KTM 690 Enduro R 2013 Repair manual
REPAIR MANUAL 2013
690 Enduro R AUS/UK
690 Enduro R EU
690 Enduro R USA
Art. no. 3206150en
INTRODUCTION 1
INTRODUCTION
Read this repair manual carefully and thoroughly before beginning 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 NOTES..................................................... 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 ................................................ 8
4.2 Type label ........................................................ 8
4.3 Engine number................................................. 8
4.4 Key number...................................................... 8
4.5 Fork part number .............................................. 8
4.6 Shock absorber part number .............................. 9
5 MOTORCYCLE ........................................................... 10
5.1 Raising the motorcycle with the lift stand.......... 10
5.2 Removing the motorcycle from the lift stand...... 10
5.3 Raising the motorcycle with the work stand ....... 10
5.4 Removing the motorcycle from the work stand ... 11
5.5 Starting.......................................................... 11
5.6 Starting the motorcycle to make checks ............ 12
6 FORK, TRIPLE CLAMP ............................................... 13
6.1 Adjusting the compression damping of the
fork ............................................................... 13
6.2 Adjusting the rebound damping of the fork ........ 13
6.3 Bleeding the fork legs...................................... 13
6.4 Cleaning the dust boots of the fork legs............. 14
6.5 Loosening the fork protection........................... 14
6.6 Positioning the fork protector ........................... 14
6.7 Removing the fork legs .................................... 15
6.8 Installing the fork legs..................................... 16
6.9 Servicing the fork............................................ 17
6.10 Disassembling the fork legs.............................. 18
6.11 Disassembling the cartridge ............................. 21
6.12 Disassembling the tap compression .................. 22
6.13 Checking the fork legs..................................... 23
6.14 Assembling the tap compression ...................... 24
6.15 Assembling the cartridge ................................. 25
6.16 Assembling the fork legs.................................. 27
6.17 Checking the steering head bearing play............ 31
6.18 Adjusting the play of the steering head
bearing .......................................................... 31
7 HANDLEBAR, CONTROLS........................................... 33
7.1 Handlebar position.......................................... 33
7.2 Adjusting handlebar position............................ 33
7.3 Checking the routing of the throttle cable.......... 33
7.4 Checking the play in the throttle cable .............. 34
7.5 Adjusting the play in the throttle cable.............. 34
8 FRAME ..................................................................... 36
8.1 Removing the engine guard.............................. 36
8.2 Installing the engine guard .............................. 36
9 SHOCK ABSORBER, SWINGARM ................................ 37
9.1 Adjusting the high-speed compression
damping of the shock absorber......................... 37
9.2 Adjusting the low-speed compression damping
of the shock absorber ...................................... 37
9.3 Adjusting the rebound damping of the shock
absorber......................................................... 38
9.4 Measuring the unloaded rear wheel sag............. 38
9.5 Checking the static sag of the shock absorber.... 38
9.6 Checking the riding sag of the shock absorber.... 39
9.7 Adjusting the spring preload of the shock
absorber......................................................... 39
9.8 Adjusting the riding sag................................... 40
9.9 Removing the shock absorber........................... 40
9.10 Installing the shock absorber............................ 41
9.11 Servicing the shock absorber............................ 42
9.12 Removing the spring........................................ 43
9.13 Dismantling the damper .................................. 43
9.14 Disassembling the piston rod ........................... 44
9.15 Checking the damper ...................................... 45
9.16 Removing the heim joint.................................. 46
9.17 Installing the heim joint................................... 47
9.18 Assembling the piston rod................................ 48
9.19 Assembling the damper ................................... 49
9.20 Bleeding and filling the damper ....................... 51
9.21 Filling the damper with nitrogen....................... 53
9.22 Installing the spring ........................................ 54
10 EXHAUST.................................................................. 56
10.1 Removing the manifold.................................... 56
10.2 Installing the manifold .................................... 56
10.3 Removing the main silencer............................. 57
10.4 Installing the main silencer.............................. 58
11 AIR FILTER ............................................................... 59
11.1 Removing the air filter..................................... 59
11.2 Installing the air filter...................................... 59
11.3 Removing the air filter box ............................... 59
11.4 Installing the air filter box................................ 60
12 FUEL TANK, SEAT, TRIM ........................................... 62
12.1 Opening the filler cap...................................... 62
12.2 Closing filler cap............................................. 62
12.3 Removing the seat .......................................... 62
12.4 Mounting the seat ........................................... 63
12.5 Taking off the side cover.................................. 63
12.6 Mounting the side cover................................... 63
12.7 Checking the fuel pressure............................... 64
12.8 Changing the fuel filter.................................... 65
12.9 Changing the fuel pump .................................. 68
13 WHEELS ................................................................... 71
13.1 Checking the tire air pressure........................... 71
13.2 Checking the tire condition .............................. 71
13.3 Checking the brake discs................................. 72
13.4 Checking the spoke tension.............................. 72
13.5 Checking the rim run-out................................. 73
13.6 Front wheel .................................................... 73
13.6.1 Removing the front wheel ............................ 73
13.6.2 Installing the front wheel............................. 74
13.6.3 Removing the brake disc of the front brake.... 74
13.6.4 Installing the brake disc of the front brake .... 75
13.7 Rear wheel ..................................................... 75
13.7.1 Removing rear wheel ................................... 75
13.7.2 Installing the rear wheel .............................. 75
13.7.3 Removing the brake disc of the rear brake..... 76
13.7.4 Installing the brake disc of the rear brake...... 77
13.7.5 Checking the chain tension.......................... 77
13.7.6 Adjusting the chain tension ......................... 77
13.7.7 Adjusting chain guide.................................. 78
TABLE OF CONTENTS 3
13.7.8 Checking the chain, rear sprocket, engine
sprocket, and chain guide............................ 78
13.7.9 Cleaning the chain...................................... 80
13.7.10 Checking the rear hub rubber dampers.......... 80
14 WIRING HARNESS, BATTERY..................................... 82
14.1 Removing the battery ...................................... 82
14.2 Installing the battery ....................................... 82
14.3 Disconnecting the battery ................................ 82
14.4 Connecting the battery .................................... 83
14.5 Recharging the battery .................................... 83
14.6 Checking the charging voltage.......................... 84
14.7 Changing the main fuse................................... 85
14.8 Changing fuses of individual power
consumers...................................................... 85
14.9 Adjusting the engine characteristic................... 86
15 BRAKE SYSTEM ........................................................ 88
15.1 Checking the front brake linings ....................... 88
15.2 Changing the front brake linings....................... 88
15.3 Checking the free travel of the hand brake
lever .............................................................. 90
15.4 Adjusting the free travel of the hand brake
lever .............................................................. 90
15.5 Checking the front brake fluid level .................. 90
15.6 Adding front brake fluid................................... 91
15.7 Changing the front brake fluid.......................... 91
15.8 Checking the rear brake linings ........................ 93
15.9 Changing the rear brake linings ........................ 93
15.10 Checking the free travel of foot brake lever ........ 94
15.11 Adjusting the basic position of the foot brake
lever .............................................................. 95
15.12 Checking rear brake fluid level ......................... 95
15.13 Adding rear brake fluid.................................... 96
15.14 Changing the rear brake fluid ........................... 96
16 LIGHTING SYSTEM, INSTRUMENTS ........................... 98
16.1 Combination instrument .................................. 98
16.1.1 Setting kilometers or miles .......................... 98
16.1.2 Setting the clock ........................................ 98
16.1.3 Setting/resetting display TRIP 1................... 98
16.1.4 Setting/resetting display TRIP 2................... 98
16.1.5 Setting the wheel circumference .................. 99
16.2 Checking the headlight setting ....................... 100
16.3 Adjusting the headlight range......................... 100
16.4 Removing the headlight mask with the
headlight...................................................... 100
16.5 Installing the headlight mask with the
headlight...................................................... 101
16.6 Changing the parking light bulb...................... 101
16.7 Changing the headlight bulb .......................... 102
16.8 Changing the turn signal bulb ........................ 102
17 ENGINE .................................................................. 104
17.1 Removing the engine..................................... 104
17.2 Installing the engine...................................... 106
17.3 Engine disassembly....................................... 110
17.3.1 Clamping the engine into the engine
assembly stand......................................... 110
17.3.2 Draining the engine oil .............................. 110
17.3.3 Removing starter motor ............................. 111
17.3.4 Removing valve cover ................................ 111
17.3.5 Removing the alternator cover.................... 111
17.3.6 Removing spacer ...................................... 111
17.3.7 Removing gear position sensor ................... 111
17.3.8 Removing oil filter .................................... 112
17.3.9 Removing thermostat ................................ 112
17.3.10 Setting engine to ignition top dead center ... 112
17.3.11 Removing water pump wheel...................... 113
17.3.12 Removing clutch cover .............................. 113
17.3.13 Removing spacer and spring ...................... 114
17.3.14 Removing spark plug................................. 114
17.3.15 Removing timing chain tensioner................ 114
17.3.16 Removing camshafts................................. 114
17.3.17 Removing cylinder head ............................ 115
17.3.18 Removing piston....................................... 115
17.3.19 Removing rotor ......................................... 115
17.3.20 Removing timing chain rails....................... 116
17.3.21 Removing timing chain and timing chain
sprocket................................................... 116
17.3.22 Removing crankshaft position sensor .......... 117
17.3.23 Removing clutch cage ............................... 117
17.3.24 Removing primary gear.............................. 118
17.3.25 Removing starter drive............................... 118
17.3.26 Removing shift shaft ................................. 119
17.3.27 Removing shift drum locating..................... 119
17.3.28 Removing locking lever.............................. 119
17.3.29 Removing oil pumps.................................. 119
17.3.30 Removing left engine case......................... 120
17.3.31 Removing crankshaft and balancer shaft ..... 120
17.3.32 Removing transmission shafts .................... 121
17.4 Work on individual parts ................................ 122
17.4.1 Work on the right section of the engine
case ........................................................ 122
17.4.2 Work on the left section of the engine
case ........................................................ 123
17.4.3 Work on the clutch cover ........................... 125
17.4.4 Removing crankshaft bearing inner ring ...... 125
17.4.5 Removing balancer shaft drive wheel .......... 125
17.4.6 Changing the connecting rod, conrod
bearing, and crank pin .............................. 125
17.4.7 Checking crankshaft run-out at bearing
pin .......................................................... 127
17.4.8 Installing balancer shaft drive wheel........... 127
17.4.9 Installing crankshaft bearing inner ring ....... 128
17.4.10 Measuring axial clearance of crankshaft
and balancer shaft .................................... 128
17.4.11 Cylinder - Nikasil®coating ......................... 129
17.4.12 Checking/measuring the cylinder ................ 129
17.4.13 Checking/measuring the piston................... 130
17.4.14 Checking piston ring end gap ..................... 131
17.4.15 Checking piston/cylinder mounting
clearance ................................................. 131
17.4.16 Checking oil pumps for wear ...................... 131
17.4.17 Replacing autodecompressor...................... 132
17.4.18 Preparing timing chain tensioner for
installation............................................... 132
17.4.19 Checking timing assembly ......................... 133
17.4.20 Removing rocker arm ................................ 133
17.4.21 Changing camshaft bearing........................ 134
17.4.22 Removing valves....................................... 135
17.4.23 Checking valves........................................ 135
17.4.24 Checking valve springs .............................. 136
17.4.25 Checking valve spring retainer.................... 136
17.4.26 Checking cylinder head ............................. 136
17.4.27 Installing valves........................................ 137
17.4.28 Installing rocker arm ................................. 137
17.4.29 Disassembling the antihopping clutch......... 138
TABLE OF CONTENTS 4
17.4.30 Checking the clutch .................................. 138
17.4.31 Preassembling the antihopping clutch......... 140
17.4.32 Checking shift mechanism......................... 141
17.4.33 Preassembling shift shaft .......................... 141
17.4.34 Disassembling the main shaft .................... 142
17.4.35 Dismantling countershaft........................... 142
17.4.36 Checking the transmission......................... 143
17.4.37 Assembling the main shaft......................... 144
17.4.38 Assembling countershaft ........................... 145
17.4.39 Checking the starter drive.......................... 146
17.4.40 Removing freewheel.................................. 146
17.4.41 Checking freewheel................................... 147
17.4.42 Installing freewheel................................... 147
17.5 Engine assembly........................................... 148
17.5.1 Installing transmission shafts..................... 148
17.5.2 Installing crankshaft and balancer shaft...... 149
17.5.3 Installing left engine case.......................... 150
17.5.4 Installing oil pumps .................................. 150
17.5.5 Installing locking lever .............................. 151
17.5.6 Installing shift drum locating ..................... 151
17.5.7 Installing shift shaft.................................. 151
17.5.8 Installing starter drive ............................... 151
17.5.9 Installing primary gear............................... 152
17.5.10 clutch cage, installing ............................... 152
17.5.11 Installing crankshaft position sensor........... 153
17.5.12 Installing timing chain and timing chain
sprocket................................................... 154
17.5.13 Installing timing chain rails ....................... 154
17.5.14 Installing rotor.......................................... 154
17.5.15 Adjusting crankshaft position sensor
distance................................................... 155
17.5.16 Setting engine to top dead center............... 155
17.5.17 Installing piston........................................ 155
17.5.18 Installing cylinder head ............................. 157
17.5.19 Installing camshafts.................................. 157
17.5.20 Installing timing chain tensioner ................ 158
17.5.21 Checking valve clearance........................... 158
17.5.22 Adjusting valve clearance .......................... 159
17.5.23 Installing spark plug.................................. 160
17.5.24 Installing spacer and spring....................... 160
17.5.25 Installing clutch cover ............................... 160
17.5.26 Mounting water pump cover....................... 160
17.5.27 Installing thermostat................................. 161
17.5.28 Installing the oil filter................................ 161
17.5.29 Installing gear position sensor.................... 161
17.5.30 Installing the spacer.................................. 162
17.5.31 Installing oil screens ................................. 162
17.5.32 Installing alternator cover .......................... 163
17.5.33 Installing the starter motor......................... 163
17.5.34 Installing valve cover................................. 164
17.5.35 Removing the engine from the engine
assembly stand......................................... 164
18 CLUTCH.................................................................. 165
18.1 Checking/rectifying the fluid level of the
hydraulic clutch............................................ 165
18.2 Changing the hydraulic clutch fluid ................ 165
19 WATER PUMP, COOLING SYSTEM ............................ 166
19.1 Draining the coolant...................................... 166
19.2 Filling/bleeding the cooling system ................. 166
19.3 Checking the antifreeze and coolant level........ 167
19.4 Checking the coolant level ............................. 168
20 LUBRICATION SYSTEM............................................ 169
20.1 Oil circuit..................................................... 169
20.2 Checking the engine oil level.......................... 169
20.3 Checking the engine oil pressure .................... 170
20.4 Changing the engine oil and filter, cleaning
the oil screens .............................................. 171
20.5 Draining the engine oil .................................. 171
20.6 Removing the oil filter................................... 172
20.7 Installing the oil filter.................................... 172
20.8 Cleaning the oil screens................................. 173
20.9 Filling up with engine oil ............................... 174
20.10 Adding engine oil.......................................... 174
21 IGNITION SYSTEM................................................... 175
21.1 Alternator - checking the stator winding .......... 175
21.2 Checking the spark plug connector ................. 175
21.3 Ignition coil - checking the secondary
winding........................................................ 176
22 TECHNICAL DATA.................................................... 177
22.1 Engine ......................................................... 177
22.2 Engine tolerance, wear limits ......................... 177
22.3 Engine tightening torques .............................. 179
22.4 Capacities .................................................... 180
22.4.1 Engine oil ................................................ 180
22.4.2 Coolant.................................................... 180
22.4.3 Fuel ........................................................ 180
22.5 Chassis ........................................................ 180
22.6 Electrical system........................................... 181
22.7 Tires............................................................ 181
22.8 Fork............................................................. 182
22.9 Shock absorber............................................. 182
22.10 Chassis tightening torques ............................. 183
23 CLEANING/PROTECTIVE TREATMENT....................... 185
23.1 Cleaning the motorcycle ................................ 185
23.2 Checks and maintenance steps for winter
operation...................................................... 186
24 STORAGE................................................................ 187
24.1 Storage ........................................................ 187
24.2 Preparing for use after storage........................ 187
25 SERVICE SCHEDULE ............................................... 188
25.1 Service schedule........................................... 188
26 WIRING DIAGRAM ................................................... 190
26.1 Page 01 of 10 .............................................. 190
26.2 Page 02 of 10 .............................................. 192
26.3 Page 03 of 10 .............................................. 194
26.4 Page 04 of 10 .............................................. 196
26.5 Page 05 of 10 .............................................. 198
26.6 Page 06 of 10 .............................................. 200
26.7 Page 07 of 10 .............................................. 202
26.8 Page 08 of 10 .............................................. 204
26.9 Page 09 of 10 .............................................. 206
26.10 Page 10 of 10 .............................................. 208
27 SUBSTANCES ......................................................... 210
28 AUXILIARY SUBSTANCES ........................................ 212
29 SPECIAL TOOLS ...................................................... 214
30 STANDARDS ........................................................... 227
INDEX ............................................................................ 228
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 NOTES 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
The chassis number 1 is stamped on the steering head on the right.
601764-10
4.2 Type label
The type label 1 is located on the right side of the frame.
4.3 Engine number
4.4 Key number
B01289-10
The engine number 1 is stamped on the left side of the engine under the engine
sprocket.
100211-10
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.
4.5 Fork part number
100179-10
The fork part number 1 is stamped on the inner side of the fork stub.
601780-10
4 SERIAL NUMBERS 9
4.6 Shock absorber part number
The shock absorber part number 1 is on the left of the shock absorber.
101048-10
5 MOTORCYCLE 10
5.1 Raising the motorcycle with the lift stand
Note
Danger of damage The parked vehicle may roll away or fall over.
– Always place the vehicle on a firm and even surface.
– Raise the motorcycle using the underride guard under the motorcycle.
The wheels must no longer touch the ground.
– Secure the motorcycle against falling over.
601778-01
5.2 Removing the motorcycle from the lift 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 the motorcycle from the lift stand and rest it on its side stand.
– Remove the lift stand.
B01290-01
5.3 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.
– Mount the special tool on the footrest.
Work stand adapter (75029036000) ( p. 219)
300579-10
300201-10
– Position the motorcycle upright, align the special tool and raise the motorcycle.
Work stand (62529055000) ( p. 217)
5 MOTORCYCLE 11
5.4 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 the work stand and lean the vehicle on the side stand.
300201-10
– Remove the special tool.
300579-10
5.5 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 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.
– Turn the emergency OFF switch to the position .
– Switch on the ignition by turning the ignition key to position ON .
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.
– Press the electric starter button .
B00103-10
5 MOTORCYCLE 12
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 at 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 lever is pulled
when a gear is engaged. If the side stand is folded out and you shift into
gear and release the clutch lever, the engine stops.
– Take the weight off the side stand and swing it back up with your foot as far as it
will go.
5.6 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.
– Turn the emergency OFF switch to the position .
– Shift gear to neutral.
– Switch on the ignition.
– Press the electric starter button .
Info
Do not open the throttle.
B00103-10
6 FORK, TRIPLE CLAMP 13
6.1 Adjusting the compression damping of the fork
Info
The hydraulic compression damping determines the fork suspension behavior.
– Turn adjusting screws 1 clockwise all the way.
Info
The adjusting screws are located at the bottom end of the fork legs.
Make the same adjustment on both fork legs.
– Turn back counterclockwise by the number of clicks corresponding to the fork type.
Guideline
Compression damping
601775-10
Comfort 20 clicks
Standard 15 clicks
Sport 10 clicks
Full payload 10 clicks
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damping.
6.2 Adjusting the rebound damping of the fork
Info
The hydraulic rebound damping determines the fork rebound behavior.
– Turn adjusting screws 1 clockwise all the way.
Info
The adjusting screws are located at the top end of the fork legs.
Make the same adjustment on both fork legs.
– Turn back counterclockwise by the number of clicks corresponding to the fork type.
Guideline
Rebound damping
601776-10
Comfort 20 clicks
Standard 15 clicks
Sport 10 clicks
Full payload 10 clicks
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damping.
6.3 Bleeding the fork legs
601779-10
Preparatory work
– Lean the motorcycle on the side stand.
Main work
– Briefly loosen bleeder screws 1.
Any excess pressure escapes from the interior of the fork.
– Mount and tighten bleeder screws.
Info
Carry out this action on both fork legs.
6 FORK, TRIPLE CLAMP 14
6.4 Cleaning the dust boots of the fork legs
Preparatory work
– Raise the motorcycle with the lift stand. ( p. 10)
– Loosen the fork protection. ( p. 14)
Main work
– Push dust boot 1 of both fork legs downwards.
Info
The dust boots remove dust and coarse dirt particles from the inside fork
tubes. Over time, dirt can penetrate behind the dust boots. If this dirt is not
removed, the oil seals behind the dust boots can start to leak.
Warning
B01281-10
– Clean and oil the dust boots and inner fork tube of both fork legs.
– Press the dust boots back into their normal position.
– Remove excess oil.
Finishing work
– Position the fork protector. ( p. 14)
– Remove the motorcycle from the lift stand. ( p. 10)
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. 213)
6.5 Loosening the fork protection
B01282-10
6.6 Positioning the fork protector
B01282-11
– Remove screws 1 and take off clamp.
– Remove screws 2 on left fork leg. Push the fork protection downwards.
– Remove screws 3 on the right fork leg. Push the fork protector downward.
– Position the fork protector on the left fork leg. Mount and tighten screws 1.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
– Position the brake line and wiring harness. Put the clamp on, and mount and
tighten screws 2.
– Position the fork protector on the right fork leg. Mount and tighten screws 3.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
6 FORK, TRIPLE CLAMP 15
6.7 Removing the fork legs
Preparatory work
– Raise the motorcycle with the lift stand. ( p. 10)
– Tie down the rear of the vehicle.
Main work
– Remove screws 1.
– Press back the brake linings with a light lateral tilting of the brake caliper on the
brake disc. Carefully pull the brake caliper backwards from the brake disc.
Info
Do not pull the hand brake lever while the brake caliper is removed.
202022-10
– Loosen screws 2 and screw 3.
– Unscrew screw 3 about 6 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.
202023-10
– Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of
the fork.
– Remove screws 4. Take the brake line and wiring harness out of the clamp.
202024-10
202025-10
202026-10
– Remove the screws of the wheel speed sensor 5. Hang the wheel speed sensor to
one side.
– Remove cable binder 6.
– Loosen screws 7 of the triple clamp on both sides. Remove the fork legs from the
bottom.
6 FORK, TRIPLE CLAMP 16
– Remove screws 8. Remove the fork protector from above.
202027-10
6.8 Installing the fork legs
– Slide on the fork protector from above and position it. Mount and tighten screws 1.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
202027-11
– Slide the fork legs into the triple clamps on both sides.
202028-10
Info
The bleeder screws must face forwards.
The second groove A of the fork leg must be flush with the upper edge of
the upper triple clamp.
The upper fork overhang must be the same on both sides.
– Tighten screws 2 on both sides.
Guideline
Screw, top triple clamp M8 17 Nm
(12.5 lbf ft)
Screw, bottom triple clamp M8 12 Nm (8.9 lbf ft)
– Position the wheel speed sensor. Mount and tighten screws 3.
Guideline
Screw, wheel speed sensor M4 1 Nm
(0.7 lbf ft)
– Secure the cable with cable binders 4.
Loctite®243™
202025-11
202024-11
– Position the brake line, wiring harness, and clamp.
– Mount and tighten screws 5.
6 FORK, TRIPLE CLAMP 17
Warning
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.
– Clean screw 6 and the wheel spindle.
– Lift the front wheel into the fork, position it, and insert the wheel spindle.
202023-11
– Mount and tighten screw 6.
Guideline
Screw, front wheel spindle M24x1.5 45 Nm
(33.2 lbf ft)
– Position the brake caliper and check that the brake linings are seated correctly.
– Mount and tighten screws 7.
Guideline
Screw, front brake caliper M8 25 Nm
(18.4 lbf ft)
– Release the rear of the vehicle.
– Remove the motorcycle from the lift stand. ( p. 10)
Loctite®243™
6.9 Servicing the fork
202022-11
– Pull the front brake and compress the fork forcefully a few times.
This aligns the fork legs.
– Tighten screws 8.
Guideline
Screw, fork stub M8 15 Nm
(11.1 lbf ft)
202023-12
Condition
The fork legs have been removed.
– Disassemble the fork legs. ( p. 18)
– Disassemble the cartridge. ( p. 21)
– Disassemble the tap compression. ( p. 22)
– Check the fork legs. ( p. 23)
– Assemble the tap compression. ( p. 24)
– Assemble the cartridge. ( p. 25)
– Assemble the fork legs. ( p. 27)
201488-01
6 FORK, TRIPLE CLAMP 18
6.10 Disassembling the fork legs
Info
The steps are identical for both fork legs.
Condition
The fork legs are disassembled.
– Note down the present state of rebound damping 1 and compression damping 2.
– Completely open the adjusters of the rebound and compression damping.
201470-10
– Clamp the fork leg in the area of the lower triple clamp.
Clamping stand (T1403S) ( p. 225)
200643-10
200644-12
201471-10
– Loosen screw cover 3.
Info
The screw cover cannot be removed yet.
– Release the fork leg and clamp it with the axle clamp.
Info
Use soft jaws.
– Push the outer tube downward.
– Pull the spring down. Mount the special tool on the hexagonal part.
Open-end wrench (T14032) ( p. 225)
200646-12
Info
Preload spacers 4 should be above the special tool.
6 FORK, TRIPLE CLAMP 19
– Clamp the special tool in the vise. Loosen screw cover 3.
200647-12
– Remove screw cover 3 with preload spacers 4.
– Remove adjusting tube 5.
200648-12
– Pull the spring down. Remove the special tool.
– Remove the spring.
200649-01
200650-01
201472-10
– Drain the fork oil.
Info
Pull out and push in the piston rod a few times to empty the cartridge.
– Clamp the fork leg with the axle clamp.
Guideline
Use soft jaws.
– Loosen and remove screw 6.
Info
Place a container underneath to catch any oil that may run out.
– Loosen and remove compression damping A.
Info
This operation is not needed for further disassembly.
201473-10
6 FORK, TRIPLE CLAMP 20
– Remove the cartridge.
200653-01
– Remove dust boot 7.
200735-10
– Remove lock ring 8.
200656-01
201474-10
Info
The lock ring has a beveled end where a screwdriver can be applied.
– Warm up the outer tube in area B of the lower sliding bushings.
Guideline
50 °C (122 °F)
– Pull the outer tube forcefully off of the inner tube.
Info
The lower sliding bushing 9 must be pulled out of its bearing seat when
doing this.
– Remove upper sliding bushing bk.
Info
Without using a tool, carefully pull the stack apart by hand.
200658-01
200659-11
– Take off the lower sliding bushing 9.
– Take off support ring bl.
– Take off seal ring bm.
– Take off lock ring 8.
– Take off dust boot 7.
– Unclamp the fork leg.
6 FORK, TRIPLE CLAMP 21
6.11 Disassembling the cartridge
Info
The steps are identical for both fork legs.
Preparatory work
– Disassemble the fork legs. ( p. 18)
Main work
– Degrease the piston rod.
– Clamp the piston rod with the special tool.
Clamping stand (T14016S) ( p. 224)
– Remove fluid barrier 1 from the piston rod.
200746-10
– Take washer 2 and spring seat 3 off of the cartridge.
201479-10
201480-10
201481-10
– Degrease the cartridge and clamp it with the special tool.
Clamping stand (T14015S) ( p. 224)
– Remove lock ring 4.
– Pull tap compression 5 out of the cartridge using a screw.
– Take piston rod 6 out of the cartridge.
– Heat the cartridge in area A.
Guideline
50 °C (122 °F)
200749-12
– Unscrew and remove screw sleeve B.
Info
This operation is not needed for further disassembly.
6 FORK, TRIPLE CLAMP 22
– Degrease the piston rod.
– Clamp the piston rod with the special tool.
Clamping stand (T14016S) ( p. 224)
200697-10
– Remove nut 7.
– Remove shim stack 8 completely.
200698-11
– Remove the piston.
– Completely remove shim stack 9.
200699-11
– Remove spring bk.
– Loosen and remove tap rebound bl.
200700-10
– Remove spring bm.
– Remove valve bn of the rebound damping with the spring.
– Unclamp the piston rod.
200701-10
6.12 Disassembling the tap compression
Info
The steps are identical for both fork legs.
Preparatory work
– Disassemble the fork legs. ( p. 18)
6 FORK, TRIPLE CLAMP 23
Main work
– Clamp the tap compression in a bench vise using soft jaws.
– Remove nut 1.
– Remove the spring.
– Remove washer 2.
201482-10
– Remove piston 3.
– Remove shim stack 4.
201483-10
– Extract the tap compression.
– Remove O-ring 5.
201484-10
6.13 Checking the fork legs
200728-10
Condition
Fork dismantled.
– Check the inner tube and the axle clamp for damage.
» If damage is found:
– Replace the inner tube.
– Measure the external diameter of the inner tube in several places.
External diameter of inner tube 47.975… 48.005 mm (1.88878…
1.88996 in)
» If the measured value is less than the specified value:
– Replace the inner tube.
200684-10
6 FORK, TRIPLE CLAMP 24
– 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:
– Replace the inner tube.
200685-10
– Check the outer tube for damage.
» If damage is found:
– Replace the outer tube.
200632-10
– Check the surface of the sliding bushings.
» If the bronze-colored layer A under sliding layer B is visible:
– Replace the sliding bushings.
200665-10
200666-10
6.14 Assembling the tap compression
Info
The steps are identical for both fork legs.
– Check the spring length.
Guideline
Spring length with preload spacer(s) 472 mm (18.58 in)
» If the measured value is greater than the specified value:
– Reduce the strength of the pretensioning bushes.
» If the measured value is less than the specified value:
– Increase the strength of the preload spacers.
– Mount O-ring 1.
– Lubricate the O-ring.
Lubricant (T158) ( p. 212)
201484-11
6 FORK, TRIPLE CLAMP 25
– Clamp the tap compression in a bench vise using soft jaws.
– Mount shim stack 2.
Info
Mount the smaller shims below.
– Mount pistons 3 with O-ring.
Info
201485-10
– Grease the piston O-ring.
– Mount washer 4.
– Mount spring 5 with the tighter coil facing downward.
– Mount and tighten the nut 6.
201486-10
– Lock the nut using a punch.
– Extract the tap compression.
The side with the largest inside diameter faces upward.
Fork oil (SAE 4) (48601166S1) ( p. 211)
Guideline
Tap compression nut M6x0.5 3 Nm (2.2 lbf ft)
Info
Washer 4 must be free to move against the spring force.
6.15 Assembling the cartridge
Info
The steps are identical for both fork legs.
200715-10
200718-10
– Clamp in the piston rod.
Clamping stand (T14016S) ( p. 224)
– Mount valve 1 of the rebound damping, with the spring and O-ring.
– Lubricate the O-ring.
Lubricant (T158) ( p. 212)
– Mount spring 2.
– Grease the O-ring of tap rebound 3.
Lubricant (T158) ( p. 212)
– Mount and tighten the tap rebound.
Guideline
Tap rebound M9x1 18 Nm
(13.3 lbf ft)
– Position spring 4.
– Mount shim stack 5.
Loctite®2701
200719-10
Info
Mount the smaller shims below.
– Press the shim stack downward against the spring force.
Info
The shim stack must be pressed downward over the collar.
6 FORK, TRIPLE CLAMP 26
– Mount piston 6 with the piston ring.
Info
The side with the largest inside diameter faces downward.
– Mount shim stack 7.
Info
Align the triangular plate exactly with the piston opening.
– Mount and tighten nut 8.
Guideline
Tap rebound nut M6x0.5 5 Nm (3.7 lbf ft)
200720-10
200749-11
201481-11
Info
Mount the nut with the collar facing downward.
– Lock the nut using a punch.
– Degrease the cartridge and clamp it with the special tool.
Clamping stand (T14015S) ( p. 224)
– Mount and tighten screw sleeve 9.
Guideline
Screw sleeve M29x1 46 Nm
(33.9 lbf ft)
– Before mounting on the piston, wrap the piston ring around the shaft of a screw-
driver.
– Slide piston rod bk into the cartridge.
– Mount tap compression bl in the cartridge.
– Mount lock ring bm.
Loctite®241
201487-10
201479-11
– Mount washer bn and spring seat bo.
6 FORK, TRIPLE CLAMP 27
– Screw on fluid barrier bp as far as it will go.
Info
The fluid barrier must be tightened as much as possible. Do not use tools.
200746-12
6.16 Assembling the fork legs
Info
The steps are identical for both fork legs.
Preparatory work
– Check the fork legs. ( p. 23)
– Assemble the cartridge. ( p. 25)
Main work
– Clamp the inner tube with the axle clamp.
Guideline
Use soft jaws.
200669-10
– Mount special tool.
Protecting sleeve (T1401) ( p. 224)
– Grease and push on dust boot 1.
Lubricant (T511) ( p. 212)
Info
Always change the dust boot, lock ring, seal ring, and support ring.
Mount the sealing lip with the spring expander facing downward.
– Push on lock ring 2.
– Grease and slide on seal ring 3.
Lubricant (T511) ( p. 212)
Info
Mount with the sealing lip facing downward with the open side facing
upward.
– Push on support ring 4.
– Remove the special tool.
– Sand the edges of the sliding bushings with 600-grain sandpaper, then clean and
grease them.
Fork oil (SAE 4) (48601166S1) ( p. 211)
200670-10
6 FORK, TRIPLE CLAMP 28
– Push on the lower sliding bushing 5.
– Mount the upper sliding bushing 6.
Info
Without using a tool, carefully pull the stack apart by hand.
200671-10
– Heat up the outer tube in area A of the lower sliding bushings.
Guideline
50 °C (122 °F)
– Slide the outer tube onto the inner tube.
– Hold the lower sliding bushing with the longer side of the special tool.
Assembly tool (T1402S) ( p. 225)
– Push the sliding bushing all the way into the outer tube.
200723-10
– Position the support ring.
– Hold the seal ring with the shorter side of the special tool.
200724-10
200656-11
Assembly tool (T1402S) ( p. 225)
– 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.
– Mount dust boot 1.
200655-11
200725-10
– Mount adjusting tube 7 of the rebound damping in the cartridge.
The adjusting tube protrudes 5 mm from the cartridge and can be pressed in
against the resistance of the spring.
The adjusting tube protrudes more than 7 mm from the cartridge and cannot
be pressed in against the resistance of the spring.
– Screw on fluid barrier B as far as it will go.
Info
The fluid barrier must be tightened as much as possible. Do not use tools.
– Install the special tool on the cartridge.
Gripping tool (T14026S1) ( p. 225)
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