! pump contr" 2 ton, Dsmantle the special to test by pressing uit" but11. FUEL TANK, SEAT, TRIM 49 = Gonneet the fuel Hine and ps = Remove the to Danger Fire hazard Fuel 9 ghly flavwrable 1 oper = Never refuel the mes or burr 5, and always sv fe ergire first, Be careful that no i ‘ot ven cle conparents, Clean up spilt uel mmediately = Fuel she fuel tank expar if the tark s overfiled. See the nates or refueling, Warning Danger of poisoning Fuel spo sorvs and 2 health hazard — Avoid contact between fuel and skin, ees and clothing. Do rot inhale fuel ately with water and contact a doctor. Wash alfecie skin areas mired ately w ths lect doctor mmediately, Ci has come into cartac: with fuel, Stow (vel i lo reguletions and kes Warning Environmental hazard. Improper handing of fuel is a darger to the env ronmrt = Be net allow fuel to get ito the ground water, tre ground, or the sewage system. Preparatory work = Remove the passenger seat. (* p, 28) = Remove she seat. (7 p. 37) = Remove the fuel tank cover. (% p, 38) = Dismount the fuel tank. p. 43) = Drain the Main mark = Toke fuel fier @ out of the holder uel from the fuel k into a suitable co 3018871 Remove hese clamp @ ard pull eff the fuel hose11. FUEL TANK, SEAT, TRIM 50 sition the fue flter Connection @ faces tothe lef = Positian the fuel roses and mount nos = Position hose clans ©. co fuel filter @ ir che holder o1aa Finishing work = Irstall te fuel tark.(% p. 49) = Irstal he fuel tank cover. (& p. 42) = Move! the seat. p, 38) Mourt the passenger sest. p. 38) Danger Fire hazard Fuel sh ehly flee = Never refuel fuel s spilt, esp = Ful he fuel tank exp igarettes, and zluay miporents. Clear up spilt fuel or is wher warm ard can escape ifthe ‘ark s verflled, See the notes or refueling off tre engine fist, Be careful thet no my ee Danger of poisoning Fuel s po-sorcus and = health hazard = Avoid contact between fuel a ately wth mater and contact 2 doctor. Wi lect doctor medi lo regulations and keep it out of hing. Do rot inhale fuel vapors. If fuel ges into your eyes, rinse immed shin areas miredataly wth scap ard water. If fuel 1s svalicu nie into cartact with fuel, Store Warning Environmental hazard Improper handling of fuel is @ danger te the = De not allow fuel to get ito the aroun Preparatory work = Remove the passenger seat. (* p, 38) = Remove the seat. (® p. 37) Remove the fuel tank cover. (& p, 38) = Dismount the fuel tank. (% p.4 = Dain the fuel from the fuel rk into a suitable container. Main ark = Rens 5@, = Remeve the fuel pum with 301939.11 FUEL TANK, SEAT, TRIM 0180, pump with the ns @ ered tighten them di 51 Slat Ter Finishing work = Irstall te fuel tark.(% p. 49) = Testa he fuel tank cov seat. ( p38) = Move! th = Mourt tre p (p42) LU p38)12 WHEELS 52 4124 Cheeking the tie airpressue = Info Low tre a pressure leads to abnorral wear ard overheating of he tre Correct Ure ar pressure ersures optimal rid rg cerfor: ard trax rum tre service life eRe, Front ear Gas Bos Tre ar pressure with passennerul pay Front ps Rear (SZ esi = lie tre air o ions = Correct t Mount the dus: cap, Warning. Danger of accidents Uncontrollable vehicle Farag in the event ofa flat tie = Ie the interest of safety, replace damaged er worn tires immediately Warning Danger of crashing Por vehicle handling dve te different sire tread patterns on front and rear wheels loss of cor‘ol over the vehicle = The froot ard rear wheels must be fitted with tres with sim lar ‘read lems to p Warning Danger af accidents Uncon‘olletle handling characrarstic dus to nan approved andlor non-racem™ended *resiwheals = oniy Ihe eorrespor ding speed index should be used Info Do the type Worn tires ye @ major impact. on the riding behavior of pecially ar wet surfaces we motorcycle = Check the front ard rea ties for cu + Ifthe tres exhibit cuts, run-in obj = Change the tres = Chack the depth ofthe tread rur-in objects ard ether damage or other damage: Info Note local nat onal regulations cancer ng sonia Minimo we2d deh 22 em @ OORT) 1d depth 6 less than the eminrrum permissible depth re te bres Info The tre's date of the manufacture is usually part of the tre markings and is ingicares by the last four dgits of the DOT marking, The fist two digs refer tothe week of manvizccure and last two digits reer to the year of manufas KTM recommends thatthe atthe lates after 5 years, 3 are chenged regardless of the actual weer,12 WHEELS 33 + Mathes more tha years old = Change the tres i ine Danger of accidents Resi.ced braking eff ciancy due to worn orake vise) = Charge the worn brake disols) wthout delay. = Check the thickness ofthe fron: ard reer brake discs al s lo see if confers to messurement @. I places or the disk = Info Wear reduces the th ckness oft @ of the brake disc ake dis in ar Brake dies weer It Ze nm O12 Bem (0.192 95 ig lass than the sei ed value = Change the brake discs, hack the font and rear brake discs fa » I the brake dso shows signs of dara the brake crackirg, and deformation, cracking, or deformation = Changs cs 12.4.1 Removing the front whee! Preparatory work = Raise the metoroycle wit the rear wreel stand. (Fp. 10) = Raise the ‘otereycle with the font wheel stand. p. 10) Main wark = Loosen screw @ and serens ®. © 2bout si turns and press your hand or the serew to push the = Unseren sox ‘wheel spirale out of the axle clap, Remove screw @, Warning Danger of accidents Reduced braking ef ed by damaged brake discs = Always lay the wheel dow in such 2 way thatthe brake dses are not ores. damaged. the wheel spre. Take the font wheel eut of = Hold the fort wheel, withar the fork Info BE be not pull the hand wher the front wheel is eeneved 12.4.2 _ Installing the front whi i rine Danger of accidents Reduced traking efficiency due weil ora = Al beep the brake d ses fee of ol and grease, end clean ther wh brake cleaner wh