KTM 390 Duke 2013 Owner's Manual
REPAIR MANUAL 2013
390 Duke 2014 COL
390 Duke EU
390 Duke AUS
390 Duke MAL
Art. no. 3206167en
INTRODUCTION 1
INTRODUCTION
It is important that you read this repair manual carefully and completely before the start of work.
This vehicle can only fulfill the demands placed on it in the long run if the specified service work is performed regularly by qualified
experts.
The repair manual was written to correspond to the most current state of this model series. We reserve the right to make changes in
the interest of technical advancement without, at the same time, updating this repair manual.
We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop are not specified here.
It is assumed that repair work will be performed by a fully trained mechanic.
All specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical 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 misprints and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of supply.
© 2013 KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright
owner.
ISO 9001(12 100 6061)
According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead
to the maximum possible quality of the products.
Issued by: TÜV Management Service
KTM-Sportmotorcycle AG
5230 Mattighofen, Austria
TABLE OF CONTENTS 2
TABLEOF CONTENTS
1 MEANS OF REPRESENTATION ..................................... 5
1.1 Symbols used ................................................... 5
1.2 Formats used.................................................... 5
2 SAFETY ADVICE........................................................... 6
2.1 Repair Manual .................................................. 6
2.2 Safety advice .................................................... 6
2.3 Degrees of risk and symbols............................... 6
2.4 Work rules ........................................................ 6
3 IMPORTANT INFORMATION ......................................... 7
3.1 Guarantee, warranty .......................................... 7
3.2 Operating and auxiliary substances ..................... 7
3.3 Spare parts, accessories .................................... 7
3.4 Figures ............................................................ 7
4 SERIAL NUMBERS ...................................................... 8
4.1 Chassis number/type label ................................. 8
4.2 Key number...................................................... 8
4.3 Engine number ................................................. 8
5 MOTORCYCLE ............................................................. 9
5.1 Raising the motorcycle with the rear wheel
stand ............................................................... 9
5.2 Taking the motorcycle off of the rear wheel
stand ............................................................... 9
5.3 Raising the motorcycle with the front wheel
stand ............................................................... 9
5.4 Taking the motorcycle off of the front wheel
stand ............................................................. 10
5.5 Raising the motorcycle with the work stand ....... 10
5.6 Removing the motorcycle from the work stand ... 11
5.7 Starting.......................................................... 12
5.8 Starting the motorcycle to make checks ............ 13
6 FORK, TRIPLE CLAMP ............................................... 14
6.1 Cleaning the dust boots of the fork legs............. 14
6.2 Removing fork legs.......................................... 14
6.3 Installing the fork legs ..................................... 15
6.4 Disassembling the fork legs.............................. 16
6.5 Checking the fork legs ..................................... 18
6.6 Assembling the fork legs.................................. 19
6.7 Removing the lower triple clamp....................... 21
6.8 Installing the lower triple clamp ....................... 23
6.9 Checking the steering head bearing play............ 26
6.10 Adjusting the steering head bearing play ........... 26
7 HANDLEBAR, CONTROLS........................................... 28
7.1 Checking the play in the throttle cable.............. 28
7.2 Adjusting the play in the throttle cable.............. 28
7.3 Checking the clutch lever play.......................... 28
7.4 Adjusting the clutch cable play ........................ 29
8 SHOCK ABSORBER, SWINGARM ................................ 30
8.1 Adjusting the spring preload of the shock
absorber......................................................... 30
8.2 Removing the shock absorber ........................... 30
8.3 Installing the shock absorber............................ 30
8.4 Removing the spring........................................ 31
8.5 Installing the spring ........................................ 31
9 EXHAUST.................................................................. 33
9.1 Removing the exhaust manifold........................ 33
9.2 Installing the exhaust manifold ........................ 34
9.3 Removing the main silencer ............................. 35
9.4 Installing the main silencer.............................. 36
10 AIR FILTER ............................................................... 37
10.1 Removing the air filter ..................................... 37
10.2 Installing the air filter...................................... 37
11 FUEL TANK, SEAT, TRIM ........................................... 38
11.1 Opening the filler cap...................................... 38
11.2 Closing the filler cap ....................................... 38
11.3 Removing the seat .......................................... 38
11.4 Mounting the seat........................................... 39
11.5 Removing the passenger seat ........................... 39
11.6 Mounting the passenger seat............................ 39
11.7 Removing the fuel tank cover ........................... 39
11.8 Installing the fuel tank cover............................ 42
11.9 Removing the fuel tank.................................... 44
11.10 Installing the fuel tank .................................... 45
11.11 Removing the front spoiler ............................... 47
11.12 Fitting front spoiler ......................................... 47
11.13 Dismounting the front fender ........................... 48
11.14 Installing the front fender ................................ 48
11.15 Checking the fuel pressure............................... 48
11.16 Changing the fuel filter.................................... 49
11.17 Replacing the fuel pump ................................. 51
12 WHEELS ................................................................... 52
12.1 Checking the tire air pressure........................... 52
12.2 Checking the tire condition .............................. 52
12.3 Checking the brake discs ................................. 53
12.4 Front wheel .................................................... 53
12.4.1 Removing the front wheel ............................ 53
12.4.2 Installing the front wheel ............................. 53
12.4.3 Removing the brake disc of the front brake.... 54
12.4.4 Installing the brake disc of the front brake .... 54
12.5 Rear wheel ..................................................... 55
12.5.1 Removing the rear wheel ............................. 55
12.5.2 Installing the rear wheel .............................. 55
12.5.3 Removing the brake disc of the rear brake ..... 56
12.5.4 Installing the brake disc of the rear brake...... 56
12.5.5 Checking the chain tension.......................... 57
12.5.6 Adjusting the chain tension ......................... 57
12.5.7 Checking the chain, rear sprocket, and
engine sprocket .......................................... 58
12.5.8 Cleaning the chain...................................... 59
12.5.9 Checking the rear hub rubber dampers.......... 60
13 WIRING HARNESS, BATTERY..................................... 61
13.1 Removing the battery ...................................... 61
13.2 Installing the battery ....................................... 61
13.3 Disconnecting the negative cable of the
battery ........................................................... 62
13.4 Reconnecting the negative cable of the
battery ........................................................... 62
13.5 Recharging the battery .................................... 62
13.6 Checking the charging voltage .......................... 63
13.7 Changing the fuses of individual power
consumers...................................................... 64
14 BRAKE SYSTEM ........................................................ 65
14.1 Checking the front brake linings ....................... 65
14.2 Changing the front brake linings....................... 65
14.3 Checking the brake fluid level of the front
brake ............................................................. 67
14.4 Adding front brake fluid................................... 67
14.5 Changing the front brake fluid.......................... 68
14.6 Checking the rear brake linings ........................ 69
14.7 Changing the rear brake linings ........................ 70
14.8 Checking the free travel of foot brake lever ........ 71
14.9 Adjusting the free travel of the foot brake
lever .............................................................. 72
14.10 Checking the rear brake fluid level.................... 72
TABLE OF CONTENTS 3
14.11 Adding rear brake fluid .................................... 73
14.12 Changing the rear brake fluid ........................... 73
15 LIGHTING SYSTEM, INSTRUMENTS ........................... 75
15.1 Setting kilometers or miles............................... 75
15.2 Adjusting the shift speed RPM 1 ...................... 75
15.3 Adjusting the shift speed RPM 2 ...................... 75
15.4 Setting the time.............................................. 76
15.5 Resetting the service interval display ................ 76
15.6 Checking the headlight setting ......................... 76
15.7 Adjusting the headlight range........................... 77
15.8 Changing the parking light bulb........................ 78
15.9 Changing the headlight bulb ............................ 79
16 ENGINE .................................................................... 81
16.1 Removing the engine....................................... 81
16.2 Installing the engine........................................ 85
16.3 Disassembling the engine ................................ 90
16.3.1 Preparations............................................... 90
16.3.2 Draining the engine oil ................................ 90
16.3.3 Removing the chain securing guide .............. 90
16.3.4 Removing the valve cover............................. 91
16.3.5 Removing the spark plug ............................. 91
16.3.6 Removing the clutch cover........................... 91
16.3.7 Setting the engine to ignition top dead
center........................................................ 92
16.3.8 Removing the timing chain tensioner............ 93
16.3.9 Removing the camshaft............................... 93
16.3.10 Removing the cylinder head ......................... 94
16.3.11 Removing the piston ................................... 95
16.3.12 Removing the starter motor.......................... 95
16.3.13 Removing the timing chain .......................... 95
16.3.14 Removing the water pump wheel .................. 96
16.3.15 Removing the alternator cover ...................... 96
16.3.16 Removing the rotor...................................... 97
16.3.17 Removing the starter drive ........................... 97
16.3.18 Removing the balancer shaft drive wheel....... 98
16.3.19 Removing the gear position sensor................ 98
16.3.20 Removing the suction pump......................... 99
16.3.21 Removing the spacer................................. 100
16.3.22 Removing the clutch cage.......................... 100
16.3.23 Removing the primary gear ........................ 101
16.3.24 Removing the force pump.......................... 102
16.3.25 Removing the shift shaft............................ 103
16.3.26 Removing the shift drum locating............... 103
16.3.27 Removing the locking lever ........................ 103
16.3.28 Removing the oil filter ............................... 103
16.3.29 Removing the left engine case.................... 104
16.3.30 Removing the shift rails............................. 105
16.3.31 Removing the shift drum ........................... 105
16.3.32 Removing the shift forks............................ 106
16.3.33 Removing the transmission shafts............... 106
16.3.34 Removing the balancer shaft...................... 106
16.3.35 Removing the crankshaft ........................... 106
16.4 Work on individual parts ................................ 107
16.4.1 Work on the left section of the engine
case ........................................................ 107
16.4.2 Work on the right section of the engine
case ........................................................ 108
16.4.3 Changing the shaft seal ring of the water
pump ...................................................... 108
16.4.4 Checking the radial play of the lower
conrod bearing ......................................... 109
16.4.5 Changing the conrod bearing...................... 110
16.4.6 Changing the balancer shaft bearing........... 111
16.4.7 Work on the cylinder head ......................... 112
16.4.8 Checking the cylinder head........................ 113
16.4.9 Checking the pivot point of the
camshafts ................................................ 113
16.4.10 Checking/measuring the cylinder................ 114
16.4.11 Checking the piston ring end gap ............... 114
16.4.12 Checking/measuring the piston................... 115
16.4.13 Checking the piston/cylinder mounting
clearance ................................................. 115
16.4.14 Checking the oil pump .............................. 115
16.4.15 Checking the oil pressure regulator valve..... 116
16.4.16 Checking the clutch .................................. 117
16.4.17 Checking the shift mechanism ................... 118
16.4.18 Preassembling the shift shaft ..................... 119
16.4.19 Disassembling the main shaft .................... 119
16.4.20 Dismantling the countershaft ..................... 120
16.4.21 Checking the transmission......................... 120
16.4.22 Assembling the main shaft......................... 121
16.4.23 Assembling the countershaft...................... 122
16.4.24 Checking the timing assembly.................... 124
16.4.25 Changing the stator................................... 124
16.4.26 Checking the electric starter drive .............. 125
16.4.27 Checking the freewheel ............................. 126
16.5 Assembling the engine .................................. 126
16.5.1 Installing the crankshaft............................ 126
16.5.2 Installing the balancer shaft....................... 126
16.5.3 Installing the transmission shafts ............... 127
16.5.4 Installing the shift forks............................. 127
16.5.5 Installing the shift drum ............................ 127
16.5.6 Installing the shift rails ............................. 127
16.5.7 Installing the left engine case .................... 128
16.5.8 Installing the oil filter................................ 129
16.5.9 Installing the locking lever ......................... 129
16.5.10 Installing the shift drum locating................ 130
16.5.11 Installing the shift shaft ............................ 130
16.5.12 Installing the oil pump .............................. 130
16.5.13 Installing the primary gear ......................... 131
16.5.14 Installing the clutch cage .......................... 132
16.5.15 Installing the spacer.................................. 133
16.5.16 Installing the suction pump ....................... 134
16.5.17 Installing the gear position sensor .............. 135
16.5.18 Installing the balancer shaft drive wheel ..... 135
16.5.19 Installing the starter drive.......................... 136
16.5.20 Installing the rotor .................................... 137
16.5.21 Installing the alternator cover..................... 137
16.5.22 Installing the water pump cover.................. 137
16.5.23 Installing the timing chain ......................... 138
16.5.24 Installing the starter motor......................... 138
16.5.25 Installing the piston .................................. 138
16.5.26 Installing the cylinder head........................ 140
16.5.27 Installing the camshafts ............................ 141
16.5.28 Installing the timing chain tensioner........... 141
16.5.29 Checking the valve clearance ..................... 142
16.5.30 Adjusting the valve clearance ..................... 143
16.5.31 Installing the clutch cover ......................... 143
16.5.32 Installing the spark plug ............................ 144
16.5.33 Installing the valve cover ........................... 144
16.5.34 Installing the chain securing guide ............. 145
16.5.35 Installing the oil screen ............................. 145
16.5.36 Removing the engine from the engine
assembly stand......................................... 146
TABLE OF CONTENTS 4
17 SHIFT MECHANISM ................................................. 147
17.1 Adjusting the shift lever................................. 147
18 WATER PUMP, COOLING SYSTEM ............................ 148
18.1 Draining the coolant...................................... 148
18.2 Filling/bleeding the cooling system ................. 148
18.3 Checking the antifreeze and coolant level ........ 149
18.4 Checking the coolant level ............................. 150
19 LUBRICATION SYSTEM............................................ 152
19.1 Oil circuit..................................................... 152
19.2 Checking the engine oil level.......................... 152
19.3 Checking the engine oil pressure .................... 152
19.4 Changing the engine oil and oil filter,
cleaning the oil screen................................... 154
19.5 Adding engine oil.......................................... 155
20 IGNITION SYSTEM................................................... 156
20.1 Alternator - checking the stator winding .......... 156
21 TECHNICAL DATA.................................................... 157
21.1 Engine ......................................................... 157
21.2 Engine tolerance, wear limits ......................... 157
21.3 Engine tightening torques .............................. 158
21.4 Capacities .................................................... 159
21.4.1 Engine oil ................................................ 159
21.4.2 Coolant.................................................... 159
21.4.3 Fuel ........................................................ 159
21.5 Chassis ........................................................ 159
21.6 Electrical system........................................... 160
21.7 Tires............................................................ 160
21.8 Fork............................................................. 160
21.9 Shock absorber ............................................. 160
21.10 Chassis tightening torques ............................. 161
22 CLEANING/PROTECTIVE TREATMENT....................... 163
22.1 Cleaning the motorcycle ................................ 163
22.2 Checks and maintenance steps for winter
operation...................................................... 164
23 STORAGE................................................................ 165
23.1 Storage ........................................................ 165
23.2 Preparing for use after storage........................ 165
24 SERVICE SCHEDULE ............................................... 166
24.1 Service schedule........................................... 166
25 WIRING DIAGRAM ................................................... 168
25.1 Page 1 of 9 .................................................. 168
25.2 Page 2 of 9 .................................................. 170
25.3 Page 3 of 9 .................................................. 172
25.4 Page 4 of 9 .................................................. 174
25.5 Page 5 of 9 .................................................. 176
25.6 Page 6 of 9 .................................................. 178
25.7 Page 7 of 9 .................................................. 180
25.8 Page 8 of 9 .................................................. 182
25.9 Page 9 of 9 .................................................. 184
26 SUBSTANCES ......................................................... 186
27 AUXILIARY SUBSTANCES ........................................ 187
28 SPECIAL TOOLS ...................................................... 189
29 STANDARDS ........................................................... 198
INDEX ............................................................................ 199
1 MEANS OF REPRESENTATION 5
1.1 Symbols used
The meaning of specific symbols is described below.
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).
Indicates a page reference (more information is provided on the specified page).
Indicates information with more details or tips.
Indicates the result of a testing step.
Denotes a voltage measurement.
Denotes a current measurement.
Denotes a resistance measurement.
1.2 Formats used
The typographical formats used in this document are explained below.
Proprietary name Identifies a proprietary name.
®
Name
Brand™ Identifies a trademark.
Identifies a protected name.
2 SAFETY ADVICE 6
2.1 Repair Manual
Read this Repair Manual carefully and thoroughly before beginning work. It contains useful information and tips that will help you
repair and maintain your vehicle.
This manual assumes that the necessary special KTM tools and KTM workplace and workshop equipment are available.
2.2 Safety advice
A number of safety instructions need to be followed to operate the vehicle safely. Therefore, read this manual carefully. The safety
instructions are highlighted in the text and are referred to at the relevant passages.
Info
The vehicle has various information and warning labels at prominent locations. Do not remove information/warning labels. If
they are missing, you or others may not recognize dangers and may therefore be injured.
2.3 Degrees of risk and symbols
Danger
Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures
are not taken.
Warning
Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.
Caution
Identifies a danger that may lead to minor injuries if the appropriate measures are not taken.
Note
Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.
Warning
Identifies a danger that will lead to environmental damage if the appropriate measures are not taken.
2.4 Work rules
Special tools are necessary for certain tasks. The tools are not contained in the vehicle but can be ordered under the number in parentheses. E.g.: bearing puller (15112017000)
During assembly, non-reusable parts (e.g. self-locking screws and nuts, seals and seal rings, O-rings, pins, lock washers) must be
replaced by new parts.
In some instances, a thread locker (e.g. Loctite®) is required. The manufacturer instructions for use must be followed.
After disassembly, clean the parts that are to be reused and check them for damage and wear. Change damaged or worn parts.
After you complete the repair or service work, check the operating safety of the vehicle.
3 IMPORTANT INFORMATION 7
3.1 Guarantee, warranty
The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's
Service & Warranty Booklet and in the KTM dealer.net; otherwise, all warranty claims will be void. No warranty claims can be considered for damage resulting from manipulations and/or alterations to the vehicle.
Additional information on the guarantee or warranty and the procedures involved can be found in the Service & Warranty Booklet.
3.2 Operating and auxiliary substances
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to get into the ground water, the ground, or the sewage system.
Use the operating and auxiliary substances (such as fuel and lubricants) as specified in the manual.
3.3 Spare parts, accessories
Only use spare parts and accessories approved and/or recommended by KTM. KTM accepts no liability for other products and any
resulting damage or loss.
The current KTM PowerParts for your vehicle can be found on the KTM website.
International KTM Website: http://www.ktm.com
3.4 Figures
The figures contained in the manual may depict special equipment.
In the interest of clarity, some components may be shown disassembled or may not be shown at all. It is not always necessary to disassemble the component to perform the activity in question. Please follow the instructions in the text.
4 SERIAL NUMBERS 8
4.1 Chassis number/type label
The chassis number 1 is stamped on the right of the steering head.
The type label 2 is on the right of the frame behind the steering head.
101877-10
4.2 Key number
The key number 1 can be found on the KEYCODECARD.
Info
You need the key number to order a spare key. Keep the KEYCODECARD in a safe
place.
4.3 Engine number
B00755-10
The engine number 1 is stamped on the left side of the engine under the engine
sprocket.
101876-10
5 MOTORCYCLE 9
5.1 Raising the motorcycle with the rear wheel stand
Note
Danger of damage The parked vehicle may roll away or fall over.
– Always place the vehicle on a firm and even surface.
– Mount the support of the wheel stand.
– Insert the adapter in the rear wheel stand.
Adapter (61029055130) ( p. 190)
Rear wheel stand (61029055400) ( p. 191)
– Stand the motorcycle upright, align the lifting gear with the swingarm and the
adapters, and lift the motorcycle.
B01387-01
5.2 Taking the motorcycle off of the rear wheel stand
Note
Danger of damage The parked vehicle may roll away or fall over.
– Always place the vehicle on a firm and even surface.
– Secure the motorcycle against falling over.
– Remove the rear wheel stand and lean the vehicle on the side stand 1.
– Remove the support of the wheel stand.
101884-10
5.3 Raising the motorcycle with the front wheel stand
Note
Danger of damage The parked vehicle may roll away or fall over.
– Always place the vehicle on a firm and even surface.
Preparatory work
– Raise the motorcycle with the rear wheel stand. ( p. 9)
Condition
– Remove cap 1.
101887-10
5 MOTORCYCLE 10
– Move the handlebar to the straight-ahead position. Attach the lifting gear to the
steering stem.
Adapter (61029955620) ( p. 191)
Front wheel stand (61029055500) ( p. 191)
Info
Always raise the rear of the motorcycle first.
101888-01
– Raise the front of the motorcycle.
5.4 Taking the motorcycle off of the front wheel stand
Note
Danger of damage The parked vehicle may roll away or fall over.
– Always place the vehicle on a firm and even surface.
– Secure the motorcycle against falling over.
– Remove the front wheel stand.
101889-01
– Mount cap 1.
101887-10
5.5 Raising the motorcycle with the work stand
Note
Danger of damage The parked vehicle may roll away or fall over.
– Always place the vehicle on a firm and even surface.
– Remove screw 1.
308227-10
5 MOTORCYCLE 11
– Mount special tool 2 on the right side of the vehicle.
Work stand (62529055000) ( p. 192)
308228-10
– Remove screw 3.
308229-10
– Mount special tool 2 on the left side of the vehicle.
Work stand (62529055000) ( p. 192)
308230-10
– Position the motorcycle upright, align the special tool and raise the motorcycle.
308231-10
5.6 Removing the motorcycle from the work stand
Note
Danger of damage The parked vehicle may roll away or fall over.
– Always place the vehicle on a firm and even surface.
– Secure the motorcycle against falling over.
– Remove special tool 1.
308231-11
5 MOTORCYCLE 12
– Mount and tighten screws 23.
Guideline
Screw, engine bearer on frame M8 30 Nm
(22.1 lbf ft)
308232-10
5.7 Starting
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death.
– When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed
space without an effective exhaust extraction system.
Caution
Danger of accidents If the vehicle is operated with a discharged battery or without a battery, electronic components and safety
equipment may be damaged.
– Never operate the vehicle with a discharged battery or without a battery.
Note
Engine failure Unfiltered intake air has a negative effect on the service life of the engine.
– Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear.
Note
Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine.
– Always warm up the engine at low engine speeds.
– Sit on the vehicle, take the weight off of the side stand, and move up all the way.
– Turn the emergency OFF switch to the position .
– Switch on the ignition by turning the ignition key to the position .
After you switch on the ignition, you can hear the fuel pump working for about
two seconds. The function check of the combination instrument is run at the
same time.
– Shift gear to neutral.
The green idling speed indicator lamp N lights up.
B00782-10
– Press the electric starter button .
The ABS warning lamp lights up and goes back out after starting off.
Info
Do not press the electric starter button until the combination instrument
function check is finished.
When starting, DO NOT open the throttle. If you open the throttle during the
starting procedure, fuel is not injected by the engine management system
and the engine cannot start.
Press the starter for a maximum of 5 seconds. Wait for a least 5 seconds
before trying again.
This motorcycle is equipped with a safety starting system. You can only start
the engine if the transmission is in neutral or if the clutch is pulled when a
gear is engaged. If the side stand is folded out and you shift into gear and
release the clutch, the engine stops.
5 MOTORCYCLE 13
Switching off ABS
KTM recommends riding with ABS at all times. However, situations may arise in
which ABS is not advantageous.
Condition
Vehicle stationary, engine running.
– Press the 1 button for 3 – 5 seconds.
The ABS warning lamp starts flashing; ABS is deactivated.
401685-15
5.8 Starting the motorcycle to make checks
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death.
– When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed
space without an effective exhaust extraction system.
Info
Press the starter for a maximum of 5 seconds. Wait for a least 5 seconds before trying again.
B00782-10
– Turn the emergency OFF switch to the position .
– Shift gear to neutral.
– Switch on the ignition by turning the ignition key to the position .
– Press the electric starter button .
Info
Do not open the throttle.
6 FORK, TRIPLE CLAMP 14
6.1 Cleaning the dust boots of the fork legs
– Push dust boot 1 of both fork legs downwards.
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.
Warning
308233-10
– Clean and oil the dust boots and inside fork tube of both fork legs.
– Press the dust boots back into their normal position.
– Remove excess oil.
6.2 Removing fork legs
Preparatory work
– Raise the motorcycle with the work stand. ( p. 10)
– Tie the rear of the vehicle down.
– Dismount the front fender. ( p. 48)
Main work
– Remove screw 1.
– Remove the cable binder.
– Pull off the ABS sensor and hang it to one side.
Danger of accidents Reduced braking efficiency due to oil or grease on the
brake discs.
– Always keep the brake discs free of oil and grease, and clean them with
brake cleaner when necessary.
Universal oil spray ( p. 188)
308235-10
308236-10
308237-10
– Remove screws 2.
– Press back the brake linings with a light lateral tilting of the brake caliper on the
brake disc. Pull the brake caliper carefully back from the brake disc and hang it to
one side.
Info
Do not pull the hand brake lever when the brake caliper has been removed.
– Loosen screws 3 and screw 4.
– Unscrew screw 3 about six turns and press your hand on the screw to push the
wheel spindle out of the axle clamp. Remove screw 3.
Warning
Danger of accidents Reduced braking effect caused by damaged brake
discs.
– Always lay the wheel down in such a way that the brake discs are not
damaged.
– Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of
the fork.
6 FORK, TRIPLE CLAMP 15
– Loosen screws 5. Remove the fork legs from the bottom.
308238-10
6.3 Installing the fork legs
Warning
Danger of accidents Modifications to the suspension settings can seriously alter the vehicle's ride behavior.
– Following modifications, ride slowly at first to get the feel of the new ride behavior.
Main work
– Push the fork legs into the triple clamps.
– Align the fork legs in the required position using the fork rings.
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– Tighten screws 1.
Guideline
Screw, top triple clamp M8 11 Nm (8.1 lbf ft)
– Tighten screws 2.
Guideline
Screw, bottom triple clamp M8 15 Nm
(11.1 lbf ft)
– Check the wheel bearing for damage and wear.
» If the wheel bearing is damaged or worn:
– Change the wheel bearing.
– Clean and grease the shaft seal rings 3 and contact surfaces A of the spacers.
Long-life grease ( p. 187)
– Clean screw 4 and the wheel spindle.
– Lift the front wheel into the fork, position it, and insert the wheel spindle.
– Mount and tighten screw 4.
Guideline
Screw, front wheel spindle M8 30 Nm
(22.1 lbf ft)
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6 FORK, TRIPLE CLAMP 16
– Position the brake calipers and check that the brake linings are seated correctly.
– Mount screws 5 but do not tighten yet.
– Operate the hand brake lever repeatedly until the brake linings are in contact with
the brake disc and there is a pressure point. Fix the hand brake lever in the activated position.
The brake calipers straighten.
– Tighten screws 5.
Guideline
308236-11
Screw, front brake caliper M8x1 27 Nm
(19.9 lbf ft)
– Remove the fixation of the hand brake lever.
– Unload the rear of the vehicle.
– Remove the motorcycle from the work stand. ( p. 11)
– Position the ABS sensor.
– Mount and tighten screw 6.
Guideline
Screw, wheel speed sensor holder M6 8 Nm (5.9 lbf ft)
– Route the cable and secure with a cable binder.
Loctite®243™
308235-11
308241-10
6.4 Disassembling the fork legs
Info
These operations are the same on both fork legs.
– Pull the front brake and compress the fork powerfully a few times.
The fork legs straighten.
– Tighten screws 7.
Guideline
Screw, fork stub M8 15 Nm
(11.1 lbf ft)
Finishing work
– Install front fender. ( p. 48)
Condition
The fork legs have been removed.
– Clamp the fork leg in the area of the lower triple clamp.
Clamping stand (T612S) ( p. 197)
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6 FORK, TRIPLE CLAMP 17
– Loosen the screw cap 1.
Info
The screw cap cannot be removed yet.
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– Empty the fork oil.
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– Release the fork leg and clamp it with the fork stub.
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201509-10
Info
Use soft jaws.
– Push the outer tube downward.
– Hold screw cap 1. Loosen nut 2. Remove the screw cap.
– Detach the outer tube from the inner tube.
Info
Place a container underneath to catch any oil that may run out.
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201511-10
– Unclamp the inner tube. Drain the oil.
6 FORK, TRIPLE CLAMP 18
– Clamp the outer tube in the area of the lower triple clamp.
Clamping stand (T612S) ( p. 197)
– Remove dust boot 3.
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– Remove lock ring 4.
Info
The lock ring has a beveled end where a screwdriver can be applied.
201513-10
– Remove seal ring 5. Remove support ring 6.
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6.5 Checking the fork legs
– Unclamp the outer tube.
– Heat up the outer tube in the area of sliding bushing 7.
Guideline
50 °C (122 °F)
– Strike the lower edge of the outer fork tube on a wooden board.
Sliding bushing 7 must fall out of its seat.
Condition
The fork legs have been disassembled.
– Check the inner tube and the axle clamp for damage.
» If damage is found:
– Change the fork leg.
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6 FORK, TRIPLE CLAMP 19
– Measure the outside diameter of the inner tube in several places.
External diameter of inner tube 42.975… 43.005 mm (1.69193…
1.69311 in)
» If the measured value is less than the specified value:
– Change the fork leg.
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– Measure the run-out of the inner tube.
Run-out of inner tube ≤ 0.20 mm (≤ 0.0079 in)
» If the measured value is greater than the specified value:
– Change the fork leg.
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– Check the outer tube for damage.
» If damage is found:
– Change the fork leg.
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201517-10
6.6 Assembling the fork legs
Info
These operations are the same on both fork legs.
– Check the surface of the sliding bushings.
» If the dark layer A is worn off:
– Change the fork leg.
Preparatory work
– Check the fork legs. ( p. 18)
Main work
– Clamp in the inner tube with the axle clamp.
Guideline
Use soft jaws.
202092-10
– Grease and slide on dust boot 1.
Lubricant (T511) ( p. 187)
Info
Always change the dust boot, lock ring, seal ring, and support ring.
Install the dust boot with the sealing lip and spring expander facing downward.
6 FORK, TRIPLE CLAMP 20
– Slide on lock ring 2.
– Grease and slide on seal ring 3.
Lubricant (T511) ( p. 187)
Info
Mount with the sealing lip facing down and the open side facing up.
– Slide on support ring 4.
– Sand the edges of sliding bushing 5 with 600-grit sandpaper, then clean and
grease.
Fork oil (SAE 4) (48601166S1) ( p. 186)
– Slide on sliding bushing 5.
– Warm up the outer tube in the lower sliding bushing area A.
Guideline
50 °C (122 °F)
– Slide the outer tube onto the inner tube.
– Hold the sliding bushing with the longer shoulder of the special tool.
Mounting tool (T528S) ( p. 197)
– Push the sliding bushing all the way into the outer tube.
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– Position the support ring.
– Hold the seal ring with the shorter shoulder of the special tool.
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202095-10
Mounting tool (T528S) ( p. 197)
– Push the seal ring and support ring all the way into the outer tube.
– Mount lock ring 2.
Info
The lock ring must engage audibly.
– Install dust boot 1.
202096-10
6 FORK, TRIPLE CLAMP 21
– Mount screw cap 6 onto the piston rod.
Info
Nut 7 must be turned all the way down.
– Hold the screw cap and tighten the nut.
Guideline
Nut, piston rod on screw cap M12x1 30 Nm
(22.1 lbf ft)
202097-10
– Fill it with fork oil.
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201522-10
6.7 Removing the lower triple clamp
Fork oil 450 ml
(15.21 fl. oz.)
Fork oil (SAE 4) (48601166S1)
( p. 186)
Info
If it should be impossible to add the full quantity of oil, close the screw cap
of the outer tube, unclamp the fork and bounce a number of times. Then
add the remaining quantity.
– Push the outer tube upward.
– Mount screw cap 6.
– Unclamp the fork leg in the area of the lower triple clamp.
Clamping stand (T612S) ( p. 197)
– Tighten the screw cap.
Guideline
Screw cap on outer tube M47x1.5 30 Nm
Preparatory work
– Raise the motorcycle with the work stand. ( p. 10)
– Tie the rear of the vehicle down.
– Dismount the front fender. ( p. 48)
– Remove the fork legs. ( p. 14)
Main work
– Remove expanding rivets 1.
(22.1 lbf ft)
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308243-10
– Remove screws 2.
– Lift the headlight mask slightly and swing forward.
6 FORK, TRIPLE CLAMP 22
– Detach connectors 3 and 4.
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– Detach connectors 5 and 6.
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– Remove the connector holder.
– Disconnect connector 7.
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– Remove the combination instrument.
– Remove screws 8.
– Remove the headlight mask.
– Remove screw 9.
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6 FORK, TRIPLE CLAMP 23
– Remove the upper triple clamp with the handlebar and set aside.
Info
Protect the vehicle and its attachments from damage by covering them.
308251-10
– Expose the cable.
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– Remove nut bk.
Castle nut wrench; ½" drive (90129050100) ( p. 195)
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308254-10
6.8 Installing the lower triple clamp
308254-11
– Remove washer bl.
– Remove steering head bearing bm.
– Remove the lower triple clamp with the steering stem.
Main work
– Clean the bearing and sealing elements, check for damage, and grease.
High viscosity grease ( p. 187)
– Insert the lower triple clamp with the steering stem.
– Mount the upper steering head bearing 1.
– Mount washer 2 with the cut-out facing downward.
Alternative 1
A new steering head bearing is used.
– Mount and tighten nut 3.
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6 FORK, TRIPLE CLAMP 24
Guideline
Nut, steering head M30x1 Step 1
50 Nm
(36.9 lbf ft)
2nd stage
(loosen, counterclockwise)
2 turns
Step 3
5 Nm (3.7 lbf ft)
Castle nut wrench; ½" drive (90129050100) ( p. 195)
Alternative 2
The steering head bearing is used again.
– Mount and tighten nut 3.
Guideline
Nut, steering head M30x1 5 Nm (3.7 lbf ft)
Castle nut wrench; ½" drive (90129050000) ( p. 195)
– Secure the cable in the bracket.
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308250-10
– Position the upper triple clamp with the handlebar.
– Mount screw 4 with the washer but do not tighten it yet.
Guideline
Screw, top steering head M16x1.5 52 Nm
(38.4 lbf ft)
Holding lugs A reach into the drilled holes.
– Position the headlight mask.
– Mount and tighten screw 5.
Guideline
Screw, headlight mask M6 11 Nm (8.1 lbf ft)
308248-11
6 FORK, TRIPLE CLAMP 25
– Position the combination instrument.
– Plug in connector 6.
– Mount the connector holder 7.
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– Plug in connectors 8 and 9.
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– Plug in connectors bk and bl.
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308243-11
308242-11
– Fold the headlight mask up.
– Mount and tighten screws bm.
Guideline
Screw, headlight mask M6 11 Nm (8.1 lbf ft)
– Mount expanding rivets bn on both sides.
– Install the fork legs. ( p. 15)
– Loosen screws bo.
– Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains.
– Tighten screw 4.
Guideline
Screw, top steering head M16x1.5 52 Nm
(38.4 lbf ft)
308255-10
– Tighten screws bo.
Guideline
Screw, top triple clamp M8 11 Nm (8.1 lbf ft)
6 FORK, TRIPLE CLAMP 26
Finishing work
– Check that the wiring harness, throttle cables, and brake line have the necessary
freedom of movement and are correctly routed.
– Check the steering head bearing play. ( p. 26)
– Remove the motorcycle from the work stand. ( p. 11)
6.9 Checking the steering head bearing play
Warning
Danger of accidents Unstable vehicle handling from incorrect steering head bearing play.
– Adjust the steering head bearing play without delay.
Info
If the bike is ridden with play in the steering head bearing, the bearing and the bearing seats in the frame can become damaged with time.
Preparatory work
– Raise the motorcycle with the work stand. ( p. 10)
Main work
– 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.
» If there is noticeable play present:
– Adjust the play of the steering head bearing. ( p. 26)
–
Move the handlebar to and fro over the entire steering range.
400738-11
The handlebar must be able to move easily over the entire steering range. No
resting locations should be noticeable.
» If click positions are noticeable:
– Adjust the play of the steering head bearing. ( p. 26)
– Check the steering head bearing and change if necessary.
Finishing work
– Remove the motorcycle from the work stand. ( p. 11)
6.10 Adjusting the steering head bearing play
Preparatory work
– Raise the motorcycle with the work stand. ( p. 10)
Main work
– Loosen screws 1.
– Loosen screw 2.
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308257-10
– Tighten nut 3 with the special tool until there is no play in the steering head bear-
ing.
Key for steering head bearing (90129051000) ( p. 195)
6 FORK, TRIPLE CLAMP 27
– Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains.
– Tighten screw 2.
Guideline
Screw, top steering head M16x1.5 52 Nm
(38.4 lbf ft)
– Tighten screws 1.
Guideline
308256-10
Screw, top triple clamp M8 11 Nm (8.1 lbf ft)
Finishing work
– Check the steering head bearing play. ( p. 26)
– Remove the motorcycle from the work stand. ( p. 11)
7 HANDLEBAR, CONTROLS 28
7.1 Checking the play in the throttle cable
– Check the throttle grip for smooth operation.
– Move the handlebar to the straight-ahead position. Move the throttle grip back-
wards and forwards to ascertain the play in the throttle cable.
Throttle cable play 3… 5 mm (0.12… 0.2 in)
» If the throttle cable play does not meet specifications:
– Adjust the play in the throttle cable. ( p. 28)
Danger
400192-10
– Start the engine and let it run idle. Move the handlebar to and fro over the entire
Danger of poisoning Exhaust gases are toxic and inhaling them may result
in unconsciousness and/or death.
– When running the engine, always make sure there is sufficient ventila-
tion, and do not start or run the engine in an enclosed space without an
effective exhaust extraction system.
steering range.
The idle speed must not change.
» If the idle speed changes:
– Check the throttle cable routing.
7.2 Adjusting the play in the throttle cable
– Move the handlebar to the straight-ahead position.
– Push back sleeve 1.
– Loosen lock nut 2.
– Adjust the play in the throttle cable by turning adjusting screw 3.
Guideline
Throttle cable play 3… 5 mm (0.12… 0.2 in)
– Tighten lock nut 2.
B00728-10
– Slide on sleeve 1.
7.3 Checking the clutch lever play
– Check the clutch lever for smooth operation.
– Move the handlebar to the straight-ahead position. Lightly pull the clutch lever and
ascertain the clutch lever play A.
Clutch lever play 1… 3 mm (0.04… 0.12 in)
» If the clutch lever play does not meet specifications:
Note
101914-10
Clutch damage If there is no play on the clutch lever, the clutch will begin to slip.
– When operating the motorcycle, always check the clutch lever play.
– Adjust the clutch cable play. ( p. 29)
– Move the handlebar to and fro over the entire steering range.
The clutch lever play must not change.
» If the clutch lever play changes:
– Check the routing of the clutch cable.
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