ktm rc8 repair manual

REPAIR MANUAL 2009

1190 RC8 R EU/UK1190 RC8 R AUS

1190 RC8 R FR1190 RC8 R JP

Article no. 3206077en

PartS

hark

.com

877-

999-

5686

PartS

hark

.com

877-

999-

5686

INTRODUCTION 1

INTRODUCTION

Read this repair manual carefully and thoroughly before beginning work.

Only use ORGINAL KTM SPARE PARTS.

The vehicle will only be able to meet the demands placed on it if the specified service work is performed regularly and properly.

This repair manual was written to correspond to the latest state of this series. We reserve the right to make changes in the interest oftechnical advancement without at the same time updating this manual.We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop will not be specifiedhere. It is assumed that the 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 specifica-tions, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adaptthese to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for deliveryoptions, deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain spe-cial equipment that does not form part of the regular scope of delivery.

© 2009 by KTM-Sportmotorcycle AG, Mattighofen AustriaAll rights reservedReproduction, even in part, 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 leadto the maximum possible quality of the products.Issued by: TÜV Management Service

KTM-Sportmotorcycle AG5230 Mattighofen, Austria

PartS

hark

.com

877-

999-

5686

CONTENTS 2

CONTENTS

MEANS OF REPRESENTATION ............................................ 6IMPORTANT NOTES............................................................ 7LOCATION OF SERIAL NUMBERS ........................................ 8

Vehicle identification number/type label ............................ 8Key number .................................................................... 8Engine number................................................................ 8Fork part number............................................................. 8Shock absorber part number............................................. 8Steering damper part number ........................................... 9

MOTORCYCLE................................................................... 10Jacking up motorcycle front............................................ 10Taking front of motorcycle off work stand......................... 10Jacking up the motorcycle in the middle (screw-in type).... 10Removing the motorcycle from the work stand (screw-intype) ............................................................................ 11Jacking up the motorcycle in the middle (insertabletype) ............................................................................ 12Removing the motorcycle from the work stand (insertabletype) ............................................................................ 12Jacking up motorcycle at the rear.................................... 13Taking the rear from the workstand ................................. 13Starting ........................................................................ 13

01/FORK, TRIPLE CLAMP.................................................. 15Adjusting the compression damping of the fork ................ 15Adjusting the rebound damping of the fork....................... 15Adjusting the spring preload of the fork ........................... 16Bleeding fork legs.......................................................... 16Vehicle level ................................................................. 17Adjusting front vehicle level............................................ 17Removing the fork ......................................................... 18Installing the fork .......................................................... 19performing a fork service ................................................ 21Disassembling the fork legs ............................................ 21Disassembling the outer tubes ........................................ 24Checking the fork legs.................................................... 25changing the lower DU bush........................................... 26Assembling the outer tubes ............................................ 27Assembling the fork legs ................................................ 27

02/HANDLEBAR, CONTROLS AND INSTRUMENTS.............. 32Adjusting basic position of clutch lever............................ 32Adjusting the steering damper ........................................ 32Adjusting the handlebar height ....................................... 32Adjusting the play in the throttle cable ............................ 33Throttle grip.................................................................. 34Changing the throttle grip............................................... 34Adjusting the throttle cable at the throttle valve................ 37

03/FRAME........................................................................ 40Side stand switch .......................................................... 40Footrest position............................................................ 40Adjusting footrest position.............................................. 40Rear frame position ....................................................... 41Adjusting the rear frame position .................................... 41

04/SHOCK ABSORBER, SWINGARM................................... 44Adjusting the low-speed compression damping of theshock absorber .............................................................. 44Adjusting the high-speed compression damping of theshock absorber .............................................................. 44Adjusting the rebound damping of the shock absorber....... 45Adjusting the spring preload of the shock absorber ........... 45Adjusting the vehicle level at the rear .............................. 46Removing the shock absorber ......................................... 46Installing the shock absorber .......................................... 47

Servicing the shock absorber .......................................... 48Removing the spring ...................................................... 48Disassembling the damper ............................................. 49Disassembling the piston rod .......................................... 50Checking the damper ..................................................... 51Assembling the piston rod .............................................. 52Assembling the damper.................................................. 53Bleeding and filling the damper ...................................... 55Filling the damper with nitrogen ..................................... 58Installing the spring....................................................... 59Removing the heim joint ................................................ 59Installing the heim joint ................................................. 60

05/EXHAUST .................................................................... 62Lambda sensor.............................................................. 62Lambda sensor heater.................................................... 62Removing the exhaust cover completely ........................... 63Installing the exhaust cover completely............................ 63Removing the exhaust system ......................................... 63Installing the exhaust system.......................................... 65

06/AIR FILTER.................................................................. 67Removing the air filter ................................................... 67Installing the air filter .................................................... 67Removing the filter box bottom ....................................... 67Installing the filter box bottom........................................ 68

07/FUEL TANK, SEAT, TRIM.............................................. 70Removing the seat ......................................................... 70Fitting the seat.............................................................. 70Removing the passenger seat.......................................... 70Mounting the passenger seat .......................................... 70Dismounting the fuel tank .............................................. 70Installing the fuel tank................................................... 71Removing the fuel tank guard ......................................... 72Installing the fuel tank guard.......................................... 73Checking the fuel pressure ............................................. 73Checking the fuel pressure during the actuator test........... 74

08/MASK, FENDER, DECAL ............................................... 75Removing the side covers ............................................... 75Installing the side covers................................................ 75Removing the inside cover.............................................. 75Installing the inside cover .............................................. 76

09/FRONT WHEEL ............................................................ 77Removing the front wheel............................................... 77Installing the front wheel................................................ 77Checking the tire condition............................................. 78Checking the tire pressure .............................................. 79Checking the front brake discs........................................ 80

10/REAR WHEEL .............................................................. 81Removing the rear wheel ................................................ 81Installing the rear wheel................................................. 81Installing the rear wheel - when installing the engine ........ 82Checking the rear brake disc........................................... 83Checking for chain dirt................................................... 83Cleaning the chain......................................................... 84Checking the chain tension ............................................ 84Adjusting the chain tension ............................................ 85Checking rear sprocket / engine sprocket for wear ............. 85Checking chain wear...................................................... 86Checking chain sliding guard .......................................... 86Checking rear hub cush drive.......................................... 86

11/WIRING HARNESS, BATTERY ....................................... 88Electric starter lock control unit ...................................... 88

PartS

hark

.com

877-

999-

5686

CONTENTS 3

Fuel pump relay ............................................................ 88Removing the battery ..................................................... 88Installing the battery...................................................... 89Recharging the battery ................................................... 90Changing the main fuse ................................................. 91Changing the fuses of individual power consumers............ 91

13/BRAKE SYSTEM........................................................... 93Brake linings................................................................. 93Checking the front brake linings...................................... 93Changing the front brake linings ..................................... 93Checking the front brake fluid level ................................. 95Adding front brake fluid ................................................. 95Adjusting the basic position of the hand brake lever.......... 96Checking the rear brake linings ....................................... 96Changing the rear brake linings....................................... 97Checking the rear brake fluid level .................................. 99Adding rear brake fluid .................................................. 99Adjusting the foot brake pedal stub ............................... 100Adjusting the foot brake pedal ...................................... 100Removing the rear brake system.................................... 101Installing the rear brake system .................................... 101

14/LIGHT SYSTEM, INSTRUMENTS ................................. 102Immobilizer control unit ............................................... 102Activating/deactivating ignition key ............................... 102Activating the ICU ....................................................... 104Combination instrument - Activation of theBOOTLOADER mode.................................................... 105Updating the combination instrument software............... 105Setting ROAD or RACE mode........................................ 106Setting the clock with SET CLOCK ................................ 106Adjusting shift speed RPM1/2 ...................................... 106Setting the blank time of the LAP buttonLAP BLANK T ............................................................. 107Setting the number of laps SET NUM LAPS ................... 107Setting the fuel reserve display TRIPF RESET ................ 108Setting the kilometers/miles SET KM/MILES .................. 108Setting the temperature unit SET °C/°F ......................... 109Switching the external temperature display on/off ........... 109Resetting service display .............................................. 110Checking the headlight setting...................................... 110Adjust the headlight range............................................ 111Changing the parking light bulb .................................... 111Changing the low beam bulb......................................... 112Changing the high beam bulb ....................................... 113

30/ENGINE..................................................................... 115Removing the engine ................................................... 115Preparing the engine for installation .............................. 117Installing the engine .................................................... 117Setting the engine to ignition top dead center of therear cylinder................................................................ 120Setting the engine to ignition top dead center of thefront cylinder .............................................................. 121

30/DISASSEMBLING THE ENGINE................................... 122Clamping the engine into the engine work stand ............. 122Removing the engine bracket........................................ 122Draining the engine oil ................................................. 122Removing the front valve cover ..................................... 123Removing the rear valve cover....................................... 123Setting the engine to ignition top dead center of therear cylinder................................................................ 123Removing the starter motor .......................................... 124Removing the oil filler tube .......................................... 124

Removing the heat exchanger ....................................... 124Removing the rear timing chain tensioner ...................... 124Removing the rear camshaft ......................................... 125Removing the rear cylinder head ................................... 125Removing the rear piston.............................................. 125Setting the engine to ignition top dead center of thefront cylinder .............................................................. 126Removing the front timing chain tensioner ..................... 126Removing the front camshafts ...................................... 126Removing the front cylinder head.................................. 126Removing the front piston ............................................ 127Removing the generator cover ....................................... 127Removing the ignition pulse generator ........................... 127Removing the torque limiter and idler............................ 128Removing the rotor ...................................................... 128Removing the idler and timing chain on the left ............. 128Removing the oil filter.................................................. 129Removing the balancer shaft ........................................ 129Removing the drive wheel of the balancer shaft .............. 129Removing the gear position sensor ................................ 130Removing the left suction pump ................................... 130Removing the water pump wheel................................... 131Removing the clutch cover ........................................... 131Removing the idler and timing chain on the right............ 132Removing the clutch facing .......................................... 132Removing the outer clutch hub ..................................... 132Removing the primary gear ........................................... 133Removing the force pump ............................................ 133Removing the shift shaft .............................................. 134Removing the shift drum locating.................................. 134Removing the locking lever........................................... 135Removing the left engine case ...................................... 135Removing the crankshaft.............................................. 135Removing the middle suction pump .............................. 136Removing the transmission shaft................................... 136Removing the oil spray tube ......................................... 137Removing the timing chain rails of the right engine casesection ....................................................................... 137Removing the timing chain rails of the left engine casesection ....................................................................... 137

30/ENGINE - WORK ON INDIVIDUAL PARTS..................... 138Work on the right section of the engine case .................. 138Removing the main bearing of the right engine casesection ....................................................................... 139Selecting the main bearing shells.................................. 140Installing the right main bearing ................................... 140Work on the left section of the engine case .................... 141Removing the left main bearing .................................... 143Installing the left main bearing ..................................... 143Changing the conrod bearing ........................................ 144Work on the clutch cover.............................................. 145Changing the step bearing of the crankshaft................... 146Checking the radial clearance of the bottom connectingrod bearing ................................................................. 147Checking/measuring the cylinder................................... 147Checking/measuring the piston ..................................... 148Checking the piston ring end gap .................................. 149Checking the piston/cylinder mounting clearance............ 149Work on the cylinder head ............................................ 149Checking the cylinder head .......................................... 152Work on the right idler ................................................. 153Checking the timing assembly ...................................... 154

PartS

hark

.com

877-

999-

5686

CONTENTS 4

Preparing the timing chain tensioner for installation ....... 154Checking the oil pressure regulator valve........................ 155Checking the oil pumps................................................ 155Checking the clutch..................................................... 156Checking the shift mechanism...................................... 157Preassembling the shift shaft........................................ 158Dismantling the main shaft .......................................... 158Dismantling the countershaft........................................ 159Checking the transmission............................................ 160Assembling the main shaft ........................................... 161Assembling the countershaft......................................... 161

30/ASSEMBLING THE ENGINE ........................................ 163Installing the timing chain rails of the left engine casesection ....................................................................... 163Installing the timing chain rails of the right engine casesection ....................................................................... 163Installing the oil spray tube .......................................... 164Installing the transmission shaft ................................... 164Installing the middle suction pump ............................... 165Installing the crankshaft............................................... 165Installing the left engine case ....................................... 166Installing the locking lever............................................ 167Installing the shift drum locating .................................. 167Installing the shift shaft ............................................... 167Installing the force pump ............................................. 168Installing the left suction pump .................................... 169Setting the engine to ignition top dead center of therear cylinder................................................................ 169Installing the primary gear............................................ 170Installing the outer clutch hub...................................... 170Installing the clutch facing........................................... 171Installing the idler and timing chain on the right ............ 172Installing the clutch cover ............................................ 172Installing the water pump wheel ................................... 173Installing the gear position sensor ................................. 173Installing the drive wheel of the balancer shaft............... 173Installing the balancer shaft ......................................... 174Installing the idler and timing chain on the left .............. 174Installing the oil filter .................................................. 175Installing the rotor ....................................................... 175Installing the torque limiter and idler ............................ 176Installing the ignition pulse generator............................ 176Installing the generator cover........................................ 176Installing the oil drain plug........................................... 176Installing the rear piston .............................................. 177Installing the rear cylinder head.................................... 178Installing the rear camshaft .......................................... 179Installing the rear timing chain tensioner ....................... 179Setting the engine to ignition top dead center of thefront cylinder .............................................................. 180Installing the front piston ............................................. 180Installing the front cylinder head................................... 182Installing the front camshafts ....................................... 182Installing the front timing chain tensioner...................... 183Installing the heat exchanger ........................................ 183Installing the oil filler tube ........................................... 184Installing the starter motor ........................................... 184Checking the rear cylinder control time.......................... 184Adjusting the rear cylinder control time ......................... 184Checking the rear valve clearance ................................. 185Adjusting the rear valve clearance ................................. 186Checking the front cylinder control time ........................ 186

Adjusting the front cylinder control time ........................ 186Checking the front valve clearance ................................ 187Adjusting the front valve clearance................................ 188Installing the front valve cover ...................................... 188Installing the rear valve cover ....................................... 188Mounting the engine bracket ........................................ 189Dismounting the engine from the work stand.................. 189

31/SECONDARY AIR SYSTEM .......................................... 190Exhaust air injection .................................................... 190

32/CLUTCH .................................................................... 191Checking fluid level of hydraulic clutch ......................... 191Correcting fluid level of hydraulic clutch........................ 191

34/SHIFT MECHANISM ................................................... 192Adjusting shift lever stub.............................................. 192Adjusting shift lever..................................................... 192

35/WATER PUMP, COOLING SYSTEM .............................. 194Checking the coolant level............................................ 194Checking the antifreeze................................................ 194Removing the radiator.................................................. 195Installing the radiator................................................... 195Adding coolant/bleeding the cooling system ................... 196Filling the cooling system compensating tank................. 197

36/CYLINDER HEAD........................................................ 198Engine coolant temperature sensor cylinder 1 ................ 198Engine coolant temperature sensor for cylinder 2............ 199Checking the valve clearance ........................................ 200Adjusting the rear valve clearance ................................. 201Adjusting the front valve clearance................................ 202Checking the rear cylinder control time.......................... 202Checking the front cylinder control time ........................ 202Adjusting the rear cylinder control time ......................... 203Adjusting the front cylinder control time ........................ 204Removing the rear camshaft ......................................... 205Installing the rear camshaft .......................................... 205Removing the front camshafts ...................................... 206Installing the front camshafts ....................................... 206Installing the rear timing chain tensioner ....................... 207Installing the front timing chain tensioner...................... 207

38/LUBRICATION SYSTEM .............................................. 208Oil circuit ................................................................... 208Checking the engine oil level ........................................ 209Changing the engine oil and filter, cleaning the oilscreens....................................................................... 209Draining engine oil, cleaning oil screens ........................ 209Removing the oil filter.................................................. 211Installing the oil filter .................................................. 212Filling up with engine oil .............................................. 212Adding engine oil ........................................................ 213Checking the engine oil pressure................................... 213Removing the oil jet for the clutch lubrication ................ 215Checking / cleaning the oil jet for clutch lubrication........ 216Installing the oil jet for the clutch lubrication................. 216

39/IGNITION SYSTEM..................................................... 218Crankshaft position sensor............................................ 218Ignition coil ................................................................ 218

41/THROTTLE VALVE BODY............................................. 219Throttle position sensor circuit A................................... 219Throttle position sensor circuit A - checking in the"zero" position ............................................................. 219Adjusting the position of the throttle position sensor incircuit A ..................................................................... 220Removing the throttle valve body to adjust ..................... 221

PartS

hark

.com

877-

999-

5686

CONTENTS 5

Reinstalling the throttle valve body when theadjustments have been made........................................ 222Throttle position sensor circuit B................................... 223Manifold absolute pressure sensor................................. 223Connecting the vacuum hand pump to the manifoldabsolute pressure sensor .............................................. 224Ambient air pressure sensor.......................................... 225Injector ...................................................................... 225Rollover sensor............................................................ 226EFI control unit ........................................................... 227Requesting the EFI control unit activation code.............. 227Coding the EFI control unit........................................... 227Flashing the EFI control unit ........................................ 228

IMMOBILIZER BLINK CODE............................................. 229ENGINE CONTROL TROUBLE CODE................................. 238CONNECTOR OVERVIEW.................................................. 391

Motor drive circuit A connector AE ................................ 391Connector AI ............................................................... 391Crankshaft position sensor connector AL........................ 391Clutch switch, connector AL ......................................... 391Throttle position sensor circuit A, connector AM............. 391Throttle position sensor circuit B, connector AM............. 392Gear position sensor, connector AM............................... 392Fuel pump connector AM ............................................. 392Wheel speed sensor, connector AM ............................... 392Connector AO.............................................................. 392Diagnostic connection plug AP...................................... 393Rollover sensor connector AP........................................ 393Throttle position sensor circuit A, connector AR.............. 393Throttle position sensor circuit B, connector AR ............. 394Fuel pump connector AR.............................................. 394Side stand switch, connector AR................................... 394Ignition coil cylinder 1 connector AS ............................. 394Ignition coil cylinder 2 connector AS ............................. 394CAN bus terminating resistor connector AT .................... 395Crankshaft position sensor, connector AT....................... 395Clutch switch connector AT .......................................... 395Engine coolant temperature sensor cylinder 1 connectorAX.............................................................................. 395Throttle stepper motor circuit B, connector CA ............... 395Lambda sensor cylinder 1, connector CA ....................... 396Lambda sensor cylinder 2, connector CA ....................... 396Lambda sensor cylinder 1, connector CE ....................... 396Lambda sensor cylinder 2, connector CE ....................... 396Secondary air valve connector CK.................................. 396Connector CM ............................................................. 397Connector CO.............................................................. 397Connector CP .............................................................. 398Connector CQ.............................................................. 398Connector CU.............................................................. 398Fuel evaporation valve connector DF.............................. 399Secondary air valve connector DF.................................. 399Electric starter lock control unit, connector DN .............. 399Immobilizer control unit, connector DN ......................... 399Electric starter lock control unit, connector DO............... 399Immobilizer control unit, connector DO.......................... 400Ambient air pressure sensor connector DP ..................... 400Manifold absolute pressure sensor cylinder 1,connector DP .............................................................. 400Manifold absolute pressure sensor cylinder 2connector DP .............................................................. 400Injector cylinder 1 connector DQ................................... 400

Injector cylinder 2 connector DQ................................... 401ICU antenna connector DV ........................................... 401Fuel pump relay connector EB ...................................... 401ICU antenna connector EL............................................ 401Connector EQ.............................................................. 401Connector ER.............................................................. 402Connector ES .............................................................. 402Connector ET .............................................................. 402Combination instrument connector EV ........................... 403Exhaust air injection valve, connector FE ....................... 403Fuel pump relay .......................................................... 404CAN bus terminating resistor ........................................ 404

TECHNICAL DATA - ENGINE............................................ 405Capacity - engine oil .................................................... 405Capacity - coolant........................................................ 406

TECHNICAL DATA - TOLERANCE, WEAR LIMITS OFENGINE ......................................................................... 407TECHNICAL DATA - ENGINE TIGHTENING TORQUES........ 409TECHNICAL DATA - CHASSIS .......................................... 411

Lighting equipment ..................................................... 411Capacity - fuel............................................................. 412

TECHNICAL DATA - FORK................................................ 413TECHNICAL DATA - SHOCK ABSORBER ........................... 414TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ...... 415CLEANING/CONSERVATION............................................. 417

Cleaning motorcycle .................................................... 417Conservation for winter operation .................................. 417

STORAGE ....................................................................... 419Storage....................................................................... 419Putting into operation after storage ............................... 419

SERVICE SCHEDULE....................................................... 420Important service tasks to be carried out by anauthorized KTM-RC8 workshop. .................................... 420Important service tasks to be carried out by anauthorized KTM-RC8 workshop. (as additional job) ......... 421

WIRING DIAGRAM .......................................................... 4221 of 3......................................................................... 4222 of 3......................................................................... 4263 of 3......................................................................... 432

OPERATING SUBSTANCES.............................................. 436AUXILIARY SUBSTANCES................................................ 438SPECIAL TOOLS.............................................................. 440STANDARDS................................................................... 452INDEX ............................................................................ 453

PartS

hark

.com

877-

999-

5686

MEANS OF REPRESENTATION 6

Symbols usedThe 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).

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

Formats usedThe typographical formats used in this document are explained below.

Specific name Identifies a proprietary name.

Name® Identifies a protected name.

Brand™ Identifies a brand available on the open market.

PartS

hark

.com

877-

999-

5686

IMPORTANT NOTES 7

WarrantyThe work described in the service schedule must be carried out exclusively in an authorized KTM-RC8 workshop and confirmed in theservice record, since otherwise any warranty claim is meaningless. No warranty claim can be met for damage resulting from manipula-tion and/or other changes to the vehicle.

MaterialsThe fuels, lubricants and other materials named in this repair manual must be used according to specifications.

Spare parts, accessoriesOnly use spare parts and accessories approved and/or recommended by KTM. KTM accepts no liability for other products and anyresulting damage.

You will find the current KTM PowerParts for your vehicle on the KTM website.International KTM Website: http://www.ktm.com

Work rulesSpecial tools are necessary for some of the work. These are not included with the vehicle and can be ordered under the number inparentheses. Ex: valve spring mounter (59029019000)During assembly, non-reusable parts (e.g. self-locking screws and nuts, seals and seal rings, O-rings, pins, lock washers) must bereplaced by new parts.If thread lock (e.g. Loctite®) is used for screw connections, be sure to comply with the manufacturer's specific instructions on itsusage.Parts that you want to reuse following repairs and servicing should be cleaned and checked for damage and wear. Change damaged orworn parts.Following repairs or servicing, the vehicle must be checked for roadworthiness.

Notes/warningsPay close attention to the notes/warnings.

InfoVarious information and warning labels are affixed to the vehicle. Do not remove information/warning labels. If they are miss-ing, you or others may not recognize sources of danger and may therefore be injured.

Grades of risks

DangerIdentifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measuresare not taken.

WarningIdentifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.

CautionIdentifies a danger that may lead to minor injuries if the appropriate measures are not taken.

NoteIdentifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.

WarningIdentifies a danger that will lead to environmental damage if the appropriate measures are not taken.

Repair manual– Read this repair manual carefully and thoroughly before beginning work. It contains useful information and tips that will help you

repair and service your motorcycle.

– This manual assumes that the necessary special KTM tools and workplace and workshop equipment are available.

PartS

hark

.com

877-

999-

5686

LOCATION OF SERIAL NUMBERS 8

3.1Vehicle identification number/type label

100654-10

The vehicle identification number is stamped on the frame behind the steering headon the right.The type label is on the frame above the vehicle identification number.

3.2Key number

700222-01

The key number Code number can be found on the KEYCODECARD.

InfoYou need the key number to order a spare key. Keep the KEYCODECARD in a safeplace.Use the orange programming key to activate and deactivate the black ignitionkey. Keep the orange programming key in a safe place: it must only be used forlearning and programming functions.

3.3Engine number

100655-10

The engine number is stamped on the right side of the engine.

3.4Fork part number

100656-10

The fork part number is stamped on the inner side of the fork stub.

3.5Shock absorber part number

100657-10

The shock absorber part number is stamped on the upper part of the shock absorberabove the adjusting ring towards the rear.

PartS

hark

.com

877-

999-

5686

LOCATION OF SERIAL NUMBERS 9

3.6Steering damper part number

100658-10

The steering damper part number is stamped on the top of the steering damper.

PartS

hark

.com

877-

999-

5686

MOTORCYCLE 10

4.1Jacking up motorcycle front

NoteDanger of damage The parked vehicle can roll away or fall over.

– Always place the vehicle on a firm and even surface.

– Jack up the motorcycle at the rear. ( p. 13)

100679-10

– Move the handlebar to the straight-ahead position. Align the work stand at the frontwith the adapters to the fork legs.

Front work stand (61029055300) ( p. 443)

InfoAlways jack up the rear of the motorcycle first.

– Jack up the motorcycle at the front.

4.2Taking front of motorcycle off work stand



– Secure the motorcycle against falling over.

– Remove the work stand from the front.

4.3Jacking up the motorcycle in the middle (screw-in type)



200598-01

– Remove screw .

– Remove screws . Take off the footrest bracket.

200599-01

– Unplug connector of the brake light switch. Remove cable binder .

– Remove screw . Hang the brake fluid reservoir to the side.

– Remove screws . Hang the footrest bracket to the side.

PartS

hark

.com

877-

999-

5686

MOTORCYCLE 11

200600-01

– Screw the holder of the special tool all the way into the lower drill holes of thefootrest brackets. Select the required height and width of the work stand.

Work stand (62529055000) ( p. 447)

– Jack up the motorcycle.

InfoCheck that the work stand is seated correctly.

4.4Removing the motorcycle from the work stand (screw-in type)



200600-01

– Remove the motorcycle from the work stand and rest it on the side stand.

– Unscrew the holder of the special tool from the drill holes in the footrest brackets.Remove the work stand.

Work stand (62529055000) ( p. 447)

200599-11

– Position the footrest bracket. Mount and tighten screws .

Guideline

Screw, front footrestbracket

M8 25 Nm(18.4 lbf ft)

Loctite® 243™

– Position the brake fluid reservoir. Mount and tighten screw .

Guideline

Screw, brake fluid reser-voir of rear brake

M5 5 Nm(3.7 lbf ft)

Loctite® 243™

– Plug in connector of the brake light switch. Secure the cable with cablebinder .

PartS

hark

.com

877-

999-

5686

MOTORCYCLE 12

200598-11


Guideline


M8 25 Nm(18.4 lbf ft)

Loctite® 243™

– Position the shift rod. Mount and tighten screw .

Guideline

Screw, shift rod M6 12 Nm(8.9 lbf ft)

Loctite® 243™

4.5Jacking up the motorcycle in the middle (insertable type)



200597-01

– Let the work stand engage in the opening of the swingarm pivot with the plasticsleeve. Select the required height and width of the work stand.

Work stand (62529055000) ( p. 447)

– Jack up the motorcycle.

InfoCheck that the work stand is seated correctly.

4.6Removing the motorcycle from the work stand (insertable type)


– Always place the vehicle on a firm and even surface.PartS

hark

.com

877-

999-

5686

MOTORCYCLE 13

200597-01

– Remove the motorcycle from the work stand and rest it on the side stand.

– Remove the work stand.

Work stand (62529055000) ( p. 447)

4.7Jacking up motorcycle at the rear



100680-10

– Insert the work stand adapter in the rear of the work stand.

Work stand adapter (61029055120) ( p. 442)

Work stand rear (61029055100) ( p. 442)

– Stand the motorcycle upright, align the work stand to the link fork and theadapters, and jack up the motorcycle.

4.8Taking the rear from the workstand



– Secure the motorcycle against falling over.

– Remove the work stand from the rear and lean the vehicle on the side stand.

4.9Starting

DangerDanger of poisoning Exhaust gases are poisonous and can result in unconsciousness and/or death.

– When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in a closedspace without an effective exhaust extraction system.

CautionDanger of accidents If the vehicle is operated with a discharged battery or without a battery, electronic components and safetyequipment may be damaged.

– Never operate the vehicle with a discharged battery or without a battery.

PartS

hark

.com

877-

999-

5686

MOTORCYCLE 14

NoteEngine 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.

100677-10

– Press the emergency OFF switch into the position .

– Switch on the ignition by turning the black programming key to the position ON .

After you switch on the ignition, you can hear the fuel pump working for abouttwo seconds. The function test of the combination instrument is run at thesame time.

– Shift into neutral.

The green idling speed indicator lamp N lights up.

– Press the electric starter button .

InfoDo not press the electric starter button until the function test of the combi-nation instrument is finished.When starting the engine, DO NOT apply the throttle. If you apply the throttleduring the starting procedure, the engine management shuts off the injec-tors and the engine will not start.Press the starter for a maximum of 5 seconds. Wait for a least 5 secondsbefore trying again.This motorcycle is equipped with a safety start system. You can only startthe engine if the transmission is in neutral or if the clutch is pulled when agear is engaged. If the side stand is folded down and you shift into gear andrelease the clutch, the engine stops.

– Take the weight off the side stand and swing it upwards with your foot as far as itwill go.

PartS

hark

.com

877-

999-

5686

01/FORK, TRIPLE CLAMP 15

5.1Adjusting the compression damping of the fork

InfoThe hydraulic compression damping determines the fork suspension behavior.An optimally adjusted compression damping ensures that the fork does not compress too far and fast when you brake hard orwhen the load shifts very fast. It gives the rider good feedback about the road conditions.

100682-10

– Turn adjusting screws clockwise until they stop.

InfoThe 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

Comfort 15 clicks

Standard 10 clicks

Sport 5 clicks

Full payload 5 clicks

InfoTurn clockwise to increase damping, turn counterclockwise to reduce sus-pension damping.

5.2Adjusting the rebound damping of the fork

InfoThe hydraulic rebound damping determines the fork rebound behavior.An optimally adjusted rebound damping brakes the springing energy and enables a fast, vibration-free resetting of the fork tothe zero position.

100683-10

– Turn adjusting screws clockwise to the stop.

InfoThe adjusting screws are located at the top end of the fork legs.Adjust both fork legs to the same setting.

– Turn back counterclockwise by the number of clicks corresponding to the fork type.

Guideline

Rebound damping

Comfort 15 clicks

Standard 10 clicks

Sport 5 clicks


InfoTurn clockwise to increase suspension damping; turn counterclockwise toreduce damping.

PartS

hark

.com

877-

999-

5686


5.3Adjusting the spring preload of the fork

InfoSpring preload determines the initial fork position.The spring preload setting is optimal when it is set for the weight of the rider and that of any baggage and a passenger, andthus ensures a compromise between maneuverability and stability.

100683-11

– Turn adjusting screws clockwise to the stop.

InfoThe adjustment screws are located at the top end of the fork legs.Adjust both fork legs to the same setting.

– Turn back counterclockwise by the number of turns according to the fork type.

Guideline

Spring preload - Preload Adjuster

Comfort 5 turns

Standard 5 turns

Sport 3 turns

Full payload 3 turns

InfoTurn clockwise to increase preload, turn counterclockwise to reduce springpreload.Changing the spring preload has no influence on the rebound dampingalthough the adjustment screws turn during the adjustment work. However,you should also adjust the rebound damping when you alter the springpreload.

5.4Bleeding fork legs– Lean the motorcycle on the side stand.

100684-10

– Remove bleeder screws briefly.

Any excess pressure escapes from the interior of the fork.

– Mount and tighten bleeder screws.

InfoPerform this action on both fork legs.

PartS

hark

.com

877-

999-

5686


5.5Vehicle level

100693-01

WarningDanger of accidents Modifications to the suspension settings can seriously alterthe vehicle's ride behavior.

– Following modifications, ride slowly at first to get the feel of the new ridebehavior.

The vehicle level can be adjusted at the front by means of the fork leg clamp and atthe rear by the eccentric shaft.The fork legs can be clamped at three positions in the triple clamps.

Upper triple clamp flushwith upper edge of fork legs

0 mm (0 in)

Upper triple clamp flushwith 1st ring of fork legs

2.5 mm (0.098 in)

Upper triple clamp flushwith 2nd ring of fork legs(standard)

5 mm (0.2 in)

The infinitely variable frame height setting can be adjusted by turning the eccentricshaft.

Frame height differenceHIGH - LOW

12 mm (0.47 in)

Maximum adjustment rangebetween HIGH - LOW

180°

5.6Adjusting front vehicle level

WarningDanger 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.

100694-10

– Loosen screws on the lower triple clamp.

– Loosen screw on the upper triple clamp.

– Loosen screw of the handlebar stub.

InfoLoosen the screws far enough to prevent damage to the lacquer when thefork legs are moved.Make the adjustments first on one fork leg and then on the other. When thescrews of both fork legs are loosened, the vehicle sags toward the front.

100695-01

– Align the fork leg in the desired position by means of the fork rings.

Guideline

Upper triple clamp flush with upperedge of fork legs

0 mm (0 in)

Upper triple clamp flush with 1st ringof fork legs

2.5 mm (0.098 in)

Upper triple clamp flush with 2nd ringof fork legs (standard)

5 mm (0.2 in)

InfoThe standard adjustment is the setting that provides the best vehicle han-dling. When the fork is compressed, the suspension setting changes, caus-ing the vehicle to become more stable but also more difficult to handle.

PartS

hark

.com

877-

999-

5686


100694-11

– Tighten screw .

Guideline

Screw, top triple clamp M8 17 Nm(12.5 lbf ft)

– Tighten screws .

Guideline

Screw, bottom triple clamp M8 15 Nm(11.1 lbf ft)

– Tighten screw .

Guideline

Screw, handlebar stub M8 20 Nm(14.8 lbf ft)

– Repeat the adjustment on the other fork leg.

InfoThe vehicle level setting on both fork legs must be identical.

5.7Removing the fork– Jack up the motorcycle in the middle (insertable type). ( p. 12)

– Clamp down the rear of the vehicle.

100719-10

– Remove the screws from both brake calipers.

– Press back the brake linings with a light lateral tilting of the brake calipers on thebrake disc. Pull the brake caliper carefully back from the brake discs and hang it tothe side.

InfoDo not pull the hand brake lever when the brake calipers are removed.

201056-10

– Loosen screws and .

– Unscrew screw about six turns and press your hand on the screw to push thewheel spindle out of the axle clamp. Remove screw .

WarningDanger of accidents Reduced braking efficiency caused by damaged brakediscs.

– Always lay the wheel down in such a way that the brake discs are notdamaged.

– Holding the front wheel, withdraw the wheel spindle. Take the front wheel out ofthe fork.

201057-10

– Remove the screws on both sides of the fender . Take off the fender.

PartS

hark

.com

877-

999-

5686


201058-10

– Remove screws . Hang the wheel speed sensor to the side.

201059-10

– Unscrew screws of the triple clamps and handlebar stubs. Remove the fork legsdownward.

5.8Installing the fork



100695-01

– Slide the fork legs into the triple clamps and handlebar stubs.

– Align the fork leg in the desired position by means of the fork rings.

Guideline

Upper triple clamp flush with upperedge of fork legs

0 mm (0 in)

Upper triple clamp flush with 1st ringof fork legs

2.5 mm (0.098 in)

Upper triple clamp flush with 2nd ringof fork legs (standard)

5 mm (0.2 in)

InfoThe standard adjustment is the setting that provides the best vehicle han-dling. When the fork is compressed, the suspension setting changes, caus-ing the vehicle to become more stable but also more difficult to handle.

201059-11

– Tighten screws of the triple clamps and handlebar stubs.

Guideline

Screw, top triple clamp M8 17 Nm(12.5 lbf ft)

Screw, bottom triple clamp M8 15 Nm(11.1 lbf ft)


201058-11

– Position the wheel speed sensor. Mount and tighten screws .

Guideline

Screw, wheel speed sensor M4 2 Nm(1.5 lbf ft)

Loctite® 243™

PartS

hark

.com

877-

999-

5686


201057-11

– Position the fender. Mount and tighten screws .

Guideline

Remaining chassis screws M6 10 Nm (7.4 lbf ft)

100781-11

– Clean and grease the shaft seal rings and mating surfaces of the spacers.

Long-life grease ( p. 438)

100780-11

– Insert the wide spacer on the left-hand side (when looking in the direction oftravel).

InfoThe arrow indicates the direction of rotation of the front wheel.

– Insert the narrow spacer on the right-hand side (when viewed in the direction oftravel).

201060-10

WarningDanger of accidents Reduced braking efficiency due to oil or grease on thebrake discs.

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

– Clean screw and the wheel spindle.

– Lift the front wheel into the fork, position it, and insert the wheel spindle.

– Mount and tighten screw .

Guideline

Bolt, front axle M25x1.5 45 Nm(33.2 lbf ft)

100719-12

– Position the brake calipers and check that the brake linings are seated correctly.

– Mount screws on both brake calipers but do not tighten yet.

– Operate the hand brake lever repeatedly until the brake lining presses up againstthe brake disc and there is a pressure point. Fix the hand brake lever in the acti-vated position.

The brake calipers align themselves.

– Tighten screws on both brake calipers.

Guideline

Screw, front brake caliper M10x1.25 45 Nm(33.2 lbf ft)

Loctite® 243™

– Release the fixation of the hand brake lever.

– Release the rear of the vehicle.

– Remove the motorcycle from the work stand (insertable type). ( p. 12)

PartS

hark

.com

877-

999-

5686


100782-11

– Pull the front brake and compress the fork powerfully a few times.

The fork legs straighten.


Guideline

Fork end pinch bolts M8 15 Nm(11.1 lbf ft)

5.9performing a fork service

InfoThese operations are the same on both fork legs.

ConditionThe fork legs have been removed.

201097-01

– Disassemble the fork legs. ( p. 21)

– Disassemble the outer tubes. ( p. 24)

– Change the lower DU bush. ( p. 26)

– Check the fork legs. ( p. 25)

– Assemble the outer tubes. ( p. 27)

– Assemble the fork legs. ( p. 27)

5.10Disassembling the fork legs


ConditionThe fork legs have been removed.

200605-10

– Determine and note down the current setting of rebound damping and compres-sion damping .

– Completely open the adjusting elements of the rebound and compression damping.

– Determine and note down the current setting of spring preload .

– Completely open the adjusting elements of the spring preload.

PartS

hark

.com

877-

999-

5686


200606-10

– Clamp the fork leg in the area of the lower triple clamp.

Clamping stand (T612S) ( p. 451)

200607-10

– Release Preload Adjuster .

Key (T524) ( p. 450)

InfoThe Preload Adjuster cannot be removed yet.

– Unclamp the fork leg. Slide the outer tube down.

200608-10

– Clamp aluminum tube with the special tool.


200609-10

– Pull up Preload Adjuster . Mount the special tool on the hexagonal piece.

Open-end wrench (T14032) ( p. 450)

200610-10

– Hold the hexagonal piece in place with the special tool. Release Preload Adjuster and remove it with preload spacers .Par

tSha

rk.c

om

877-

999-

5686


200611-10

– Remove adjusting tube .

200612-10

– Screw special tool onto the piston rod and pull it up.

Gripping tool (T14026S1) ( p. 449)

– Remove the special tool from the hexagonal piece.


– Release special tool .


200613-10

– Unclamp the fork leg and clamp it with the axle clamp.

– Pull out pin of the special tool.

200614-10

– Pull collar bushing off of aluminum tube . Slide the aluminum tube over thespecial tool.

– Unscrew the special tool.

– Remove the collar bushing.

– Remove spring .

– Unclamp the fork leg.

InfoHold the fork leg by the axle clamp.

– Drain the fork oil.

InfoPull out the piston rod and push back in a number of times to empty thecartridge.

200615-10

– Pull outer tube off of inner tube .

PartS

hark

.com

877-

999-

5686


200616-10

– Clamp the fork leg with the axle clamp.

– Remove screws .

200617-10

– Unscrew screws of the cartridge and remove with the seal ring.

InfoPlace a drain pan underneath.

200618-10

– Remove the cartridge.

5.11Disassembling the outer tubes

InfoThese operations are the same on both outer tubes.

– Disassemble the fork legs. ( p. 21)

200619-10

– Clamp the outer tube in the area of the lower triple clamp.


– Remove dust boot .

PartS

hark

.com

877-

999-

5686


200620-10

– Remove lock ring .

200621-10

– Remove seal ring .

200622-10

– Remove support ring .

5.12Checking the fork legsConditionThe fork legs must be disassembled.

200629-10

– Check the inner tube and axle clamp for damage.

» If there is damage:

– Change the inner tube.

200630-10

– Measure the outside diameter at several locations on the inner tube.

Outside diameter of inner tube 42.975… 43.005 mm (1.69193…1.69311 in)

» If the measured value is less than the specified value:


PartS

hark

.com

877-

999-

5686


200631-10

– 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:


200632-10

– Check the outer tube for damage.

» If there is damage:

– Change the outer tube.

200665-10

– Check the surface of the upper DU bush.

» If the bronze-colored layer under the sliding layer is visible:

– Change the outer tube.

– Check the surface of the lower DU bush.

» If the bronze-colored layer under the sliding layer is visible:

– Change the lower DU bush. ( p. 26)

200666-10

– Check the spring length.

Guideline

Spring length with preload spacer(s) 405 mm (15.94 in)


– Reduce the thickness of the preload spacer.

» If the measured value is less than the specified value:

– Increase the thickness of the preload spacer.

5.13changing the lower DU bush– Disassemble the outer tubes. ( p. 24)

200664-10

– Heat the outer tube in the area of the lower DU bush.

Guideline

50 °C (122 °F)

– Remove DU bush .

– Press the new DU bush all the way in.


PartS

hark

.com

877-

999-

5686


5.14Assembling the outer tubes

InfoThese operations are the same on both outer tubes.

– Check the fork legs. ( p. 25)

200622-11

– Clamp the outer tube in the area of the lower triple clamp.


– Insert support ring .

200621-11

– Lubricate seal ring and mount it with the open side facing downward.

Lubricant (T511) ( p. 438)

200620-11

– Mount lock ring .

The lock ring engages audibly.

200619-11

– Lubricate and mount dust boot .


5.15Assembling the fork legs



PartS

hark

.com

877-

999-

5686


200618-11

– Slide the cartridge into the inner tube with spring seat and the preload bush.

200626-10

– Clamp the fork leg with the axle clamp.


Guideline

Screw, cartridge M12x1 25 Nm(18.4 lbf ft)

200616-11

– Lubricate and mount screws of the axle clamp but do not tighten.


200615-11

– Vertically clamp the fork leg with the axle clamp.

– Slide outer tube onto inner tube .

200623-10

– Position the spring in the inner tube.

PartS

hark

.com

877-

999-

5686


200624-10

– Slide on collar bushing .

– Slide adjusting tube into the piston rod.

200627-10

– Install the special tool.


InfoThe special tool must be used to prevent the adjusting tube from beingraised, which would cause oil to enter into the piston rod.

– Add fork oil.

Fork oil per forkleg

520 ml(17.58 fl. oz.)

Fork oil (SAE 5) ( p. 437)

InfoPull out the piston rod and push back in a number of times to bleed the car-tridge.

200625-10

– Slide on aluminum tube . Mount collar bushing .

200612-11

– Mount pin of special tool .


– Clamp the fork leg at the aluminum tube with the special tool.


– Pull up special tool and mount special tool onto the hexagonal piece.

Open-end wrench (T14032) ( p. 450)PartS

hark

.com

877-

999-

5686


200628-10

– Unscrew the special tool from the piston rod.


– Lubricate the thread of the piston rod.


– Lubricate the upper edge of the piston rod.


– Mount Preload Adjuster with preload spacer .

InfoThe Preload Adjuster must reach the stop before the piston rod begins turn-ing as well. If the piston rod thread is stiff, the rod must be held to preventit from turning. If the Preload Adjuster is not screwed in all the way, therebound adjustment will not function properly.

– Counter with the special tool and tighten the Preload Adjuster.

Guideline

Preload Adjuster on piston rod M12x1 25 Nm(18.4 lbf ft)


200609-11

– Pull up Preload Adjuster and remove the special tool from the hexagonal piece.


200606-10

– Unclamp the fork leg. Slide the outer tube up and clamp in the area of the lowertriple clamp.


200607-11

– Lubricate the O-ring of the Preload Adjuster .


– Screw on the Preload Adjuster and tighten.

Guideline

Preload Adjuster on outer tube M46x1 50 Nm(36.9 lbf ft)

Key (T524) ( p. 450)

200605-11

Alternative 1– Turn the adjusting screw of compression damping and the adjusting screw of

rebound damping all the way clockwise.

– Turn back counterclockwise by the number of clicks corresponding to the forkleg type.

PartS

hark

.com

877-

999-

5686


Guideline

Rebound damping

Comfort 15 clicks

Standard 10 clicks

Sport 5 clicks


Compression damping

Comfort 15 clicks

Standard 10 clicks

Sport 5 clicks


– Turn the adjusting screw of spring preload all the way clockwise.

– Turn back counterclockwise by the number of turns according to the fork type.

Guideline


Comfort 5 turns

Standard 5 turns

Sport 3 turns


Alternative 2

WarningDanger of accidents Modifications to the chassis can seriously alter thevehicle's handling characteristics.

– Extreme modifications to the adjustment of the spring elements cancause a serious deterioration in the handling characteristics andoverload some components.

– Make settings within the recommended range only.

– Following modifications, ride slowly at first to get the feel of the newhandling characteristics.

– Return the adjusting screws to the position determined when the unit was dis-assembled.

PartS

hark

.com

877-

999-

5686

02/HANDLEBAR, CONTROLS AND INSTRUMENTS 32

6.1Adjusting basic position of clutch lever

100751-10

– Adjust the basic setting of the clutch lever to your hand size by turning adjustingscrew .

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

6.2Adjusting the steering damper

InfoThe hydraulic steering damper stabilizes the steering if the front wheel is raised off the ground or carries no load.In contrast to other damping elements, the steering damper is adjusted with the damping element open.

100692-10

– Turn the adjusting screw counterclockwise towards "–" as far as the last percep-tible click.

– Adjust the steering damper according to your riding style and the road conditionsby turning the adjust screw clockwise towards "+".

Guideline

Steering damper adjustment range 1… 32 clicks

Recommended range for use 1… 20 clicks

Standard 1 click

InfoDo not change the adjustment of the steering damper during the journey!After adjusting the steering damper, check the steering for smooth oper-ation, making sure that the handlebar can be moved from extreme left toextreme right without a tendency to lock.

6.3Adjusting the handlebar height

InfoThe handlebar stub position must be identical on the left and right of the vehicle.

100756-10

Adjusting the high position of the handlebar stubs:– Loosen screw .

InfoLoosen the screw several turns to prevent damage to the fork lacquerwhen moving the handlebar stub.

– Remove screw .

100757-10

– Remove distance sleeve .

– All cables routed under the upper triple clamp must now be routed under thehandlebar stub.

– Push the handlebar stub carefully up to the upper triple clamp.

– Position the distance sleeve above the triple clamp.

– Mount and tighten the screw.

Guideline

Remaining frame bolts M5 5 Nm (3.7 lbf ft)

PartS

hark

.com

877-

999-

5686


100759-01

– Tighten the screw.

Guideline


– Repeat the adjustments on the other handlebar stub.

– Move the handlebar to and fro over the entire steering range.

» If the cables restrict the freedom of movement of the steering:

– Correct the cable routing.

100759-10

Adjusting the low position of the handlebar stubs:– Loosen screw .

InfoLoosen the screw several turns to prevent damage to the fork lacquerwhen moving the handlebar stub.

100760-10

– Remove screw with distance sleeve .

– Carefully shift the handlebar stub by the length of the distance sleeve.

Guideline

Long distance sleeve 15 mm (0.59 in)

– Lay all cables between the upper triple clamp and the handlebar stub.

– Position the distance sleeves.

– Mount and tighten the screw.

Guideline


100761-01

– Tighten the screw.

Guideline


– Repeat the adjustments on the other handlebar stub.

– Move the handlebar to and fro over the entire steering range.

» If the cables restrict the freedom of movement of the steering:

– Correct the cable routing.

6.4Adjusting the play in the throttle cable

100754-10

– Move the handlebar to the straight-ahead position.

– Throttle position sensor circuit A - check in the "zero" position. ( p. 219)

InfoIt is imperative to use the KTM diagnostics tool for this.

– Push back protective cover .

– Loosen counter nut .

– Set the play in the throttle cable by turning adjusting screw .

Guideline

Throttle cable play 3… 5 mm (0.12… 0.2 in)

– Tighten counter nut .

– Mount the protective cover.

PartS

hark

.com

877-

999-

5686


6.5Throttle grip

100783-10

The installed throttle grip twists opens uniformly (linear) over the entire range of thethrottle valve.The throttle grip supplied does not open the throttle valves as widely at the sameturning angle lower down the rev range. This makes the throttle response in the lowerrev range less aggressive and can fed in more progressively.By installing the corresponding throttle grip the throttle response can be set to suityour personal riding style / according to the operating requirements.

100784-10

The throttle grips can be distinguished by the markings stamped into the inner face.The installed throttle grip has the marking 3081.The supplied throttle grip has the marking 5209.

InfoResetting the throttle cable play is necessary after replacement has been carriedout. It is imperative to use the KTM diagnostics tool for this.

6.6Changing the throttle grip

301446-10

– Loosen screw .

– Take off handlebar weight .

301447-10

– Unscrew screw .

301448-10

– Remove screw .

– Remove the spacer.

– Loosen screw .

PartS

hark

.com

877-

999-

5686


301449-10

– Turn the handlebar all the way to the right.

– Turn the handlebar stub to the left.

– Remove the throttle grip.

301450-10

– Push back protective cover .

– Unscrew lock nut .

– Screw adjusting screw all the way in.

301451-10

– Remove screws .

– Take off cover .

301452-10

– Detach the throttle cables.

– Remove the throttle grip.

301455-10

Throttle grip with code 3081:– Check that angle piece of the throttle cable (closer) is seated correctly.

Guideline

Distance 9… 11 mm (0.35… 0.43 in)

» If the specified value is not reached:

– Adjust the throttle cable at the throttle valve. ( p. 37)

– Position the throttle grip.

– Attach the throttle cables.

PartS

hark

.com

877-

999-

5686


301455-10

Throttle grip with code 5209:– Check that angle piece of the throttle cable (closer) is seated correctly.

Guideline

Distance 9… 11 mm (0.35… 0.43 in)


– Adjust the throttle cable at the throttle valve. ( p. 37)

– Position the throttle grip.


301462-10

– Open the throttle to the point where there is no play in the throttle cable.

Guideline

Marking of the throttle grip must be aligned with the bottom edge ofthe housing.

» The marking is not aligned:

– Correct the play in the throttle cable using barrel adjuster .

301456-10

– Grease the front and rear parts of the cover.


– Position cover .

– Mount screws but do not tighten them yet.

301449-10

– Turn the handlebar all the way to the right.

– Turn the handlebar stub to the left.

– Slide on the throttle grip.

PartS

hark

.com

877-

999-

5686


301448-10

– Align the handlebar stub.

– Position the distance sleeves.

– Mount screw but do not tighten them yet.

– Tighten screw .

Guideline


– Tighten screw .

Guideline


301447-10

– Fully tighten screws .

Guideline


301446-10

– Mount handlebar weight .

– Tighten screw .

Guideline


– Adjust the play in the throttle cable. ( p. 33)

6.7Adjusting the throttle cable at the throttle valve– Dismount the fuel tank. ( p. 70)

– Remove the air filter. ( p. 67)

301457-10

– Unscrew lock nuts .

– Unscrew barrel adjuster .

– Detach the throttle cables.

301458-10

– Detach throttle cable wire (closer) and remove it.

PartS

hark

.com

877-

999-

5686


301459-10

– Unscrew lock nut .

– Screw in angle piece until it is seated correctly.

Guideline

Distance 9… 11 mm (0.35… 0.43 in)

301458-10

– Route the throttle cable so it is not under tension.

– Attach throttle cable wire (closer).

301457-10


– Mount barrel adjuster .

– Mount lock nuts but do not tighten them yet.

– Connect the KTM diagnostics tool.

– Select the model.

– Select "ECU Diagnosis".

– Mark the "Engine management EFI LC8 RC8" control unit.

– Press "Continue".

– Select "Adjustment".

– "Please enter the password:"


– Select "Throttle position sensor circuit A adjustment".


InfoThe motor drive moves the throttle valve in circuit A to the zero setting.

301461-10

– Adjust the throttle cable play at the throttle grip using barrel adjusters .

Guideline

Throttle cable play 3… 5 mm (0.12… 0.2 in)

– Tighten lock nuts .

– Complete the adjustment by pressing the "Quit" button.

PartS

hark

.com

877-

999-

5686


301460-10

– Ensure that rubber grommets are seated correctly.

– Install the air filter. ( p. 67)

– Install the fuel tank. ( p. 71)

PartS

hark

.com

877-

999-

5686

03/FRAME 40

7.1Side stand switch

900040-60

Installation location– The side stand switch is fitted to the side stand.

Side stand switch, connector AR ( p. 394) pin assignment

Side stand signal"SSTAND SW"

Retracted

Side stand signal"SSTAND SW"

Extended

Side stand voltage "Side stand AD"

Retracted 1.5… 3.2 V

Extended 4.0… 5.0 V

7.2Footrest position

100699-10

The adjustable footrest system enables an individual setting of the footrest height andan individual adjustment of the controls.The lower footrest position enables a more comfortable knee angle, the upper footrestposition a sporting sitting position and more forward-leaning freedom for use in racing.

7.3Adjusting footrest position

InfoThe footrest position must be identical on the left and the right.

100713-10

– Remove screws .

100700-10

– Position the footrest bracket with spacers and screws.

Guideline

Standard Lower position

InfoThe adjustable footrest bracket enables a more comfortable lower footrestposition or a sporting upper footrest position.

100701-01

– Mount and tighten screws.

Guideline


M8 25 Nm(18.4 lbf ft)

Loctite® 243™

PartS

hark

.com

877-

999-

5686

03/FRAME 41

100702-01

– Repeat adjustment work on the footrest bracket on the other side.

– Adjust the shift lever. ( p. 192)

– Adjust the foot brake pedal. ( p. 100)

7.4Rear frame position

400439-10

The frame rear height can be set to two different positions, enabling ergonomic adjust-ment of the seat height.

Seat height (standard) 805 mm (31.69 in)

Seat height 825 mm (32.48 in)

7.5Adjusting the rear frame position



– Remove the seat. ( p. 70)

100762-10

– Remove screws with the bushings.

100763-10

Setting a higher seat position:– Remove screw with washer on the left and right sides of the vehicle.

– Push the rear end down until the drill holes of the frame are level with thelower front drill holes of the rear.

100764-01

– Mount the screw and washer on the left and right sides of the vehicle, but donot tighten.

PartS

hark

.com

877-

999-

5686

03/FRAME 42

100765-10

– Remove screw with washer on the left and right sides of the vehicle.

– Push the rear end up until the drill holes of the frame are level with the lowerrear drill holes of the rear.

– Mount the screw and washer on the left and right sides of the vehicle, andtighten.

Guideline

Screw, subframe M8 20 Nm(14.8 lbf ft)

Loctite® 243™

100766-10

– Tighten screw on the left and right sides of the vehicle.

Guideline


Loctite® 243™

100763-11

Setting a lower seat position:– Remove screw with washer on the left and right sides of the vehicle.

– Push the rear end down until the drill holes of the frame are level with theupper rear drill holes of the rear.

– Mount the screw and washer on the left and right sides of the vehicle, but donot tighten.

100765-11

– Remove screw with washer on the left and right sides of the vehicle.

– Push the rear end up until the drill holes of the frame are level with the upperfront drill holes of the rear.

100764-01

– Mount the screw and washer on the left and right sides of the vehicle, andtighten.

Guideline


Loctite® 243™

100765-12

– Tighten screw on the left and right sides of the vehicle.

Guideline


Loctite® 243™

PartS

hark

.com

877-

999-

5686

03/FRAME 43

100767-10

– When you screw in the rear left fixing screw, the plug-in cable binder is pushedout of the thread. To reposition the cable of the lambda sensor, fix the plug-incable binder in the remaining free drill hole.

InfoCheck the cable routing. The cable of the lambda sensor should not be taut.

100768-10

– Position bushings .

– Mount and tighten screws .

Guideline


– Fit the seat. ( p. 70)

PartS

hark

.com

877-

999-

5686

04/SHOCK ABSORBER, SWINGARM 44

8.1Adjusting the low-speed compression damping of the shock absorber

DangerDanger of accidents Disassembly of pressurized parts can lead to injury.

– The shock absorber is filled with high density nitrogen. Adhere to the description provided.

InfoThe low-speed setting can be seen during the slow to normal compression of the shock absorber.

100686-10

– Turn adjusting screw clockwise with a screwdriver up to the last perceptibleclick.

InfoDo not loosen nut !

– Turn back counterclockwise by the number of clicks corresponding to the shockabsorber type.

Guideline

Compression damping, low-speed

Comfort 20 clicks

Standard 15 clicks

Sport 10 clicks



8.2Adjusting the high-speed compression damping of the shock absorber



InfoThe high-speed setting can be seen during the fast compression of the shock absorber.

100687-10

– Turn adjusting screw clockwise with an open-ended spanner until it stops.

InfoDo not loosen nut !

– Turn back counterclockwise by the number of turns corresponding to the shockabsorber type.

Guideline

Compression damping, high-speed

Comfort 2 turns

Standard 1.5 turns

Sport 1 turn

Full payload 1 turn


PartS

hark

.com

877-

999-

5686


8.3Adjusting the rebound damping of the shock absorber



100688-10

– Turn adjusting screw clockwise up to the last perceptible click.


Guideline

Rebound damping

Comfort 15 clicks

Standard 10 clicks

Sport 5 clicks


InfoTurn clockwise to increase damping; turn counterclockwise to reduce sus-pension damping.

8.4Adjusting the spring preload of the shock absorber



InfoThe spring preload defines the initial situation of the spring process on the shock absorber.The spring preload setting is optimal when it is set for the weight of the rider and that of any baggage and a passenger, andthus ensures a compromise between maneuverability and stability.

100689-10

– Take the weight off the rear wheel and swingarm.

InfoThe spring preload can be adjusted correctly only if the rear wheel and theswingarm are fully relieved of weight.

– Loosen screw two turns, but do not remove.

100690-01

– Turn the adjusting ring counterclockwise with the wrench from the tool kit until thespring is no longer under tension.

Hook wrench (69012022000)

Extension (60012060000)

– Turn the adjusting ring clockwise and tension it to the specified value.

Guideline

Spring preload

Comfort 6 mm (0.24 in)

Standard 6 mm (0.24 in)

Sport 8 mm (0.31 in)

Full payload 8 mm (0.31 in)

InfoTurn clockwise to increase preload, turn counterclockwise to reduce springpreload.

PartS

hark

.com

877-

999-

5686


100689-11

– Tighten screw .

Guideline


8.5Adjusting the vehicle level at the rear



100696-10

– Loosen screw but do not remove it.

100697-10

– Turn eccentric shaft to the desired position using the tool from the tool set.

Guideline

Standard LOW

Maximum adjustment range betweenHIGH - LOW

180°

Open end wrench SW 38 (69012021000)

InfoThe chassis height can be adjusted in both directions.

100698-10

– Tighten screw .

Guideline

Screw, clamp, eccentric shaft ofdeflector

M8 18 Nm(13.3 lbf ft)

8.6Removing the shock absorber– Jack up the motorcycle in the middle (insertable type). ( p. 12)

200602-10

– Remove the lower screw of the shock absorber.

PartS

hark

.com

877-

999-

5686


200603-10

– Remove screw .

– Remove upper screw of the shock absorber.

– Remove nut . Pull out the pin of bell crank on the frame. Remove the bellcrank.

200604-01

– Remove the shock absorber toward the rear right.

8.7Installing the shock absorber

200604-01

– Fit the shock absorber from the rear left.

200603-11

– Position bell crank . Mount the pin and nut of the bell crank on the frame.Tighten the nut.

Guideline

Nut of bell crank on frame M14x1.5 100 Nm(73.8 lbf ft)


Guideline

Screw, shock absorber M10 45 Nm(33.2 lbf ft)

Loctite® 243™


Guideline

Screw, connecting lever,shock absorber deflector

M10 45 Nm(33.2 lbf ft)

Loctite® 243™

200602-11


Guideline

Screw, shock absorber M10 45 Nm(33.2 lbf ft)

Loctite® 243™

– Remove the motorcycle from the work stand (insertable type). ( p. 12)

PartS

hark

.com

877-

999-

5686


8.8Servicing the shock absorberConditionThe shock absorber has been removed.

201094-01

– Remove the spring. ( p. 48)

– Disassemble the damper. ( p. 49)

– Disassemble the piston rod. ( p. 50)

– Check the damper. ( p. 51)

– Assemble the piston rod. ( p. 52)

– Assemble the damper. ( p. 53)

– Install the spring. ( p. 59)

8.9Removing the springConditionThe shock absorber has been removed.

– Clamp the shock absorber into the vice with soft jaws.

– Measure and note the spring length while the spring is under tension.

200561-01

– Loosen screw .

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

Hook wrench (T106S) ( p. 448)

200562-01

– Remove spring retainer .

– Remove the spring.PartS

hark

.com

877-

999-

5686


8.10Disassembling the damper– Remove the spring. ( p. 48)

200563-10

– Determine and note down the current setting of the rebound and compressiondamping.

– Completely open the adjusting elements of the rebound and compression damping.

– Remove rubber cap of the reservoir.

– Remove adjusting ring .

200564-10

– Slowly open screw .

The nitrogen pressure dissipates.

200565-10

– Remove locking cap .

200566-10

– Push in seal ring retainer . Remove lock ring .

InfoDo not scratch the inside surface.

200567-10

– Remove screw . Let the oil drain.

200568-10

– Remove the piston rod. Drain the remaining oil.

PartS

hark

.com

877-

999-

5686


200569-10

– Remove compression damping adjuster . Remove the spring, sleeve and piston.

8.11Disassembling the piston rod– Disassemble the damper. ( p. 49)

200570-10

– Clamp the piston rod into a vise with the heim joint.

– Remove nut .

200571-10

– Remove supporting plate and rebound shim stack together with piston .

InfoSlip the rebound shim stack onto a screwdriver and set the shims downtogether.

200572-10

– Remove compression shim stack with supporting plate .

InfoSlip the compression shim stack onto a screwdriver and set the shims downtogether.

PartS

hark

.com

877-

999-

5686


200573-10

– Remove seal ring retainer .

200574-10

– Remove locking cap and rubber buffer .

8.12Checking the damperConditionThe damper has been disassembled.

300601-10

– Measure the inside diameter at both ends and in the middle of the damper car-tridge.

Damper cartridge

Minimum diameter 46.10 mm (1.815 in)


– Change the damper cartridge.

– Check the damper cartridge for damage and wear.

» If there is damage or wear:

– Change the damper cartridge.

300554-10

– Measure the diameter of the piston rod.

Piston rod

Diameter ≥ 13.95 mm (≥ 0.5492 in)


– Change the piston rod.

– Measure the run-out of the piston rod.

Piston rod

Run-out ≤ 0.06 mm (≤ 0.0024 in)



– Check the piston rod for damage and wear.



PartS

hark

.com

877-

999-

5686


300460-01

– Check the heim joint for damage and wear.


– Change the heim joint.

8.13Assembling the piston rod

200574-11

– Clamp the piston rod into a vise with the heim joint.

– Mount rubber buffer plug and locking cap .

200575-10

– Position special tool on the piston rod.

Mounting sleeve (T313) ( p. 450)

– Grease the seal ring and slide seal ring retainer onto the piston rod.


– Remove the special tool.

200572-11

– Mount supporting plate with the rounded side facing downward.

– Mount compression shim stack with the smaller shims at the bottom.

200576-10

– Grind the piston on both sides on a surface plate with 1200 grade sand paper.

– Clean the piston.

– Mount the piston.

InfoThe piston is identical on both sides.

PartS

hark

.com

877-

999-

5686


200571-11

– Mount rebound shim stack with the smaller shims at the top.

– Mount supporting plate .

200570-11

– Mount and tighten nut .

Guideline

Nut, piston rod M8 30 Nm(22.1 lbf ft)

8.14Assembling the damper– Assemble the piston rod. ( p. 52)

200586-01

– Place the spring and sleeve onto the compression damping adjuster. Mount the pis-ton.

– Mount and tighten compression damping adjuster .

Guideline

Compression damping adjuster M26x1 30 Nm(22.1 lbf ft)

200567-11


Guideline

Screw, filling port M10x1 14 Nm(10.3 lbf ft)

PartS

hark

.com

877-

999-

5686


200587-01

– Fill the damper cartridge about half full.

Shock absorber oil (SAE 2.5) (50180342S1) ( p. 437)

200568-11

– Lubricate O-ring of the seal ring retainer.


– Carefully mount the piston rod.

200566-11

– Mount seal ring retainer and slide it under the ring groove.


InfoDo not scratch the inside surface.

– Pull out the piston rod until the seal ring retainer rests against the lock ring.

200588-01

– Mount locking cap of the damper cartridge.

– Bleed and fill the damper. ( p. 55)

– Fill the damper with nitrogen. ( p. 58)

200563-11

– Mount rubber cap of the reservoir.

– Mount adjusting ring and turn it all the way down.

The collar faces the spring.

200596-01

Alternative 1– Turn adjusting screw clockwise with a screwdriver to the last perceptible

click.


Guideline


Comfort 20 clicks

Standard 15 clicks

Sport 10 clicks


PartS

hark

.com

877-

999-

5686


– Turn adjusting screw clockwise as far as it will go using an open end wrench.

– Turn back counterclockwise the number of turns corresponding to the shockabsorber type.

Guideline


Comfort 2 turns

Standard 1.5 turns

Sport 1 turn

Full payload 1 turn

– Turn adjusting screw clockwise to the last perceptible click.


Guideline

Rebound damping

Comfort 15 clicks

Standard 10 clicks

Sport 5 clicks


Alternative 2





– Turn adjusting screws , and to the position noted down when the unitwas disassembled.

– Install the spring. ( p. 59)

8.15Bleeding and filling the damper

InfoBefore working with the vacuum pump, carefully read the operating manual included with the vacuum pump.Completely open the adjusting elements of the rebound and compression damping.

200590-01

– Remove the filling port screw.

– Mount adapter on the damper.

InfoHand-tighten only without using a tool.

– Connect adapter to connector of the vacuum pump.

– Clamp the damper with soft jaws or hold it as shown in the photo.

InfoClamp the damper only lightly.The filling port must be located at the highest position.The piston rod moves in and out during filling; do not immobilize it by hold-ing it with your hand.

PartS

hark

.com

877-

999-

5686


200271-10

– Position the control lever as shown in the photo.

Control lever External tank is set to Closed, Damper is set to Vacuum andOil reservoir is set to Vacuum.

– Activate On/Off switch .

The suction process begins.

Pressure gauge drops to the required value.

< 0 bar

Vacuum gauge drops to the required value.

4 mbar

200591-01

– Determine distance between the floating piston and reservoir hole with the spe-cial tool.

Depth micrometer (T107S) ( p. 449)

The floating piston is positioned all the way at the bottom.

200267-10

– When the vacuum gauge reaches the required value, turn control lever Oil reser-voir to Equalize pressure.

Guideline

4 mbar

The pressure gauge increases to the required value.

0 bar

200268-10

– When the pressure gauge reaches the required value, turn control lever Damper to Pressure.

Guideline

0 bar

Oil is pumped into the damper.


3 bar

200269-10

– When the pressure gauge reaches the required value, turn control lever Damper to Vacuum.

Guideline

3 bar

The pressure gauge drops to the required value.

0 bar

200270-10

– When the pressure gauge reaches the required value, turn control lever Oil reser-voir to Vacuum.

Guideline

0 bar

The vacuum gauge drops to the required value.

8 mbar

PartS

hark

.com

877-

999-

5686


200267-10

– When the vacuum gauge reaches the required value, turn control lever Oil reser-voir to Equalize Pressure.

Guideline

8 mbar


0 bar

200268-10

– When the pressure gauge reaches the required value, turn control lever Damper to Pressure.

Guideline

0 bar

Oil is pumped into the damper.


3 bar

200269-10

– When the pressure gauge reaches the required value, turn control lever Damper to Vacuum.

Guideline

3 bar


0 bar

– When the pressure gauge reaches the required value, activate the On/Off switch.

Guideline

0 bar

The vacuum pump is switched off.

200592-01

– Slide O-ring to the end of the special tool by the specified value (distance minus specified value).

Guideline

10 mm

Depth micrometer (T107S) ( p. 449)

– Push the floating piston into the reservoir to the distance described above using thespecial tool.

InfoWhen the piston rod is fully extended, the floating piston must be at pre-cisely this position; otherwise, damage will occur when the shock absorbercompresses and rebounds.


PartS

hark

.com

877-

999-

5686


200593-01

– Remove adapter from connector of the vacuum pump.

InfoHold the damper so that the filling port is at the highest location.

– Remove the adapter.


Guideline

Screw, filling port M10x1 14 Nm(10.3 lbf ft)

8.16Filling the damper with nitrogen

200594-01

– Fix the special tool in the vise.

Nitrogen filling tool (T170S1) ( p. 450)

– Screw in screw by approx. 2 turns but do not tighten.

InfoThe piston rod is fully extended.

200595-01

– Connect the special tool to the pressure regulator of the filling cylinder.

Filling gas - nitrogen

– Adjust the pressure regulator.

Guideline

Gas pressure 10 bar (145 psi)

– Position the damper in the special tool.

The hexagonal part of tap handle engages in the hexagon socket of the fill-ing port screw.

– Open spigot .

– Fill the damper for at least 15 seconds.

Guideline


InfoWatch the pressure regulator dial.Ensure that the damper is filled to the specified pressure.

– Close the filling port screw with tap handle .

– Close the spigot and take the damper out of the special tool.

– Tighten the filling port screw.

Guideline

Screw, filling port, reservoir M5 3.5 Nm(2.58 lbf ft)

PartS

hark

.com

877-

999-

5686


8.17Installing the spring

200562-11

– Clamp the damper into the vice with soft jaws.

– Measure the overall spring length without a load.

– Position the spring.

Guideline

Spring rate

Medium (standard) 95 N/mm (542 lb/in)

– Mount spring retainer .

The open end is opposite to the end of the spring.

Alternative 1– Tension the spring by turning the adjusting ring to the prescribed value.

Guideline

Spring preload






Alternative 2





– Adjust the spring to the value determined when it was removed by turning theadjusting ring.


200561-11

– Tighten screw .

Guideline

Screw, adjusting ring, shock absorber M6 5 Nm (3.7 lbf ft)

8.18Removing the heim joint

InfoThe operations are the same for the upper and lower heim joints.

ConditionThe shock absorber has been removed.

PartS

hark

.com

877-

999-

5686


200577-10

– Clamp the shock absorber into the vice with soft jaws.

– Remove collar bushing of the heim joint with a drift.

– Turn the shock absorber around and remove collar bushing of the heim joint witha drift.

200578-10

– Remove seal rings on both sides.

200579-10

– Remove lock rings on both sides.

200580-10

– Place special tool underneath and push out the heim joint with special tool .

Pressing tool (T1207S) ( p. 449)

8.19Installing the heim joint

InfoThe operations are the same for the upper and lower heim joints.

200581-10

– Place special tool underneath and push the heim joint to the middle using spe-cial tool .

Pressing tool (T1206) ( p. 449)

Pressing tool (T129) ( p. 449)

PartS

hark

.com

877-

999-

5686


200579-11

– Mount lock rings on both sides.

200578-11

– Mount and grease seal rings on both sides.


200582-10

– Push in both collar bushings of the heim joint.

PartS

hark

.com

877-

999-

5686

05/EXHAUST 62

9.1Lambda sensor

900007-61

Installation location– The lambda sensor for cylinder 1 is installed in the rear exhaust manifold.

– The lambda sensor for cylinder 2 is installed in the front exhaust manifold.

900008-10

Component description– In principle, the lambda sensor consists of a ceramic body that is coated with a

platinum layer on each side. The platinum layer functions like an electrode. Theouter layer comes into contact with the exhaust gas and the inner layer withambient air . At a certain temperature, the ceramic body becomes electricallyconductive and a voltage is generated when there is a difference in the oxygen con-tent of the ambient air and the exhaust gas . The greater the difference in oxygencontent, the greater the voltage.

Lambda sensor for cylinder 1, connector CE ( p. 396) pin assignmentLambda sensor for cylinder 2, connector CE ( p. 396) pin assignment

900009-01

Function description– All lambda (O₂) sensors are open to the atmosphere, which has an oxygen con-

tent (O₂) of approximately twenty one percent. The exhaust gas of a gasoline enginecontains up to two percent oxygen. The sensor output voltage is dependent on theoxygen content in the exhaust gas stream. This means that when the exhaust gascontains just two percent oxygen, the engine is running "lean" and the sensor gen-erates a low voltage. When the exhaust gas contains almost zero percent oxygen,the engine is running "rich" and the sensor generates a high voltage.

Lambda sensor

Voltage range withinthe closed loop range"HEGO1AD"

0.2… 0.8 V

Voltage range withinthe closed loop range"HEGO2AD"

0.2… 0.8 V

9.2Lambda sensor heater

900007-61

Installation location– The lambda sensor heater for cylinder 1 is integrated into the lambda sensor for

cylinder 1, which is installed in the rear exhaust manifold.

– The lambda sensor heater for cylinder 2 is integrated into the lambda sensor forcylinder 2, which is installed in the front exhaust manifold.

Component description– The lambda sensor is heated internally by a ceramic heating element, so that inde-

pendent of the exhaust gas temperature the temperature of the lambda sensor iskept constant. The connections of the heating element are completely isolated fromthe sensor signal voltage.

Lambda sensor for cylinder 1, connector CE ( p. 396) pin assignmentLambda sensor for cylinder 2, connector CE ( p. 396) pin assignment

900046-60

Description of function– The lambda sensor heater is supplied with battery voltage by the power relay. After

the engine is started, the EFI control unit switches the ground signal on/off to thelambda sensor heater. In order to control the lambda sensor heater, the signal con-trol is modulated.The lambda sensor heater is controlled at a modulation frequency T of 100 Hz. Thesmaller the duty cycle t₁ is set for the control, the greater is the supply voltage ofthe lambda sensor heater.

Lambda sensor heater

PartS

hark

.com

877-

999-

5686

05/EXHAUST 63

Resistance at: 20 °C(68 °F)

11.7… 14.3 Ω

9.3Removing the exhaust cover completely– Remove the side covers. ( p. 75)

200532-10

– Remove screws .

– Remove screws on both sides.

– Take off exhaust cover completely.

9.4Installing the exhaust cover completely

200532-11

– Position the exhaust cover.


Guideline


– Mount and tighten screws on both sides.

Guideline


– Install the side covers. ( p. 75)

9.5Removing the exhaust system

InfoThe radiator has only been removed to illustrate the procedure more clearly.

– Remove the exhaust cover completely. ( p. 63)


PartS

hark

.com

877-

999-

5686

05/EXHAUST 64

200513-10

– Unplug connector of the lambda sensor (2nd cylinder). Open the cable binder.

200514-10

– Unplug connector of the lambda sensor (1st cylinder).

200515-10

– Remove screw . Slide the clamp upward.

200516-10

– Remove screw . Slide the clamp upward.

0055

0055

0055

200517-01

– Remove screws with the washers. Take off the main silencer.PartS

hark

.com

877-

999-

5686

05/EXHAUST 65

200518-10

– Remove nuts . Remove the manifold at the front with the seals.

200519-10

– Remove nuts . Remove the manifold at the rear with the seals.

9.6Installing the exhaust system

InfoThe radiator has only been removed to illustrate the procedure more clearly.

200518-11

– Position the manifold at the front with the seals. Mount nuts but do not tightenthem yet.

200519-11

– Position the manifold at the rear with the seals. Mount nuts but do not tightenthem yet.

PartS

hark

.com

877-

999-

5686

05/EXHAUST 66

0033

0033

0033

200517-02

– Position the main silencer. Mount and tighten screws with the washers.

Guideline

Remaining chassis screws M8 25 Nm(18.4 lbf ft)

200515-11

– Position the clamp. Mount and tighten screw .

Guideline

Screw, exhaust clamp M6 8 Nm (5.9 lbf ft)

– Tighten nuts .

Guideline

Remaining chassis nuts M8 30 Nm(22.1 lbf ft)

200516-11

– Position the clamp. Mount and tighten screw .

Guideline

Screw, exhaust clamp M6 8 Nm (5.9 lbf ft)

– Tighten nuts .

Guideline

Remaining chassis nuts M8 30 Nm(22.1 lbf ft)

200513-11

– Plug in connector of the lambda sensor (2nd cylinder). Secure the cable withthe cable binders.

200514-11

– Plug in connector of the lambda sensor (1st cylinder).


– Install the exhaust cover completely. ( p. 63)

PartS

hark

.com

877-

999-

5686

06/AIR FILTER 67

10.1Removing the air filter

NoteEngine 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.

– Dismount the fuel tank. ( p. 70)

200496-10

– Remove screws .

– Slide back clamp . Pull off the engine breather hose and take off the clamp.

– Take off the filter box top.

InfoWatch out for the engine breather hose.

200497-10

– Remove air filter .

– Clean the air filter box.

10.2Installing the air filter

200497-11

– Position air filter .

200496-11

– Position the filter box top with the engine breather hose. Mount clamp with theengine breather hose.



10.3Removing the filter box bottom– Remove the air filter. ( p. 67)

200498-10

– Unplug the connector of the manifold absolute pressure sensor .

– Take the manifold absolute pressure sensor out of the holder but do not detach thevacuum hoses.

– Disconnect plug-in connector .

– Take plug-in connector out of the holding bracket.

PartS

hark

.com

877-

999-

5686

06/AIR FILTER 68

200499-10

– Remove screws . Take off the retaining plates and holding brackets.

– Remove screw . Remove the cover.

200500-10

– Loosen hose clamps .

200501-10

– Loosen the spring-loaded band-type clamp using the special tool. Pull off thefuel hose.

Pliers for spring-loaded band-type clamp (60029057100) ( p. 442)

– Pull up the throttle valve body and remove connector with the seal.

– Pull the throttle cables out of the filter box bottom with guide piece .

– Raise the throttle valve body at the front and fix it on the handlebar.

200502-10

– Remove rubber sleeves .

200503-10

– Raise the filter box bottom and pull off drain hoses .

– Detach the connector of the intake air temperature sensor.

– Remove snorkel seals .

– Raise the filter box bottom at the front and fix it on the handlebar.

10.4Installing the filter box bottom

200503-11

– Detach the filter box bottom from the handlebar. Mount drain hoses . Plug in theconnector of the intake air temperature sensor.

– Position the filter box bottom.

– Mount snorkel seals .

PartS

hark

.com

877-

999-

5686

06/AIR FILTER 69

200502-11

– Mount rubber sleeves . Position and tighten the lower hose clamps.

Guideline

Hose clip, intake flange M4 1.5 Nm(1.11 lbf ft)

200501-11

– Detach the throttle valve body from the handlebar. Mount connector with theseal.

– Connect the fuel hose. Mount the spring-loaded band-type clamp using the spe-cial tool.


InfoThe fuel hose must have a minimum distance of 4 mm to the throttle link-age in all operating positions.

– Position the throttle cables with guide piece .

– Slide the throttle valve body into the rubber sleeves.

200500-11

– Position and tighten upper hose clamps .

Guideline


200499-11

– Mount the cover. Mount and tighten screw .

– Position the retaining plates and holding brackets. Mount and tighten screws .

200498-11

– Fix plug-in connector with the holding bracket.

– Connect plug-in connector .

– Mount manifold absolute pressure sensor and plug in the connector.


PartS

hark

.com

877-

999-

5686

07/FUEL TANK, SEAT, TRIM 70

11.1Removing the seat

100669-10

– Insert the ignition key in the seat lock and turn it clockwise.

– Raise the rear of the seat, push it towards the rear, and remove it upwards.

11.2Fitting the seat

100730-10

– Position the recesses of the seat to the lugs on the frame, lower the rear end andsimultaneously push it forward.

– Lock the seat by turning the ignition key in the seat lock.

– Remove the ignition key from the seat lock.

– Finally, check that the seat is correctly mounted.

11.3Removing the passenger seat

100731-10


– Activate the release lever .

– Take off the passenger seat toward the top.

11.4Mounting the passenger seat

100732-01

WarningDanger of accidents The passenger seat can come loose from the anchoringif it is not mounted correctly.

– After mounting the passenger seat, check that it is locked correctly bypulling up on the supporting strap. There should be no play in theunlocking lever.

– Position the passenger seat in the space provided.

– Press down the passenger seat until it clicks into place.

– Finally, check that the passenger seat is correctly mounted.

11.5Dismounting the fuel tank

DangerFire hazard Fuel is highly flammable.

– Never fill up the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that nofuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.

– Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See specifications on filling up with fuel.

PartS

hark

.com

877-

999-

5686


WarningDanger of poisoning Fuel is poisonous and a health hazard.

– Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immedi-ately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, con-tact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister accordingto regulations and keep it out of the reach of children.


200488-10

– Remove screws of the steering damper.

– Remove the steering damper.

200489-10

– Remove screws .

200490-10

– Press on metal plate and disconnect the fuel hose connection.

InfoRemaining fuel may run out of the fuel hose.

– Disconnect electric plug-in connector of the fuel pump.

200491-10

– Raise the front of the fuel tank.

– Disconnect plug-in connector of the fuel level indicator.

– Detach overflow hoses .

– Take off the fuel tank.

11.6Installing the fuel tank




PartS

hark

.com

877-

999-

5686




200491-11

– Position the fuel tank and raise it at the front.

– Connect overflow hoses .

– Connect plug-in connector of the fuel level indicator.

– Lower the front of the fuel tank.

200490-10

– Connect fuel hose connector with the new O-ring.

– Connect electric plug-in connector of the fuel pump.

200489-11


Guideline


200488-11

– Position the steering damper.


Guideline



Guideline

Screw, steering damperfixing bracket on tripleclamp

M8 10 Nm(7.4 lbf ft)

Loctite® 243™


11.7Removing the fuel tank guard

InfoThe operations are the same on the left and right sides.

PartS

hark

.com

877-

999-

5686


500246-10

– Remove screw .

– Take off the fuel tank guard.

11.8Installing the fuel tank guard

InfoThe operations are the same on the left and right sides.

500246-10

– Position the fuel tank guard.


Guideline

Screw, fuel tank guard M5x17 3 Nm (2.2 lbf ft)

InfoNote the screw length!

11.9Checking the fuel pressure

200559-01

– Press down the metal plate and disconnect the fuel hose connection .

200560-01


Pressure testing tool (61029094000) ( p. 443)

DangerDanger of poisoning Exhaust gases are poisonous and can result in uncon-sciousness and/or death.

– When running the engine, always make sure there is sufficient venti-lation, and do not start or run the engine in a closed space without aneffective exhaust extraction system.

– Start the engine.

– Check the fuel pressure.

Fuel pressure

For any load 3.3… 3.7 bar (48… 54 psi)

» The specifications have not been met:

– Change the fuel filter.

– Check that the fuel lines are free of blockages.

– Change the fuel pump.

– Switch off the engine.

PartS

hark

.com

877-

999-

5686


WarningDanger of burns Some vehicle components get very hot when the machineis driven.

– Wear appropriate protective clothing and safety gloves. In case of burns,rinse immediately with lukewarm water.


– Connect the fuel hose connection.

11.10Checking the fuel pressure during the actuator test






200559-01

– Press down the metal plate and disconnect the fuel hose connection .

InfoRemaining fuel may run out of the fuel hose.

200560-01



– Start the "Fuel pump relay operation" actuator test.

– Check the fuel pressure.

Fuel pressure

When the fuel pump is active 3.3… 3.7 bar (48… 54 psi)


– Change the fuel filter.

– Check that the fuel lines are free of blockages.

– Change the fuel pump.

– End the "Fuel pump relay operation" actuator test by pressing the "Quit" button.


– Connect the fuel hose connection.

PartS

hark

.com

877-

999-

5686

08/MASK, FENDER, DECAL 75

12.1Removing the side covers

200492-10


– Remove side covers on both sides.

InfoWatch out for the projections on the inside cover.

12.2Installing the side covers

200492-11

– Position side covers on both sides.

InfoWatch out for the projections on the inside cover.

– Mount and tighten screws on both sides.

Guideline


12.3Removing the inside cover– Switch off all power consumers and the engine.


– Disconnect the negative (minus) cable of the battery.

– Remove the side covers. ( p. 75)

200493-10

– Remove expanding rivet .

200494-10

– Disconnect the plug-in connectors from generator and ignition pulse genera-tor .

– Unscrew ground wire from the frame.

– Remove screw .

200537-10

– Remove screws .

– Take off the left inside cover.

PartS

hark

.com

877-

999-

5686

08/MASK, FENDER, DECAL 76

200495-12

– Remove screw .

– Remove the screws of the EFI control unit . Unplug and remove the EFI controlunit.

– Unplug the control unit of the electric starter lock .

– Remove the overflow hose. Take off the right inside cover.

12.4Installing the inside cover

200495-11

– Position the right inside cover. Mount and tighten screw .

– Position the overflow hose.

– Plug in EFI control unit and position it. Mount and tighten the screws.

– Plug in the control unit of the electric starter lock .

200494-11

– Position the left inside cover. Mount and tighten screw .

– Connect the plug-in connectors to generator and ignition pulse generator .

– Screw ground wire onto the frame.

Guideline


200537-11


200493-11

– Mount expanding rivets .


– Connect the negative (minus) cable of the battery.


PartS

hark

.com

877-

999-

5686

09/FRONT WHEEL 77

13.1Removing the front wheel– Jack up the motorcycle at the rear. ( p. 13)

– Jack up the motorcycle at the front. ( p. 10)

100719-10

– Remove the screws from both brake calipers.

– Press back the brake linings with a light lateral tilting of the brake calipers on thebrake disc. Pull the brake calipers carefully back from the brake discs and hangthem to one side.

InfoDo not pull the hand brake lever when the brake calipers are removed.

100720-10

– Loosen screws and .

– Unscrew screw about six turns and press your hand on the screw to push thewheel spindle out of the axle clamp. Remove screw .



– Holding the front wheel, withdraw the wheel spindle. Take the front wheel out ofthe fork.

100779-10

– Remove spacers .

13.2Installing the front wheel

100781-10

– Clean and grease the shaft seal rings and mating surfaces of the spacers.


100780-10

– Insert the wide spacer on the left-hand side (when looking in the direction oftravel).

InfoThe arrow indicates the direction of rotation of the front wheel.

– Insert the narrow spacer on the right-hand side (when viewed in the direction oftravel).

PartS

hark

.com

877-

999-

5686

09/FRONT WHEEL 78

100721-10

WarningDanger of accidents Reduced braking efficiency due to oil or grease on thebrake discs.

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

– Clean screw and axle .

– Lift the front wheel into the fork, position it, and insert the wheel spindle.


Guideline

Bolt, front axle M25x1.5 45 Nm(33.2 lbf ft)

100719-11

– Position the brake calipers and check that the brake linings are seated correctly.

– Mount screws on both brake calipers but do not tighten yet.




Guideline


Loctite® 243™


– Take the front of the motorcycle off the work stand. ( p. 10)

– Take the rear from the work stand. ( p. 13)

100782-10

– Pull the front brake and compress the fork powerfully a few times.

The fork legs straighten.


Guideline

Fork end pinch bolts M8 15 Nm(11.1 lbf ft)

13.3Checking the tire condition

WarningDanger of accidents Uncontrollable handling characteristic caused by a flat tire.

– For your own safety, have damaged tires changed immediately.

WarningDanger of crashing Impairment of handling characteristic due to different tire tread patterns on front and rear wheels.

– The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle.

WarningDanger of accidents Uncontrollable handling characteristic due to non-approved and/or non-recommended tires/wheels.

– Only tires/wheels approved by KTM and with the corresponding speed index should be used.

WarningDanger of accidents Reduced road grip with new tires.

– New tires have a smooth rolling surface and therefore cannot provide full road grip. The entire rolling surface must beroughened in the first 200 kilometers (124.3 miles) by moderate riding at alternating angles. The full grip levels are notachieved until the tires have been run in.

PartS

hark

.com

877-

999-

5686

09/FRONT WHEEL 79

InfoThe type, condition and air pressure of the tires all have a major impact on the handling of the motorcycle.Worn tires have a negative effect on handling characteristics, especially on wet surfaces.

400602-10

– Check the front and rear tires for cuts, run-in objects and other damage.

» If the tires exhibit cuts, run-in objects or other damage:

– Change the tires.

– Check the depth of the tread.

InfoNote local national regulations concerning the minimum tread depth.

Minimum tread depth ≥ 2 mm (≥ 0.08 in)

» If the tread depth is less than the minimum permissible depth:


– Check the age of the tires.

InfoThe tire's date of manufacture is usually part of the tire markings and isindicated by the last four digits of the DOT marking. The first two digits referto the week of manufacture and last two digits refer to the year of manufac-ture.KTM recommends that the tires are changed regardless of the actual wear,at the latest after five years.

» If a tire is more than five years old:


13.4Checking the tire pressure

InfoLow tire pressure leads to abnormal wear and overheating of the tire.Correct tire pressure tool kit comfort and maximum tire service life.

100729-01

– Remove the dust cap.

– Check the tire pressure when the tires are cold.

Tire air pressure, Solo

Front 2.5 bar (36 psi)

Rear 2.5 bar (36 psi)

Tire air pressure with passenger / full payload



» If the tire pressure does not meet specifications:

– Correct the tire pressure.

– Mount the dust cap.

InfoThe rubber seal in the dust cap prevents air leaking out of the tire if thevalve is defective.

PartS

hark

.com

877-

999-

5686

09/FRONT WHEEL 80

13.5Checking the front brake discs

WarningDanger of accidents Reduced braking efficiency due to worn brake disc(s).

– Change the worn brake disc(s) without delay.

100135-10

– Check the thickness of the brake disc in several places to see if it is within thespecified wear tolerance .

InfoWear reduces the thickness of the brake discs in area of the brake discs.

Brake discs - wear limit

Front 4.5 mm (0.177 in)

» If the brake disc thickness is less than the specified value:

– Change the brake discs.

– Check the brake discs for damage, cracking and deformation.

» If the brake discs exhibit damage, cracking or deformation:


PartS

hark

.com

877-

999-

5686

10/REAR WHEEL 81

14.1Removing the rear wheel– Jack up the motorcycle at the rear. ( p. 13)

100722-10

– Remove nut .

– Remove chain adjuster .

– Remove the axle .

100723-01

– Push the rear wheel as far forward as possible and then remove the chain from therear sprocket.



– Take the rear wheel out of the swingarm carefully without damaging the rim orbrake disc.

InfoDo not operate the foot brake when the rear wheel is removed.

14.2Installing the rear wheel

WarningDanger 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.

WarningDanger of accidents No braking effect when operating the rear brake.

– After installing the rear wheel, always operate the foot brake until the pressure point is reached.

– Check the rear hub cush drive. ( p. 86)

100724-10

– Remove spacer . Clean and grease the mating surfaces of the spacers and theshaft seal rings.


– Install the spacer.

– Clean the thread of the axle and nut.

– Clean the mating surfaces of the brake caliper frame and swingarm.

100725-10

– Push the brake caliper frame completely to the rear.

– Position the rear wheel, and place the brake caliper frame between the rim and thebrake disc.

– Slide the brake caliper onto the brake disc.

– Position the rear wheel on the mating surfaces in the swingarm.

PartS

hark

.com

877-

999-

5686

10/REAR WHEEL 82

100726-01

– Push the rear wheel as far forward as possible and place the chain on the rearsprocket.

– Pull the rear wheel back and insert the axle.

100727-10

– Place the chain adjuster on the tensioning screw.

– Position the chain adjuster and place it on the tensioning screw.

– Tighten nut .

Guideline

In order for the rear wheel to be correctly aligned, the markings on the left andright chain adjusters must be in the same position relative to the referencemarks .

Nut, rear wheel spindle M25x1.5 90 Nm(66.4 lbf ft)

Thread greased

– Operate the foot brake lever repeatedly until the brake linings press up against thebrake disc and there is a pressure point.


– Check the chain tension. ( p. 84)

14.3Installing the rear wheel - when installing the engine



WarningDanger of accidents No braking effect when operating the rear brake.

– After installing the rear wheel, always operate the foot brake until the pressure point is reached.

100724-10

– Remove spacer . Clean and grease the mating surfaces of the spacers and theshaft seal rings.


– Install the spacer.

– Clean the thread of the wheel spindle and nut.

– Clean the contact areas of the brake caliper support and swingarm.

100725-10

– Push the brake caliper support completely to the rear.

– Position the rear wheel, and position the brake caliper support between the rim andthe brake disc.

– Position the brake caliper on the brake disc.

– Position the rear wheel on the bearing surfaces in the swingarm.

PartS

hark

.com

877-

999-

5686

10/REAR WHEEL 83

100726-01

– Push the rear wheel forward as far as possible and place the chain on the rearsprocket.

– Pull the rear wheel back and push in the wheel spindle.

100727-10

– Place chain adjuster on the tensioning screw.

– Position chain adjuster and place it on the tensioning screw.

– Tighten nut .

Guideline

In order for the rear wheel to be correctly aligned, the markings on the left andright chain adjusters must be in the same position relative to reference marks .


Thread greased

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


14.4Checking the rear brake disc

WarningDanger of accidents Reduced braking efficiency due to worn brake disc(s).

– Change the worn brake disc(s) without delay.

400480-10

– Check the thickness of the brake disc in several places to see if it conforms to mea-surement .

InfoWear reduces the thickness of the brake disc in area of the brake disc.

Brake disc - wear limit

Rear 4.5 mm (0.177 in)

» If the brake disc thickness is less than the specified value:

– Change the brake disc.

– Check the brake disc for damage, cracking and deformation.

» If damage, cracks or deformation are visible on the brake disc:


14.5Checking for chain dirt

400678-01

– Check the chain for loose dirt.

» If the chain is very dirty:

– Clean the chain. ( p. 84)

PartS

hark

.com

877-

999-

5686

10/REAR WHEEL 84

14.6Cleaning the chain

WarningDanger of accidents Oil or grease on the tires reduces their grip.

– Remove oil and grease with a suitable cleaning material.



WarningEnvironmental hazard Hazardous substances cause environmental damage.

– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

InfoThe service life of the chain depends largely on its maintenance.

– Clean the chain regularly.

– Rinse off loose dirt with a soft jet of water.

– Remove old grease remains with chain cleaner.

Chain cleaner ( p. 438)

– After drying, apply chain spray.

Chain lube for road use ( p. 438)

14.7Checking the chain tension

WarningDanger of accidents Danger caused by incorrect chain tension.

– If the chain is over tensioned, the components of the secondary power train (chain, engine sprocket, rear sprocket, bear-ings in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain maysnap or the countershaft of the transmission can break. On the other hand, if the chain is loose, it may jump off the enginesprocket or the rear sprocket, causing the rear wheel to lock or damage the engine. Check for correct chain tension andadjust if necessary.

700322-01

– Lean the motorcycle on the side stand.

– Shift into neutral.

– In the area in front of where the chain passes through the link fork, push the chainupward and measure chain tension .

InfoThe lower chain section must be taut.Chain wear is not always even, so you should repeat this measurement atdifferent chain positions.

Chain tension 15… 20 mm (0.59… 0.79 in)

» If the chain tension does not meet specifications:

– Adjust the chain tension. ( p. 85)

PartS

hark

.com

877-

999-

5686

10/REAR WHEEL 85

14.8Adjusting the chain tension

WarningDanger of accidents Danger caused by incorrect chain tension.

– If the chain is over tensioned, the components of the secondary power train (chain, engine sprocket, rear sprocket, bear-ings in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain maysnap or the countershaft of the transmission can break. On the other hand, if the chain is loose, it may jump off the enginesprocket or the rear sprocket, causing the rear wheel to lock or damage the engine. Check for correct chain tension andadjust if necessary.


100709-10

– Loosen nut .

– Loosen nuts .

– Adjust chain tension by turning the adjustment screws on the left and right.

Guideline

Chain tension 15… 20 mm (0.59… 0.79 in)

Turn the adjusting screws on the left and right so that the markings on the leftand right chain adjuster are in the same position in relation to the referencemarks . The rear wheel is then correctly aligned.

InfoThe lower chain section must be taut.Chain wear is not always even, so you should check the setting at differentchain positions.

– Tighten nuts .

– Make sure that the chain adjusters are on the adjusting screws .

– Tighten nut .

Guideline


Thread greased

InfoThe wide adjustment range of the chain adjuster (35mm / 1.38") allows dif-ferent secondary transmission ratios to be used with the same chain length.The chain adjusters can be turned through 180°.

14.9Checking rear sprocket / engine sprocket for wear

100132-10

– Check the rear sprocket / engine sprocket for wear.

» If the rear sprocket / engine sprocket are worn:

– Change the rear sprocket / engine sprocket, chain and chain sliding guard.

InfoThe rear sprocket, engine sprocket, chain and chain sliding guardshould always be changed together.

PartS

hark

.com

877-

999-

5686

10/REAR WHEEL 86

14.10Checking chain wear

700303-01

– Shift the transmission to neutral.

– Pull the lower chain section with specified weight .

Guideline

Weight, chain wear measurement 15 kg (33 lb.)

– Measure the distance of 18 chain links in the lower chain section.

InfoChain wear is not always even, so you should repeat this measurement atdifferent chain positions.

Maximum distance at the longestchain section

272 mm (10.71 in)

» If distance is greater than the specified measurement:

– Change the rear sprocket / engine sprocket, chain and chain sliding guard.

InfoNew chains wear out faster on old, worn sprockets.For safety reasons, the chain has no chain joint.

14.11Checking chain sliding guard

100710-10

– Check the chain sliding guard for wear at the opening.

» If the rivets of the chain are no longer visible at the lower edge of theopening of the chain sliding guard:

– Change the chain sliding guard.

14.12Checking rear hub cush drive

InfoThe engine power is transmitted by the rear sprocket to the rear wheel through five shock absorbers. They eventually wear outduring operation. If the shock absorbers are not changed in time, the rear sprocket carrier and the rear hub are damaged.

– Remove the rear wheel. ( p. 81)

100728-01

– Remove the rear sprocket carrier.

– Check the rear hub for damage and wear.

» If the rear hub cush drive is damaged or worn:

– Change the shock absorber.

– Position the rear sprocket carrier.

InfoA set of bolts and shock absorbers should have as little free play as possibleto increase the service life of the shock absorbers.

PartS

hark

.com

877-

999-

5686

10/REAR WHEEL 87

– Install the rear wheel. ( p. 81)

PartS

hark

.com

877-

999-

5686

11/WIRING HARNESS, BATTERY 88

15.1Electric starter lock control unit

900013-01

Installation location– The electric starter lock control unit is located behind the right-hand side cover.

Electric starter lock control unit, connector DO ( p. 399) pin assignment

Description of function

900015-10

– The electric starter lock control unit prevents the engine from starting during the initialization phase of the EFI system . Theelectric starter lock control unit controls the grounding of the auxiliary starter relay . The signal wire sends a signal to the EFIcontrol unit; the electric starter lock control unit then recognizes that the initialization process has ended and enables the startingprocess. The electric starter lock control unit utilizes the signal control wire to send a start permission status signal to the EFIcontrol unit.

15.2Fuel pump relay

600852-10

Pin overview

1 Control circuit power supply

2 Control wire

3 Fuel pump power supply

4 Working circuit power supply

15.3Removing the battery

WarningRisk of injury Battery acid and battery gases cause serious chemical burns.

– Keep batteries out of the reach of children.

– Wear suitable protective clothing and goggles.

– Avoid contact with battery acid and battery gases.

– Keep the battery away from sparks or open flames. Charge only in well-ventilated areas.

– In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least15 minutes and contact a physician.

CautionDanger of accidents If the vehicle is operated with a discharged battery or without a battery, electronic components and safetyequipment may be damaged.

– Never operate the vehicle with a discharged battery or without a battery.

– Switch off all power consumers and the engine.


PartS

hark

.com

877-

999-

5686


100734-10

– Disconnect negative (minus) cable of the battery.

100735-10

– Remove the cover of the positive terminal.

– Disconnect the positive (plus) cable of the battery.

100736-10

– Remove screws .

– Removing the securing bracket .

– Pull the battery up and out of the battery rack.

15.4Installing the battery

100737-10

– Position the battery in the battery rack.

InfoThe terminals of the battery must face the rear of the vehicle.

– Position the bracket .

100738-10


Guideline


– Reconnect the positive (plus) cable of the battery.

– Position cover of the positive terminal.

100734-11

– Reconnect the negative (minus) cable of the battery.


– Set the clock with SET CLOCK. ( p. 106)

PartS

hark

.com

877-

999-

5686


15.5Recharging the battery

WarningRisk of injury Battery acid and battery gases cause serious chemical burns.

– Keep batteries out of the reach of children.


– Avoid contact with battery acid and battery gases.

– Keep the battery away from sparks or open flames. Charge only in well-ventilated areas.

– In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least15 minutes and contact a physician.

WarningEnvironmental hazard Battery parts and acid are harmful to the environment.

– Do not discard batteries with the household trash. Dispose of a defective battery in an environmentally compatible manner.Give the battery to your KTM dealer or to a recycling center that accepts used batteries.



InfoEven when there is no load on the battery, it discharges steadily.The charge state and the type of charge are very important for the service life of the battery.Rapid recharging with a high charging current shortens the battery's service life.If the charging current, charging voltage and charging time are exceeded, electrolyte escapes through the safety valves. Thisreduces the battery capacity.If the battery is depleted from starting the vehicle repeatedly, the battery must be charged immediately.If the battery is left in a discharged state for an extended period, it will become over-discharged and sulfate, destroying thebattery.The battery is maintenance-free, i.e., the acid level does not have to be checked.



– Disconnect the negative (minus) cable of the battery to avoid damage to the motor-cycle's electronics.

100151-10

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

Battery charger (58429074000)

You can also use the battery charger to test the rest potential and start potential ofthe battery, and to test the generator. With this device, you cannot overcharge thebattery.

InfoNever remove lid .Charge the battery at no more than 10% of the capacity specified on thebattery housing .

– Switch off the charger after charging. Disconnect the battery.

Guideline

The charge current, charge voltage and charge time must not be exceeded.

Charge the battery regularly when themotorcycle is not in use

3 months



PartS

hark

.com

877-

999-

5686


15.6Changing the main fuse

WarningFire hazard The electrical system can be overloaded by the use of incorrect fuses.

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

InfoThe main fuse protects all power consumers of the vehicle. The main fuse is under the seat.



100739-10

– Remove protection covers .

– Remove the faulty main fuse .

InfoA reserve fuse is located in the starter relay.

– Install a new main fuse.

Fuse (58011109130) ( p. 411)

TipPlace the spare fuse in the starter relay so that it is available if needed.

– Attach the protection covers .



15.7Changing the fuses of individual power consumers

WarningFire hazard The electrical system can be overloaded by the use of incorrect fuses.

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

InfoThe fuse box containing the fuses of individual power consumers is located under the seat.



100740-10

– Open fuse box cover .

PartS

hark

.com

877-

999-

5686


100741-10

– Check the fuses.

InfoA defective fuse can be identified by the burned-out fuse wire .

– Remove the faulty fuse.

Guideline

Fuse 1 - 10A - ignition, combination instrument, immobilizer, alarm system(optional)

Fuse 2 - 15A - high beam, low beam, parking light, tail light, license plate lamp

Fuse 3 - 10A - horn, brake light

Fuse 4 - 10A - radiator fan

Fuse 5 - 10A - fuel pump

Fuse 6 - 10A - ignition/fuel injection

Fuse 7 - not used

Fuse 8 - 10A - for supplementary equipment (standard accessories)

Fuse 9 - 10A - for supplementary equipment (accessories connected to the igni-tion switch)

Fuse 10 - not used

Fuse SPARE - 10A/15A - spare fuses

– Use spare fuses with the correct rating only.

Fuse (75011088010) ( p. 411)

Fuse (75011088015) ( p. 411)

TipReplace the spare fuse in the fuse box so that it is available if needed.

– Close the fuse box cover.


PartS

hark

.com

877-

999-

5686

13/BRAKE SYSTEM 93

16.1Brake liningsThe brake linings fitted by KTM have been tested over long periods and guarantee optimal braking characteristics. The type names ofthe brake linings are entered in the homologation documents.

InfoBrake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The constructionand friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake lin-ings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the original license.The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid.

16.2Checking the front brake linings

WarningDanger of accidents Reduced braking efficiency caused by worn brake linings.

– Change worn brake linings immediately.

NoteDanger of accidents Reduced braking efficiency caused by damaged brake discs.

– If the brake linings are not changed in time, the steel brake lining carriers grind on the brake disc. The braking effect is greatlyreduced and the brake discs are rendered unserviceable. Check the brake linings regularly.

100715-10

– Check all brake linings on both brake calipers to ensure they have minimum thick-ness .

Minimum thickness ≥ 1 mm (≥ 0.04 in)

» If the minimum thickness is less than specified:

– Change the front brake linings. ( p. 93)

– Check all brake linings on both brake calipers for damage and cracking.

» If damage or wear is encountered:

– Change the front brake linings. ( p. 93)

16.3Changing the front brake linings

WarningSkin irritation Brake fluid can cause skin irritation on contact.

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


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

WarningDanger of accidents Reduced braking efficiency due to old brake fluid.

– Change the brake fluid of the front and rear brakes according to the service schedule.



WarningDanger of accidents Reduced braking efficiency due to use of non-approved brake linings.

– Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc-tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTMbrake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi-nal license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid.



PartS

hark

.com

877-

999-

5686

13/BRAKE SYSTEM 94

InfoNever user DOT 5 brake fluid! It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5brake fluid.Avoid contact between brake fluid and painted parts. Brake fluid is corrosive and will damage painted surfaces.Use only clean brake fluid from a sealed container!

100714-10

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

– Remove the screws.

– Remove cover with membrane .

– Press the brake piston back into the basic position and ensure that brake fluid doesnot overflow out of the brake fluid reservoir, sucking it away if necessary.

301496-10

– Remove screws .

301497-10

– Push the brake linings away from piston and remove them.

– Clean the brake caliper.

301498-10

– Position retaining bracket .

301499-10

– Slip in the brake linings and press them toward piston .

InfoAlways change the brake linings in pairs and on both sides.

PartS

hark

.com

877-

999-

5686

13/BRAKE SYSTEM 95

301496-10

– Position the brake caliper. Mount the screws but do not tighten them yet.

– Repeat the operation on the opposite side.




Guideline


Loctite® 243™


– Add brake fluid to the MAX level.

Brake fluid DOT 4 / DOT 5.1 ( p. 436)

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

InfoClean up overflowed or spilt brake fluid immediately with water.

16.4Checking the front brake fluid level

WarningDanger of accidents Failure of the brake system.

– If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings.Check the brake system and do not continue riding.



100712-10


– Check the brake fluid level in the brake fluid reservoir .

» If the brake fluid is below the MIN marking:

– Add front brake fluid. ( p. 95)

16.5Adding front brake fluid









PartS

hark

.com

877-

999-

5686

13/BRAKE SYSTEM 96




100714-10


– Loosen screw.

– Remove cover with membrane .



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


16.6Adjusting the basic position of the hand brake lever

100711-10

– Pull the brake lever forwards.

– Adjust the basic setting of the hand brake lever to your hand size by turning adjust-ing wheel .

InfoDo not make any adjustments while riding!

16.7Checking the rear brake linings

WarningDanger of accidents Reduced braking efficiency caused by worn brake linings.

– Change worn brake linings immediately.

NoteDanger of accidents Reduced braking efficiency caused by damaged brake discs.

– If the brake linings are not changed in time, the steel brake lining carriers grind on the brake disc. The braking effect is greatlyreduced and the brake discs are rendered unserviceable. Check the brake linings regularly.

100718-10

– Check the brake linings for minimum thickness .

Minimum thickness ≥ 1 mm (≥ 0.04 in)

» If the minimum thickness is less than specified:

– Change the rear brake linings. ( p. 97)

– Check the brake linings for damage and cracking.

» If damage or wear is encountered:

– Change the rear brake linings. ( p. 97)

PartS

hark

.com

877-

999-

5686

13/BRAKE SYSTEM 97

16.8Changing the rear brake linings









WarningDanger of accidents Reduced braking efficiency due to use of non-approved brake linings.

– Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc-tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTMbrake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi-nal license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid.




100717-10

– Stand the vehicle upright.

– Remove screw cover with membrane .

– Press the brake piston back into the basic position and ensure that brake fluid doesnot overflow out of the brake fluid reservoir, sucking it away if necessary.

301491-10

– Remove screws .

– Remove the brake caliper and pull the brake line out of the holder.

PartS

hark

.com

877-

999-

5686

13/BRAKE SYSTEM 98

301492-10

– Remove locking clip .

301493-10

– Remove bolt .

301494-10

– Remove brake linings .

– Remove spring .

– Clean the brake caliper.

301495-10

– Position brake linings and spring .

– Mount bolt .

301492-10

– Mount locking clip .

301491-10

– Position the brake caliper.


Guideline

Screw of rear brake caliper M8 22 Nm(16.2 lbf ft)

Loctite® 243™

– Attach the brake line to the holder.

– Operate the foot brake lever repeatedly until the brake linings press up against thebrake disc and there is a pressure point.

– Correct the brake fluid level to the MAX marking.


PartS

hark

.com

877-

999-

5686

13/BRAKE SYSTEM 99

– Refit screw with membrane.


16.9Checking the rear brake fluid level





100716-10


– Check the brake fluid level of the brake fluid reservoir.

» If the fluid level reaches the MIN mark :

– Add rear brake fluid. ( p. 99)

16.10Adding rear brake fluid












PartS

hark

.com

877-

999-

5686

13/BRAKE SYSTEM 100

100717-10


– Remove screw cover with membrane .





16.11Adjusting the foot brake pedal stub

100706-10

– Remove the screw with the foot brake pedal stub.

– Position the foot brake pedal stub with the screw in one of the holes accordingto the desired lever length.

Guideline

Standard Central hole

– Tighten screw.

Guideline

Bolt, foot brake pedal stub M6 10 Nm(7.4 lbf ft)

Loctite® 243™

16.12Adjusting the foot brake pedal

100707-10

– Use the tool to press in the anti-rotation lock , then turn the piston rod .

InfoThe range of adjustment is limited.

– Remove the tool.

The spring tension on the anti-rotation lock is released and the hex nut islocked.

100708-10

– Check the foot brake pedal setting.

InfoPosition of the foot brake lever may vary considerably, depending on thesetting.

PartS

hark

.com

877-

999-

5686

13/BRAKE SYSTEM 101

16.13Removing the rear brake system– Remove the rear wheel. ( p. 81)

200525-10

– Unplug the brake light switch. Remove the cable clip.

– Remove screw .


200526-10

– Remove screw . Take off the brake caliper with the brake caliper support.

– Take the brake line out of the guide. Completely remove the brake system.

16.14Installing the rear brake system

200526-11

– Position the brake system. Position the brake line in the guide.

– Position the brake caliper. Mount and tighten screw .

Guideline


200525-11


Guideline

Screw, rear footrest bracket M8 25 Nm(18.4 lbf ft)

– Position the brake fluid reservoir. Mount and tighten screw .

Guideline

Screw, brake fluid reser-voir of rear brake

M5 5 Nm(3.7 lbf ft)

Loctite® 243™

– Plug in the brake light switch. Mount the cable clip.

– Install the rear wheel. ( p. 81)

PartS

hark

.com

877-

999-

5686

14/LIGHT SYSTEM, INSTRUMENTS 102

17.1Immobilizer control unit

900039-60

Installation location– The ICU is located under the ignition lock.

Imobilizer control unit, connector DN ( p. 399) pin assignmentImobilizer control unit, antenna coil, connector DV ( p. 401) pin assignment

Description of functionThe purpose of the imobilizer control unit is to protect against unauthorized personsusing the vehicle. It is intended to make starting and riding the vehicle impossiblewithout proper access authorization (code) or other suitable legitimization. It uses anelectronic immobilizer that makes use of a coding procedure to disable or enable theuse of several systems, such as the starting system, fuel supply system, or the ignitionsystem. This is carried out via the EFI control unit.

Imobilizer control unitstarter OK " ICUSTR"

Unlocked

InfoThe engine may be started.

Imobilizer control unitstarter OK " ICUSTR"

Locked

InfoThe engine cannot be started.

Imobilizer control unitauthentication "ICUINIT"

Initialization in progress...

Imobilizer control unitauthentication "ICUINIT"

Initialization complete OK

17.2Activating/deactivating ignition key

InfoThe orange programming key must only be used for activating and deactivating!

100749-01

Loss of a black ignition key (second black ignition key available):If a black ignition key is lost or replaced, the black ignition keys must be individu-ally activated/deactivated using the orange programming key. This will also preventthe vehicle from being operated without authorization with the lost black ignitionkey.The following procedure deactivates all activated black ignition keys that are notincluded in the procedure.


– Insert the orange programming key in the ignition lock.

– Switch on the ignition by turning the orange programming key to the ON posi-tion .

EFI warning lamp (MIL) lights up, switches off, and then starts to flash.

The immobilizer indicator lamp lights up.

– Switch off the ignition by turning the orange programming key to the OFF posi-tion .

– Pull out the orange programming key.

– Insert the black ignition key in the ignition lock.

– Switch on the ignition by turning the black programming key tothe position ON .


The immobilizer indicator lamp lights up, switches off briefly, andswitches on again.

– Switch off the ignition by turning the black programming key tothe position OFF .

– Remove the black ignition key.

PartS

hark

.com

877-

999-

5686





The immobilizer indicator lamp lights up, switches off briefly, andflashes according to the number of functioning black ignition keys includ-ing the orange programming key. In this case, twice.



The lost black ignition key is deactivated.

The existing black ignition key is reactivated.

Loss of both black ignition keys (no black ignition key available):This procedure is important to prevent misuse of the lost black ignition key.









The immobilizer indicator lamp lights up, switches off briefly, andflashes according to the number of functioning black ignition keys includ-ing the orange programming key. In this case once, since all black ignitionkeys are deactivated.



All black ignition keys are deactivated.

– Order a new black ignition key according to the key number on the KEYCODE-CARD and activate it.

Activating ignition key:You can activate or deactivate up to four black ignition keys. Only the black igni-tion keys programmed during an activation procedure are valid. All black ignitionkeys not programmed during the activation procedure are invalid, but can be repro-grammed in a further activation procedure.








– Insert the black ignition key in the ignition lock.

– Switch on the ignition by turning the black programming key tothe position ON .


The immobilizer indicator lamp lights up, switches off briefly, andswitches on again.

PartS

hark

.com

877-

999-

5686


– Switch off the ignition by turning the black programming key tothe position OFF .

– Remove the black ignition key.

– To activate further ignition keys, repeat the last 4 steps with the respectiveignition key.




The immobilizer indicator lamp lights up, switches off briefly, andflashes according to the number of functioning black ignition keys includ-ing the orange programming key.



All black ignition keys are activated included in this job sequence are acti-vated.

17.3Activating the ICU

InfoTo program the new imobilizer control unit, the two black ignition keys are needed.

– Install the new imobilizer control unit.

100749-01


– Insert the supplied orange programming key into the ignition lock.

– Switch on the ignition by turning the orange programming key to the ON position .





– Insert the first black ignition key into the ignition lock.



The immobilizer indicator lamp lights up, switches off briefly, and switcheson again.

– Switch off the ignition by turning the black programming key to the position OFF .

– Pull out the first black ignition key.

– Insert the second black ignition key into the ignition lock.



The immobilizer indicator lamp lights up, switches off briefly, and switcheson again.

900039-60

– Connect the diagnostic tool.

– Start diagnostic software.





– Select "Coding".



– Select "Teach-in immobilizer control unit".

PartS

hark

.com

877-

999-

5686



– Read the information page in the KTM diagnostics tool then using "Continue" pro-gramm the ICU.



– Carry out the start procedure. ( p. 13)

Guideline

The start procedure was successful.

– Delete trouble code.

17.4Combination instrument - Activation of the BOOTLOADER mode

400661-10


– Press the button MODEand keep it depressed.


– Press the button MODEand keep it depressed.

BOOTLOADER mode appears in the combination instrument.

– Release MODE button.

17.5Updating the combination instrument softwareConditionThe ignition is on.The diagnostic tool is connected and running.

– Activate the combination instrument - BOOTLOADER mode. ( p. 105)

400687-60


– Select "DCL".

– Select "Connect".

In the DCL window, "ECU OK" appears in the right-hand lower part of thescreen.

In the DCL window, "ECU NOT OK" appears in the right-hand lower part of thescreen.

– Check the connection between XC_1 Scan Box and the diagnostics connec-tor on the vehicle and repeat the procedure.

In the DCL window, "ECU NOT OK" appears in the right-hand lower part of thescreen.

– Activate the combination instrument - BOOTLOADER mode. ( p. 105)

In the DCL window, "XC_1 Scan Box not found" appears in the right-hand lowerpart of the screen.

– Check KTM diagnostic tool connection to XC_1 Scan Box and repeat theprocedure.

– Press button under "Select flash file".

A selection window opens.

– Select the current file with suffix .kfw and highlight it.

InfoSelect the correct file for the vehicle type.

– Press "Open".

– Press "Transfer".

The software status is updated.

PartS

hark

.com

877-

999-

5686


17.6Setting ROAD or RACE modeConditionThe ignition is on.The motorcycle is stationary.

400475-01

– Press the button and the button for 3 - 5 seconds.

– Press the MODE button briefly.

The mode set is shown in the info display.

– Select ROAD mode or RACE mode with the button or the button.


The settings are stored and the display changes to the SET‑UP menu.

– Press the button briefly and repeatedly until the symbol shows EXIT SETUP inthe info display.


17.7Setting the clock with SET CLOCKConditionThe ignition is on.The motorcycle is stationary.

400455-01


– Press the button once until the symbol shows SET CLOCK in the info display.


The hour is shown.

– Set the hour with the button or the button.


The minutes are shown.

– Set the minutes with the button or the button.


The settings are stored and the display changes to the SET‑UP menu.



17.8Adjusting shift speed RPM1/2ConditionThe ignition is on.The motorcycle is stationary.

400460-01


– Press the button twice until the symbol appears in front of SETTINGS in theinfo display.



RPM1 and RPM2 appear in the info display.

The engine speed after RPM1 flashes.

InfoThe engine speed can be set at intervals of 50.RPM1 is the engine speed above which the shift warning light starts to flash.

– Set the engine speed with the button or the button .


The engine speed after RPM2 flashes.

InfoRPM2 is the engine speed above which the shift warning light lights up con-stantly. If RPM1 = RPM2, the shift warning light lights up constantly whenyou reach the engine speed set.

PartS

hark

.com

877-

999-

5686


– Set the engine speed with the button or the button .


The settings are stored and the display changes to the SETTING menu.

InfoAt delivery, RPM1 is set to 10000 and RPM2 to 10500.

– Press the button briefly and repeatedly until the symbol shows BACK... in theinfo display.




17.9Setting the blank time of the LAP button LAP BLANK TConditionThe ignition is on.The motorcycle is stationary.

400461-01




– Press the button once until the symbol shows LAP BLANK T in the info display.


LAP BLANK T. appears in the info display.

InfoAt delivery, LAP BLANK T. is set to 1 second.

TipWith LAP BLANK T., you can prevent the lap from being timed too short. Thismay happen if you accidentally press the LAP button twice in a row.

– Set the blank time of the LAP button with the button or the button.

InfoLAP BLANK T. can be set between 1 and 200.


The settings are stored and the display changes to the SETTINGS menu.





17.10Setting the number of laps SET NUM LAPSConditionThe ignition is on.The motorcycle is stationary.

400462-01




– Press the button twice until the symbol is on SET NUM LAPS in the info dis-play.


TOTAL LAPS appears in the info display with the number of laps.

PartS

hark

.com

877-

999-

5686


InfoWhen delivered, the number of TOTAL LAPS is set to 99 laps.

– Set the number of laps with the button or the button.

InfoYou can set TOTAL LAPS to between 1 and 99 laps.







17.11Setting the fuel reserve display TRIPF RESETConditionThe ignition is on.The motorcycle is stationary.

400463-01




– Press the button three times until the symbol shows TRIP F RESET in the infodisplay.


TRIPF RESET appears in the info display with the reaction time.

InfoAt delivery, TRIPF RESET is set to 300 seconds.

– Set the reaction time of the fuel reserve display with the button or the button.

InfoYou can set the TRIPF RESET to between 10 and 1000 seconds in steps of10.







17.12Setting the kilometers/miles SET KM/MILES

InfoMaking a country-specific setting.

ConditionThe ignition is on.The motorcycle is stationary.

PartS

hark

.com

877-

999-

5686


400464-01


– Press the button three times until the symbol shows UNITS in the info display.



The selected unit appears on the left of the display.

– Select the unit with the button or the button.


The settings are stored and the display changes to the UNITS menu.





17.13Setting the temperature unit SET °C/°FConditionThe ignition is on.The motorcycle is stationary.

400465-01


– Press the button three times until the symbol shows UNITS in the info display.


– Press the button once until the symbol shows SET °C/°F in the info display.


The selected unit appears on the left of the display.

– Select the unit with the button or the button.


The settings are stored and the display changes to the UNITS menu.





17.14Switching the external temperature display on/offConditionThe ignition is on.The motorcycle is stationary.

400466-01


– Press the button four times until the symbol shows OPTIONS in the info dis-play.


– Press the button once until the symbol shows OPTION OUTTEMP in the info dis-play.


You see ENABLED or DISABLED in the info display.

– You can switch the external temperature display on/off with the button or thebutton.


The settings are stored and the display changes to the OPTIONS menu.




PartS

hark

.com

877-

999-

5686



17.15Resetting service displayConditionThe ignition is on.The motorcycle is stationary.

– Press the button and button for 3-5 seconds.



– Press the button and button for 3-5 seconds.

– Press the button repeatedly until the symbol appears in front ofSERVICE RESET.

400486-01


SERVICE RESET appears in the info display.

ARE YOU SURE? flashes.

– Press the button .

The menu is closed.

– Press the button .

NEXT SERVICE AFTER is displayed.

400485-01

– Adjust the distance to the next service using the button and the button .


The menu is closed.

17.16Checking the headlight setting

00BB

00AA

400420-10

– On a light-colored wall behind a horizontal area, make a mark as high as the centerof the low beam headlight.

– Make another mark at a distance of under the first mark.

Guideline

Distance 5 cm (2 in)

– Position the motorcycle at a distance of away from the wall. The rider, with lug-gage and passenger if applicable, now mounts the motorcycle.

Guideline

Distance 5 m (16 ft)

– Switch on the low beam. Check the headlight setting.

The light-dark boundary must lie exactly on the lower mark when the motorcycleis ready to operate with the rider mounted along with any luggage and a passen-ger if applicable.

» If the boundary between light and dark does not meet specifications:

– Adjust the headlight range. ( p. 111)

PartS

hark

.com

877-

999-

5686


17.17Adjust the headlight range– Check the headlight setting. ( p. 110)

100748-10

– Adjust the beam distance of the headlight by turning screw .

Guideline

For a motorcycle with rider, and with luggage and a passenger if applicable, thelight/dark boundary must be exactly on the lower mark (applied in: Checkingheadlight adjustment).

InfoTurn clockwise to increase the light range, turn counterclockwise to reducethe light range.If you have a payload, you may have to correct the headlight range.

17.18Changing the parking light bulb

NoteDamage to reflector Reduced luminance.

– Grease on the bulb will evaporate due to the heat and be deposited on the reflector. Clean the bulb and keep it free of greasebefore mounting.


100745-10

– Remove screws . Remove the cover.

100746-10

– Release the latch .

– Remove the lamp cover .

100747-10

– Pull the parking light carefully out of the holder.

– Remove the light bulb.

– Position a new light bulb in the holder.

Parking light (W5W/ base W2.1x9.5d) ( p. 411)

– Carefully position the holder with the bulb in the holder in the headlight.

PartS

hark

.com

877-

999-

5686


400422-12

– Position the lug of the lamp cover in the notch. Engage the latch.

– Check that the lighting is functioning properly.

100745-12

– Position the cover.

InfoCheck for correct positioning and freedom of movement of the brake lines.


Guideline


17.19Changing the low beam bulb




100742-10

– Fold up the combination instrument. Pull the lug out of the rubber retainer .

– Remove the rubber retainer.

100743-10



PartS

hark

.com

877-

999-

5686


700295-01


– Push off the retaining clamp on both sides, squeeze and fold to the side.

– Remove headlight bulb .

700296-01

– Position the new headlight bulb in the headlight housing.

Low beam / high beam (H7 / base PX26d) ( p. 411)

InfoInsert the headlight bulb so that the lug is positioned in the cut-out.

– Position the retaining clamp.

– Position the plug-in connector.

400422-10

– Position the lug of the lamp cover in the notch. Engage the latch .


100744-10

– Position the rubber holder .

– Fold down the combination instrument. Position the lug in the rubber retainer.

17.20Changing the high beam bulb




PartS

hark

.com

877-

999-

5686


100745-10

– Remove screws . Remove the cover.

100746-10



700299-01


– Push off the retaining clamp on both sides, squeeze and fold to the side.

– Remove headlight bulb.

– Position the new headlight bulb in the headlight housing.

Low beam / high beam (H7 / base PX26d) ( p. 411)

InfoInsert the headlight bulb so that the lug is positioned in the cut-out.

– Position the retaining clamp.

– Position the plug-in connector.

400422-11

– Position the lug of the lamp cover in the notch. Engage the latch.


100745-11

– Position the cover.

InfoCheck for correct positioning and freedom of movement of the brake lines.


Guideline


PartS

hark

.com

877-

999-

5686

30/ENGINE 115

18.1Removing the engine– Jack up the motorcycle at the rear. ( p. 13)

– Dismount the fuel tank. ( p. 70)

– Remove the inside cover. ( p. 75)

– Remove the air filter. ( p. 67)

– Remove the filter box bottom. ( p. 67)

– Remove the radiator. ( p. 195)

200509-10

– Remove rear screw of the starter motor.

– Remove the screw of ground connector .

– Remove the screws of SLS cover . Take off the SLS cover.

200510-10

– Push back protective cover . Unscrew the electrical connection from the startermotor. Remove the cable.

– Unplug the connector of oil pressure sensor .

– Unplug the connector of the coolant temperature sensor .

200511-10

– Remove the screws of SLS cover . Take off the SLS cover.

200512-10

– Remove cable protector .

– Unplug connectors of the gear position sensor and of the side stand switch.

– Remove the exhaust system. ( p. 63)

200520-10

– Unplug the connectors of ignition coils .

PartS

hark

.com

877-

999-

5686

30/ENGINE 116

200521-10

– Remove screws . Remove the slave cylinder with the spacer and sleeves.

– Remove screws . Take off the engine sprocket cover.

200522-10

– Shift into first gear.

InfoThe purpose is to loosen the nut of the engine sprocket.

– Remove screws . Remove the chain securing guide with the spacer.

200523-10

– Remove screws . Remove the side stand bracket.

– Remove screw with the washers. Take off the shift shaft deflection.


200524-10

– Remove screws . Take off the horn holder.

– Remove the rear brake system. ( p. 101)

200527-10

– Position the floor jack under the engine and screw it on using the special tool.

Floor jack attachment (61229055000) ( p. 447)

– Fix the front wheel. Secure the motorcycle against falling over with belts. Removethe work stand from the rear.

200528-10

– Remove the nut of the engine sprocket with the lock washer. Take off the enginesprocket.

PartS

hark

.com

877-

999-

5686

30/ENGINE 117

200529-10

– Remove nut . Pull out the pin of the bell crank on the frame.

– Remove the nut of the swingarm pivot. Pull out the swingarm pivot.

– Take off the swingarm with the shock absorber.

200530-10

– Have an assistant hold the rear of the motorcycle. Remove the securing belts.


InfoMake sure not to misplace the washers.

– Lower the engine. Raise the rear of the motorcycle. Pull out the engine from theside.

– Mount the special tool on the frame.

Frame support (61229050000) ( p. 446)

– Remove both radiator hoses. Remove the vacuum and vent hoses.

18.2Preparing the engine for installation

200531-10

– Position both radiator hoses. Position and tighten the hose clamps.

– Position the hose fixation. Mount and tighten screw .

Guideline

Remaining engine screws M6 10 Nm (7.4 lbf ft)

– Connect the vacuum hoses of manifold absolute pressure sensor .

– Position the vent hoses as shown in the figure.

18.3Installing the engine– Prepare the engine for installation. ( p. 117)

– Raise the engine onto the special tool and screw it in place.



Frame support (61229050000) ( p. 446)

200530-11

– Raise the rear of the motorcycle. Position the engine in the frame.

– Mount screws with the washers on both sides but do not tighten them yet.

– Secure the motorcycle against falling over with belts.

PartS

hark

.com

877-

999-

5686

30/ENGINE 118

200529-01

– Position the swingarm with the shock absorber.

InfoDo not forget the chain.

– Center the swingarm.

Centering pin (61229051000) ( p. 446)

– Mount the swingarm pivot. Mount and tighten the nut.

Guideline

Nut, swingarm pivot M19x1.5 130 Nm(95.9 lbf ft)

Thread greased


Guideline

Screw, engine bearer M10 45 Nm(33.2 lbf ft)

– Mount the pin of the bell crank on the frame. Mount and tighten the nut.

Guideline

Nut of bell crank on frame M14x1.5 100 Nm(73.8 lbf ft)

– Mount the rear work stand.

– Remove the securing belts.

200527-10

– Remove the floor jack with the special tool.


– Install the rear brake system. ( p. 101)

200528-10

– Mount the engine sprocket with the lock washer.

– Mount and tighten the nut.

Guideline

Nut of engine sprocket M20x1.5 100 Nm(73.8 lbf ft)

Loctite® 243™

– Secure the nut with the lock washer.

200524-11

– Position the horn holder. Mount and tighten screws .

Guideline


PartS

hark

.com

877-

999-

5686

30/ENGINE 119

200523-11


Guideline


M8 25 Nm(18.4 lbf ft)

Loctite® 243™

– Position the shift shaft deflection. Mount and tighten screw with the washers.

Guideline

Screw, shift shaft deflectoron shift shaft

M6 18 Nm(13.3 lbf ft)

Loctite® 243™

– Position the side stand bracket. Mount and tighten screws .

Guideline

Screw, side stand bracket M8 25 Nm(18.4 lbf ft)

Loctite® 243™

200522-11

– Position the chain securing guide with the spacer. Mount and tighten screws .

Guideline

Screw, shift shaft deflectoron chain securing guide


Loctite® 243™

Remaining chassis screws M6 10 Nm(7.4 lbf ft)

–

200521-11

– Mount the slave cylinder with the spacer and sleeves. Mount and tighten screws .

Guideline


– Mount the engine sprocket cover. Mount and tighten screws .

Guideline


200520-11

– Plug in the connector of ignition coils .

– Install the exhaust system. ( p. 65)

200512-11

– Plug in connector of the gear position sensor and of the side stand switch.

– Mount cable protector .

PartS

hark

.com

877-

999-

5686

30/ENGINE 120

200511-11

– Position SLS cover . Mount and tighten the screws.

Guideline


200510-11

– Plug in the connector of engine coolant temperature sensor .

– Plug in the connector of oil pressure sensor .

– Position the cable. Screw on the electrical connection on the starter motor. Mountprotective cover .

200509-11

– Position SLS cover . Mount and tighten the screws.

Guideline


– Mount and tighten the screw of ground connection .

Guideline


– Mount and tighten rear screw of the starter motor.

Guideline

Screw, starter motor M6 10 Nm (7.4 lbf ft)

– Install the filter box bottom. ( p. 68)



– Install the radiator. ( p. 195)


– Fill up with engine oil. ( p. 212)

– Take a short test ride.

– Read out the trouble code memory using the KTM diagnostics tool.

– Check the engine for leakage.

– Check the engine oil level. ( p. 209)

– Check the cooling system for leaks.

– Check the coolant level. ( p. 194)

18.4Setting the engine to ignition top dead center of the rear cylinderConditionThe valve cover has been removed.

200539-11

– Remove screw of the generator cover.

PartS

hark

.com

877-

999-

5686

30/ENGINE 121

301441-10

– Turn the crankshaft counterclockwise until markings are flush with the edge ofthe cylinder head.

200540-11

– Remove screw .

– Look through the hole to check that the position notch of the crankshaft is visible.

– Screw in special tool .

Engine blocking screw (61229015000) ( p. 444)

18.5Setting the engine to ignition top dead center of the front cylinderConditionThe engine is positioned at ignition top dead center of the rear cylinder.

200544-10

– Loosen special tool by several turns.


301442-10

– Continue turning the crankshaft counterclockwise until markings are flush withthe edge of the cylinder head.

– Screw special tool back in.

PartS

hark

.com

877-

999-

5686

30/DISASSEMBLING THE ENGINE 122

19.1Clamping the engine into the engine work stand

301339-10

– Mount special tool on engine work stand .

Engine work stand (61229001000) ( p. 443)

Engine holder (61229002000) ( p. 443)

– Mount the engine on special tool .

InfoHave an assistant help you or use a crane.

19.2Removing the engine bracket

301345-10

– Remove screws .

– Remove screw and take off the engine bracket.

301346-10

– Remove screws .

– Remove screw and take off the engine bracket.

19.3Draining the engine oil

200480-10

– Remove oil drain plug with the magnet, O-rings and oil screen.

– Completely drain the engine oil.

PartS

hark

.com

877-

999-

5686


19.4Removing the front valve cover

301336-10

– Remove ignition coil .

– Remove screws . Take off the valve cover with the valve cover seal.

– Remove the spark plug using the special tool.

Spark plug wrench (75029172000) ( p. 448)

19.5Removing the rear valve cover

301337-10

– Remove ignition coil .

– Remove screws . Take off the valve cover with the valve cover seal.



19.6Setting the engine to ignition top dead center of the rear cylinder

301338-10

– Remove screw of the generator cover.

301341-10

– Turn the crankshaft counterclockwise until markings of the rear camshafts areflush with the edge of the cylinder head.

301340-10

– Remove screw .

– Look through the hole to check that the position notch of the crankshaft is visible.



PartS

hark

.com

877-

999-

5686


19.7Removing the starter motor

301348-10

– Remove screw . Take off the starter motor.

19.8Removing the oil filler tube

301349-10

– Remove screws .

– Remove the oil filler tube with the O-ring.

19.9Removing the heat exchanger

301350-10

– Remove screws of heat exchanger .

– Remove the heat exchanger.

301366-10

– Remove O-rings and sleeves .

– Remove seal .

19.10Removing the rear timing chain tensioner

301351-10

– Remove screw with O-ring .

– Pull out timing chain tensioner .

PartS

hark

.com

877-

999-

5686


19.11Removing the rear camshaft

301352-10

– Remove spark plug shaft insert .

– Loosen and remove screws from the outside to the inside.

InfoThe cams should not activate the valves.

– Remove the camshaft bearing bridge.

301353-10

– Raise the camshaft at the rear and take the timing chain off of the rear sprocket.Remove the camshaft.

19.12Removing the rear cylinder head

301357-10

– Remove nuts with the washers.

– Alternately loosen screws and remove them.

– Take off the cylinder head. Remove the cylinder head gasket.

19.13Removing the rear piston

301354-10

– Push the cylinder up.

InfoPush the cylinder up until the piston pin can be removed.Make sure that the two pins remain in place.

301355-10

– Remove piston pin retainer .

– Remove the piston pin.

– Remove the cylinder with the piston.

– Push the piston upward out of the cylinder.

InfoIf no additional work needs to be performed on the cylinder and piston, thepiston can remain in the cylinder.

– Take off the cylinder base gasket.

PartS

hark

.com

877-

999-

5686


19.14Setting the engine to ignition top dead center of the front cylinder

301358-10

– Loosen special tool by several turns.


– Keep the timing chain tensioned.

– Continue turning the crankshaft counterclockwise until markings of the frontcamshafts are flush with the edge of the cylinder head.

– Screw special tool back in.

19.15Removing the front timing chain tensioner

301359-10

– Remove screw with O-ring .


19.16Removing the front camshafts

301360-10





301361-10


19.17Removing the front cylinder head

301362-10

– Remove nuts with the washers.

– Alternately loosen screws and remove them.

– Take off the cylinder head. Remove the cylinder head gasket.

PartS

hark

.com

877-

999-

5686


19.18Removing the front piston

301363-10

– Push the cylinder up.

InfoPush the cylinder up until the piston pin can be removed.Make sure that the two pins remain in place.

301364-10

– Remove piston pin retainer .

– Remove the piston pin.

– Remove the cylinder with the piston.

– Push the piston upward out of the cylinder.

InfoIf no additional work needs to be performed on the cylinder and piston, thepiston can remain in the cylinder.

– Take off the cylinder base gasket.

19.19Removing the generator cover

301392-10

– Remove screws .

301393-10

– Screw in special tool and pull off the generator cover.

Extractor (61229010000) ( p. 444)

InfoGently strike the generator cover with a rubber mallet to prevent strain.

– Take off the generator cover seal. Take off the dowels.

19.20Removing the ignition pulse generator

200346-10

– Remove the screws of ignition pulse generator .

– Pull cable support sleeve out of the engine case. Take off the ignition pulse gen-erator.

PartS

hark

.com

877-

999-

5686


19.21Removing the torque limiter and idler

200347-10

– Take off torque limiter .

– Remove idler with the washers and needle bearing.

InfoThe idler has one disk at the front and one at the rear; the front washer usu-ally sticks to the generator cover.

19.22Removing the rotor

301396-10

– Remove the screws and take off freewheel holder .

– Loosen and remove screw of the rotor.

InfoThe crankshaft must be blocked.

200349-10

– Screw the special tool into the crankshaft.

Pressure piece (61229008000) ( p. 444)

– Mount special tool on the rotor, apply counterpressure, and pull off the rotor byscrewing in the screw.

Extractor (58429009000) ( p. 440)

– Remove the special tools.

200350-10

– Take free-wheel-gear from rotor .

19.23Removing the idler and timing chain on the left

200353-10

– Take off idler with washer .

PartS

hark

.com

877-

999-

5686


200354-10

– Remove the timing chain, needle bearing and the washer lying behind it.

InfoIf the timing chain is to be used again, note the direction of travel and thecylinder on which it was used.

19.24Removing the oil filter

301390-10

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

– Pull oil filter out of the oil filter housing.

Circlip pliers reverse (51012011000) ( p. 440)

19.25Removing the balancer shaft

301391-10

– Remove balancer shaft with washer .

– Mount the needle bearing and the rear washer.

19.26Removing the drive wheel of the balancer shaft

200358-10

– Remove the drive wheel of balancer shaft using special tools , and .

Puller, 2-arm (78029033100) ( p. 448)

Pressure piece (61229018000) ( p. 445)

Arms for extractor 78029033100 (61229017000) ( p. 445)

PartS

hark

.com

877-

999-

5686


19.27Removing the gear position sensor

301398-10

– Remove the screws. Remove gear position sensor with the O-ring.

301399-10

– Remove contact pin and the contact spring.

19.28Removing the left suction pump

301400-10

– Remove screws .

301401-10

– Screw fitting screws into the oil pump cover.

– Pull off the oil pump cover by screwing in the screw.

– Remove oil pump cover .

– Remove seal .

PartS

hark

.com

877-

999-

5686


301402-10

– Remove external rotor and internal rotor .

– Remove pin .

19.29Removing the water pump wheel

301394-10

– Remove screws .

– Take off the water pump cover.

200398-10

– Remove dowels .

– Remove screw . Take off the water pump wheel with the washer below it.

19.30Removing the clutch cover

200399-10

– Loosen the screws of outer clutch cover .

– Remove screws .

– Take off the clutch cover.

PartS

hark

.com

877-

999-

5686


200401-10

– Take off dowels . Remove the clutch cover seal.

– Remove check valve .

19.31Removing the idler and timing chain on the right

200403-10

– Remove idler .

– Take off the timing chain.

InfoIf the timing chain is to be used again, note the direction of travel and thecylinder on which it was used.

19.32Removing the clutch facing

200405-10

– Loosen screws of pressure cap in a crisscross pattern and remove themtogether with the spring retainers and the clutch springs.

– Take off pressure cap .

– Take off push rod .

200406-10

– Remove clutch discs , the support ring and the pretension ring.

19.33Removing the outer clutch hub

200408-10

– Insert special tool into inner clutch hub and outer clutch hub .

Clutch holder (61229003000) ( p. 443)

– Loosen nut and remove it with the washer.

– Remove components and of the clutch pressure booster.

PartS

hark

.com

877-

999-

5686


301403-10

– Remove outer clutch hub with washer .

301404-10

– Remove needle bearing and washer .

19.34Removing the primary gear

200412-10

– Loosen nut of primary gear and remove it together with the washer.

InfoLeft-handed thread!Make sure that the crankshaft is blocked.

301409-10

– Remove the primary gear with special tools , and .

Puller, 2-arm (78029033100) ( p. 448)

Pressure piece (61229018000) ( p. 445)

Arms for extractor 78029033100 (61229017000) ( p. 445)

19.35Removing the force pump

301410-10

– Remove lock washer and washer . Take off oil pump gear .

PartS

hark

.com

877-

999-

5686


301411-10

– Remove pin and washer .

– Remove screws .

– Remove the oil pump cover.

301412-10

– Remove external rotor and internal rotor .

– Remove pin .

19.36Removing the shift shaft

301413-10

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

19.37Removing the shift drum locating

301414-10

– Remove screw .

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

– Release the locking lever.

PartS

hark

.com

877-

999-

5686


19.38Removing the locking lever

301415-10

– Remove screw .

– Take off locking lever with the sleeve and spring.

19.39Removing the left engine case

200421-10

– Remove screws and .

– Swing the left section of the engine case upward. Remove screw .

– Loosen the left section of the engine case by striking it lightly with a plastic hammer and remove it.

301422-10

– Remove dowels .

– Remove seal .

19.40Removing the crankshaft

301423-10



– Remove the crankshaft.

PartS

hark

.com

877-

999-

5686


19.41Removing the middle suction pump

200425-10

– Take off oil pump shaft with internal rotor .

200426-10

– Remove internal rotor and pin from the oil pump shaft .

– Remove external rotor .

19.42Removing the transmission shaft

200427-10

– Remove shift rails .

200428-10

– Swing shift forks to one side.

InfoMake sure not to misplace shift rollers .

– Remove shift drum .

200429-10

– Remove shift forks .

InfoMake sure not to misplace the shift rollers.

PartS

hark

.com

877-

999-

5686


200430-10

– Place the engine in an upright position.

– Remove lock ring and the stop disk.

200431-10

– Pull both transmission shafts out of the bearing seats together.

19.43Removing the oil spray tube

200432-10

– Remove oil spray tube . Remove O-rings .

19.44Removing the timing chain rails of the right engine case section

200434-01

– Remove screw . Remove timing chain guide rail .

– Remove screw . Remove timing chain tensioning rail .

19.45Removing the timing chain rails of the left engine case section

200447-10

– Remove screw . Remove timing chain guide rail .

– Remove screw . Remove timing chain tensioning rail .

PartS

hark

.com

877-

999-

5686

30/ENGINE - WORK ON INDIVIDUAL PARTS 138

20.1Work on the right section of the engine case

200442-10

– Remove studs .

200440-10

– Remove jet .

– Remove oil jets .

200441-10

– Remove bearing retainers .

– Remove the dowels.

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

– Warm the engine case section in an oven.

Guideline

150 °C (302 °F)

– Knock the engine case section against a level wooden plate. This will cause thebearings to drop out of the bearing seats.

InfoAny bearings that remain in the engine case section must be removed usinga suitable tool.

– Warm the engine case section again.

Guideline

150 °C (302 °F)

– Insert the new cold bearings into the bearing seats of the hot engine case sectionand, if necessary, use a suitable press drift to push the bearing from the inside tothe outside, all the way to the stop or so it is flush.

InfoWhen pressing the bearing in, ensure that the engine case section is level toprevent damage.Only press the bearings in via the outer ring; otherwise, the bearings will bedamaged when they are pressed in.

– After the engine case section has cooled, check that the bearings are firmly seated.

PartS

hark

.com

877-

999-

5686


InfoIf the bearings are not firmly seated after cooling, it is likely that they willrotate in the engine case when warm. In this case, the engine case must berenewed.

– Mount and tighten bearing retainers .

Guideline

Screw, bearing retainer M5 6 Nm(4.4 lbf ft)

Loctite® 243™

200440-10

– Mount and tighten jet .

Guideline

Jet 140 M6x0.75 4 Nm(3 lbf ft)

Loctite® 243™

– Mount and tighten oil jets .

Guideline

Oil jet M6x0.75 4 Nm(3 lbf ft)

Loctite® 243™

– Mount the dowels.

200442-10

– Mount studs .

Guideline

Stud, chain shaft M6 8 Nm (5.9 lbf ft)

– Blow compressed air through all oil holes and check that they are clear.

20.2Removing the main bearing of the right engine case section

200435-10

– Remove the screws and take off bearing shell bracket .

200436-10

– Mark face of the main bearing shells as shown in the figure.

PartS

hark

.com

877-

999-

5686


200437-10

– Place the engine case section on special tool .

Press sleeve (61229045000) ( p. 446)

– Place special tool with the smaller diameter on the bearing shells and press fromthe inside to the outside.

Press drift/press sleeve (61229044000) ( p. 446)

20.3Selecting the main bearing shells

200451-10

New crankshaft– Select the new bearing shells according to color marking .

InfoColor marking refers to the conrod bearing.

Used crankshaft– Measure both pivot points and select the new bearing shells accordingly.

Guideline

Crankshaft - main bearing diameter

Yellow 53.965… 53.975 mm (2.1246…2.125 in)

Blue 53.976… 53.985 mm (2.12504…2.12539 in)

Red 53.986… 53.995 mm (2.12543…2.12578 in)

20.4Installing the right main bearing– Select the main bearing shells. ( p. 140)

200439-10

– Center the new main bearing shells using special tool .


200438-10

– Place the inside of the engine case section on special tool .

Press sleeve (61229045000) ( p. 446)

– Align the face of the new bearing shell with the marking made when it was disas-sembled.

– Press the bearing shells with the stepped side of special tool through presssleeve from the outside to the inside, all the way to the stop.


PartS

hark

.com

877-

999-

5686


200435-11

– Position bearing shell bracket . Mount and tighten the screws.

Guideline


Loctite® 243™

20.5Work on the left section of the engine case

200448-10

– Remove studs .

200449-10

– Remove screw .

– Remove oil jets .

200450-10

– Remove shaft seal rings .

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

– Warm the engine case section in an oven.

Guideline

150 °C (302 °F)

– Knock the engine case section against a level wooden plate. This will cause thebearings to drop out of the bearing seats.

InfoAny bearings that remain in the engine case section must be removed usinga suitable tool.

– Warm the engine case section again.

Guideline

150 °C (302 °F)

– Insert the new cold bearings into the bearing seats of the hot engine case sectionand, if necessary, use a suitable press drift to push the bearing from the inside tothe outside, all the way to the stop or so it is flush.

PartS

hark

.com

877-

999-

5686


InfoWhen pressing the bearing in, ensure that the engine case section is level toprevent damage.Only press the bearings in via the outer ring; otherwise, the bearings will bedamaged when they are pressed in.

– After the engine case section has cooled, check that the bearings are firmly seated.

InfoIf the bearings are not firmly seated after cooling, it is likely that they willrotate in the engine case when warm. In this case, the engine case must berenewed.

200449-11

– Mount oil jets .

Guideline

Oil jet M6x0.75 4 Nm(3 lbf ft)

Loctite® 243™

– Mount oil jet .

Guideline

Oil jet for clutch lubrication M6x0.75 4 Nm (3 lbf ft)


Guideline

Plug, clutch lubrication M10x1 15 Nm(11.1 lbf ft)

200450-11

– Press in shaft seal rings until they are flush.

– Press in the shaft seal ring of push rod .

Press drift (61229013000) ( p. 444)

200442-10

– Mount studs .

Guideline

Stud, chain shaft M6 8 Nm (5.9 lbf ft)

– Blow compressed air through all oil holes and check that they are clear.

PartS

hark

.com

877-

999-

5686


20.6Removing the left main bearing

200443-10

– Remove the screws and take off bearing shell bracket .

200444-10

– Mark joint of the main bearing shells as shown in the figure.

200445-10

– Place the engine case section on special tool .

Press sleeve (61229045000) ( p. 446)

– Place special tool with the smaller diameter on the bearing shells and press fromthe inside to the outside.


20.7Installing the left main bearing– Select the main bearing shells. ( p. 140)

200439-10

– Center the new main bearing shells using special tool .


200446-10

– Place the inside of the engine case section on special tool .

Press sleeve (61229045000) ( p. 446)

– Align the face of the new bearing shell with the marking made when it was disas-sembled.

– Press the bearing shells with the stepped side of special tool through presssleeve from the outside to the inside, all the way to the stop.


PartS

hark

.com

877-

999-

5686


200443-11

– Position bearing shell bracket . Mount and tighten the screws.

Guideline


Loctite® 243™

20.8Changing the conrod bearing

InfoPerform the operation on both connecting rods.

301424-10

– Clamp each connecting rod separately using soft jaws.

– Remove screws .

Multi-tooth wrench socket 10 mm; ½" drive (60029075000) ( p. 442)

– Take off the bearing cap and connecting rod. Remove the bearing shells.

InfoMark the connecting rod bearing cap and connecting rod to ensure thateach connecting rod bearing cap will be mounted on the same connectingrod.

200453-10

New crankshaft– Select the new bearing shells according to color marking .

InfoColor marking refers to the crankshaft bearing.

200485-10

Used crankshaft– Measure the crank pin diameter and select the new bearing shells accordingly.

Guideline

Crankshaft - crank pin diameter

Yellow 41.978… 41.989 mm (1.65267…1.65311 in)

Blue 41.990… 42.000 mm (1.65315…1.65354 in)

Red 42.001… 42.011 mm (1.65358…1.65397 in)

– Check the radial clearance of the bottom connecting rod bearing. ( p. 147)

PartS

hark

.com

877-

999-

5686


301425-10

– Oil the bearing shells.

– Position the connecting rod bearing cap according to the markings made when theywere disassembled. Mount the new connecting rod screws and tighten them usingthe special tool.

Guideline

Screw, conrod bearing M10x1 Step 125 Nm(18.4 lbf ft)Step 230 Nm(22.1 lbf ft)Step 390°

Multi-tooth wrench socket 10 mm; ½" drive (60029075000) ( p. 442)

Graduated disc (60029010000) ( p. 441)

InfoThe connecting rod bearing shells are laterally offset in the connecting rodto allow room for radius of the crankshaft. If installed incorrectly, thebearing shells will press against the radius and block the connecting rod.

20.9Work on the clutch cover

200456-10

– Remove water pump cover .

– Remove outer shaft seal ring .

200457-10


– Remove inner shaft seal ring .

200458-10

– Press bearing out of the clutch cover from the outside to the inside, using a suit-able tool.

– Press in new bearing from the inside to the outside, all the way to the stop,using a suitable tool.

– Change the step bearing of the crankshaft. ( p. 146)

200457-10

– Press in inner shaft seal ring fully, with the open side flush and facing inwards.


PartS

hark

.com

877-

999-

5686


200456-10

– Press in outer shaft seal ring fully, with the open side flush and facing outwards.

– Insert water pump cover .

20.10Changing the step bearing of the crankshaft

200459-10

– Mark the position of the bearing joint .

200460-10

– Pull out the step bearing shells using the special tool.

Bearing puller (15112017000) ( p. 440)

Insert for bearing puller (60029018000) ( p. 441)

200461-10

– Center the new main bearing shells using the special tool.

Step bearing tool (60029046028) ( p. 442)

200462-10

– Support the clutch cover directly under the step bearing. Press in the step bearingshells using the special tool until they are flush.

Step bearing tool (60029046028) ( p. 442)

PartS

hark

.com

877-

999-

5686


20.11Checking the radial clearance of the bottom connecting rod bearing

InfoPerform the operation on both connecting rods.

200455-10

– Position the bearing shells. Insert the Plastigauge measuring strips offset by 90°from the bearing joint.

Plastigauge measuring strips (60029012000) ( p. 441)

– Position the connecting rod bearing cap. Mount and tighten the screws.

Guideline

Screw, conrod bearing M10x1 Step 125 Nm(18.4 lbf ft)Step 230 Nm(22.1 lbf ft)Step 390°

InfoDo not twist the connecting rod.

– Remove the connecting rod bearing cap again. Compare the Plastigauge measuringstrip with the specifications on the packaging.

Guideline

Connecting rod - radial clearance of lower conrod bearing

New condition 0.030… 0.060 mm (0.00118…0.00236 in)

Wear limit 0.080 mm (0.00315 in)

InfoThe width of the Plastigauge measuring strips indicates the bearing play.

– Clean the parts.

20.12Checking/measuring the cylinder

200472-10

– Check the cylinder bearing surface for damage.

» If the cylinder bearing surface is damaged:

– Change the cylinder and piston.

– Measure the cylinder diameter at several places on the contact surface in the and axes using a micrometer to check for oval wear.

Guideline

Cylinder - bore diameter

Size I 105.000… 105.012 mm (4.13385…4.13432 in)

Size II 105.012… 105.025 mm (4.13432…4.13483 in)

200474-10

– The cylinder size is labeled on the side of the cylinder.

PartS

hark

.com

877-

999-

5686


400376-10

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

Feeler gauge (59029041100) ( p. 441)

Cylinder/cylinder head - sealing areadistortion

≤ 0.05 mm (≤ 0.002 in)

» If the measured value does not equal the specified value:

– Change the cylinder.

20.13Checking/measuring the piston

301418-10

– Check the piston bearing surface for damage.

» If the piston bearing surface is damaged:

– Change the piston and, if necessary, the cylinder.

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

» If the piston ring is stiff:

– Clean the piston ring groove.

TipUse an old piston ring to clean the piston ring groove.

– Check the piston rings for damage.

» If the piston ring is damaged:

– Change the piston ring.

InfoMount the piston ring with the marking facing upward.

00A

A0

0A

A0

0A

A

400484-10

– Use the special tool to measure clearance of the piston rings in the piston ringgroove.

Guideline

Piston ring - groove clearance

First ring (rectangular ring) ≤ 0.105 mm (≤ 0.00413 in)

Second ring (lower compressionring)

≤ 0.150 mm (≤ 0.00591 in)

Oil scraper ring ≤ 0.180 mm (≤ 0.00709 in)

Feeler gauge (59029041100) ( p. 441)

» If clearance is larger than the specified value:

– Change the piston and piston rings.

– Check/measure the cylinder. ( p. 147)

– Check the piston pin for discoloration or signs of wear.

» If the piston pin has strong discoloration/signs of wear:

– Change the piston pin.

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

» If the piston pin bearing has too much play:

– Change the connecting rod and the piston pin.

200475-10

– Measure the piston on the piston skirt.

Guideline

Piston - diameter

Size I 104.955… 104.985 mm (4.13208…4.13326 in)

Size II 104.965… 104.995 mm (4.13247…4.13365 in)

Under the edge at right angles to thepiston pin

6 mm (0.24 in)

PartS

hark

.com

877-

999-

5686


301419-10

– Piston size is marked on the piston head.

20.14Checking the piston ring end gap

200477-10

– Remove the piston ring from the piston.

– Place the piston ring in the cylinder and align it with the piston.

Guideline

Under the upper edge of the cylinder 10 mm (0.39 in)

– Measure the end gap with special tool .

Guideline

Piston ring end gap ≤ 0.5 mm (≤ 0.02 in)

Feeler gauge (59029041100) ( p. 441)

» If the end gap is more than the specified value:

– Check/measure the cylinder. ( p. 147)

» If the cylinder wear is within the tolerance range:

– Change the piston ring.

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

20.15Checking the piston/cylinder mounting clearance– Check/measure the cylinder. ( p. 147)

– Check/measure the piston. ( p. 148)

– The smallest piston/cylinder mounting clearance is the result of the smallest cylinder bore diameter minus the largest piston diam-eter. The largest piston/cylinder mounting clearance is the result of the largest cylinder bore diameter minus the smallest pistondiameter.

Guideline

Piston/cylinder - mounting clearance

New condition 0.015… 0.057 mm (0.00059… 0.00224 in)


20.16Work on the cylinder head

InfoThe following operations apply to both cylinder heads.

200466-10

– Remove oil pressure switch .

InfoThis only applies to the front cylinder head!

– Remove engine coolant temperature sensor .

– Remove screw .

– Remove vacuum connection .

– Remove O-rings .

PartS

hark

.com

877-

999-

5686


200467-10

– Remove plugs with the O-ring.

– Pull out cam lever axle with a suitable M5 screw and remove the cam lever.

200468-10

– Remove shims and label the installation position.

200469-10

– Tension the valve spring with a special tool.

Valve spring mounter (59029019000) ( p. 440)

Valve spring mounting device (78029060000) ( p. 448)

– Remove valve keys and release tension on the valve spring.

99

bkbk

blblbmbm 200470-01

– Remove valve spring retainer , valve spring, valve stem seals and valve springsupports .

InfoPlace the valve into a box according to the installation position and label thebox.

– Check the cylinder head. ( p. 152)

– Mount valve spring supports and new valve stem seals .

– Mount valve spring and valve spring retainer .

The tight winding of the valve spring is at the bottom.

PartS

hark

.com

877-

999-

5686


200469-10

– Tension the valve spring with a special tool.

Valve spring mounter (59029019000) ( p. 440)

Valve spring mounting device (78029060000) ( p. 448)

– Mount valve keys . Release the tension on the valve spring.

InfoWhen mounting the valve keys, check that they are seated correctly; prefer-ably, fix the valve keys to the valve with a little grease.

200468-10

– Place shims into the valve spring retainer according to the installation position.

200467-11

– Position the cam lever and mount cam lever axles .

– Mount plugs with new O-rings.

Guideline

Plug, cam lever axis M10x1 15 Nm(11.1 lbf ft)

200466-10

– Mount oil pressure sensor .

Guideline

Oil pressure sensor M10x1 10 Nm (7.4 lbf ft)

InfoThis only applies to the front cylinder head!

– Mount engine coolant temperature sensor .

Guideline

Coolant temperature sensor M12x1.5 12 Nm (8.9 lbf ft)

PartS

hark

.com

877-

999-

5686


– Mount screw .

Guideline

Plug, vacuum connection M6 5 Nm(3.7 lbf ft)

Loctite® 243™

– Mount vacuum connection .

Guideline

Vacuum connection M6 5 Nm(3.7 lbf ft)

Loctite® 243™

– Mount and grease O-rings .

20.17Checking the cylinder head

200470-10

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

» If there is wear or tearing:

– Change the cylinder head.

– Check the valve guides using the special tool.

Limit plug gauge (59029026006) ( p. 440)

Valve guide - diameter

New condition 6.004… 6.016 mm (0.23638…0.23685 in)


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

– Change the valve guide and valve.

00A

A

400373-10

– Check sealing seat of the valves.

Valve - sealing seat width

Intake: New condition 1.0 mm (0.039 in)

Intake: Wear limit 1.7 mm (0.067 in)

Exhaust: New condition 1.0 mm (0.039 in)

Exhaust: Wear limit 2.0 mm (0.079 in)


– Machine the valve seat.

400376-10

– Check the sealing area of the cylinder for distortion using a straight edge and thespecial tool.

Feeler gauge (59029041100) ( p. 441)

Cylinder/cylinder head - sealing areadistortion

≤ 0.05 mm (≤ 0.002 in)


– Change the cylinder head.

– Check the pivot points of the camshafts in the cylinder head and in the camshaftbearing bridge for damage and wear.


– Change the cylinder head with the camshaft bearing bridge.

200471-10

– Check valve for damage and wear.


– Change the valve.

– Check the valve for run-out.

Valve - run-out

On the valve stem ≤ 0.05 mm (≤ 0.002 in)

On the valve plate: New condition ≤ 0.016 mm (≤ 0.00063 in)

On the valve plate: Wear limit ≤ 0.030 mm (≤ 0.00118 in)

PartS

hark

.com

877-

999-

5686




– Check the valve stem diameter.

Valve - valve stem diameter

Exhaust 5.893… 5.970 mm (0.23201…0.23504 in)

Intake 5.965… 5.980 mm (0.23484…0.23543 in)



– Check valve spring for damage and wear.


– Change the valve spring.

– Measure the valve spring lengths.

Valve spring - length

New condition 42.0 mm (1.654 in)



– Change the valve springs.

– Check cam lever for damage and wear.


– Change the cam lever.

– Check cam lever axle for damage and wear.


– Change the cam lever axle.

– Check valve spring support for damage and wear.


– Change the valve spring seat.

– Check valve spring retainer for damage and wear.


– Change the valve spring retainer.

20.18Work on the right idler

200465-10

– Remove bushing .

– Remove O-ring .

– Remove inner bearing races and .

Extractor (61229020000) ( p. 445)

– Push on new bearing inner races and .

– Mount the new O-ring .

– Mount the new bushing .

PartS

hark

.com

877-

999-

5686


20.19Checking the timing assembly

00110011

22

0022

0033

0033

0044

44

55

55

66

66

0044

301420-01

– Clean all parts well.

– Check idler for damage and wear.


– Change the idler.

– Check timing chain tensioning rail for damage and wear.


– Change the timing chain tensioning rail.

– Check timing chain guide rail for damage and wear.


– Change the timing chain guide rail.

– Check camshaft for damage and wear.


– Change the camshaft.

– If the cam surface is damaged, check the oil supply to the camshaft andcam lever.

– Measure the cam height.

Guideline

Camshaft - cam height

Intake 39.34… 39.44 mm (1.5488…1.5528 in)

Exhaust 38.59… 38.69 mm (1.5193…1.5232 in)

» If cam wear is outside of the tolerance range:

– Change the camshaft.

– Check timing chain for damage and wear.


– Change the timing chain.

– Check that the timing chain links move easily. Let the timing chain hang downfreely.

» If the chain links no longer straighten out:

– Change the timing chain.

– Check guide rail for damage and wear.


– Change the guide rail.

20.20Preparing the timing chain tensioner for installation

200171-10

– Fully compress the timing chain tensioner.

InfoThis requires considerable force since the oil has to be pressed out.Without pressure, the timing chain tensioner expands fully.

200172-10

– Place two spacing washers or similar aids next to the piston of the timing chaintensioner. This should ensure that when pushed down, the piston does not fullywithdraw.

Guideline

Thickness of spacers 2… 2.5 mm (0.08… 0.098 in)

– Release the timing chain tensioner.

The latching system locks and the piston stops moving.

End position of piston after latching 3 mm (0.12 in)

PartS

hark

.com

877-

999-

5686


InfoThis position is necessary for installation.If the timing chain tensioner is now pressed in once more (while it isinstalled) and then pulled out no more than halfway (preventing it fromcoming out fully), the latching system locks and the timing chain tensionercan no longer be compacted; this function is necessary to ensure sufficienttension of the timing chain, even at low oil pressure.

20.21Checking the oil pressure regulator valve

3322

11

44

301419-01

– Remove supporting plate and spring .

– Measure the length of spring .

Oil pressure regulator valve - minimumspring length

40.5 mm (1.594 in)

» If the measured length is less than the specified value:

– Change the spring.

– Check control piston for damage and wear.


– Change the control piston.

– Check the control piston hole in oil pump cover for damage and wear.


– Change the oil pump cover.

– Oil control piston and spring well and mount them.

– Mount supporting plate .

20.22Checking the oil pumps

InfoThe following operations apply to all three oil pumps.

200464-10

– Check the clearance between internal rotor and external rotor and betweenthe external rotor and the engine case.

Oil pumps

Clearance between external rotorand engine case

0.20… 0.40 mm (0.0079…0.0157 in)

Clearance between external rotorand internal rotor

0.10… 0.25 mm (0.0039…0.0098 in)

Axial clearance 0.04… 0.25 mm (0.0016…0.0098 in)

» If the clearance exceeds the specifications:

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

tSha

rk.c

om

877-

999-

5686


20.23Checking the clutch

0033

00110022

0044

0055

0066

0077

0088

0099

99

99blbl

bmbm

bnbn

bkbk

00bobo

301421-01

– Check pressure piece for damage and wear.


– Change the push rod.

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

» If there is run-out:

– Change the push rod.

– Check axial bearing for damage and wear.


– Change the axial bearing.

– Check the length of clutch springs .

Clutch spring - length 33.00… 34.00 mm (1.2992… 1.3386 in)

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

– Change all clutch springs.

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


– Change the pressure cap.

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

Outer clutch hub - contact surface of clutch facing discs


» If the contact surface is very worn:

– Change the clutch facing discs and the outer clutch hub.

– Check needle bearing for damage and wear.


– Change the needle bearing.

– Check the intermediate clutch discs for damage and wear.

» If the intermediate clutch discs are not level and have pittings:

PartS

hark

.com

877-

999-

5686


– Change all intermediate clutch discs.

– Check the thickness of intermediate clutch discs .

Intermediate disk - thickness



» If the intermediate clutch discs do not meet specifications:

– Change all intermediate clutch discs.

– Check clutch facing discs for discoloration and scoring.

» If there is discoloration or scoring:

– Change all clutch facing discs.

– Check the thickness of clutch facing discs .

Clutch facing disc - thickness



» If the clutch facing discs do not meet specifications:

– Change all clutch facing discs.

– Check pretension ring and support ring for damage and wear.


– Change the pretension ring and support ring.

– Check inner clutch hub for damage and wear.


– Change the inner clutch hub.

– Check the components of clutch pressure booster for damage and wear.


– Change all components of the clutch pressure booster.

– Check the springs of outer clutch hub for damage and wear.

» If there is damage, wear or play in the direction of rotation:

– Change the outer clutch hub.

20.24Checking the shift mechanism

00BB

0011

0022

00AA

0033

0033

00110044

0055

55

66 0044

77

CC

DD

EE

301418-01

– Check shift forks at leaf for wear.

Shift fork

Thickness at leaf 4.85… 4.95 mm (0.1909…0.1949 in)

Clearance in the sliding geargroove: New condition

0.35… 0.55 mm (0.0138…0.0217 in)

Clearance in the sliding geargroove: Wear limit

0.70 mm (0.0276 in)


– Change the shift fork and the idler/fixed gear pair.

– Check shift grooves of shift drum for wear.

» If the shift groove is worn:

– Change the shift drum.

– Check the seat of the shift drum in grooved ball bearings .

» If the shift drum is not seated correctly:

– Change the shift drum and/or the grooved ball bearing.

– Check grooved ball bearing for stiffness and wear.

» If the grooved ball bearings do not move freely or are worn:

– Change the grooved ball bearing.

– Check shift drums for ovality, surface damage and cracking.

» If the shift drum is oval, or shows signs of surface damage or cracks:

PartS

hark

.com

877-

999-

5686


– Change the shift drum.

– Check springs of the shift rails for damage and wear.

» If the spring is broken or worn:

– Change the spring of the shift rail.

– Check the shift rails on a flat surface for run-out.

» If there is run-out:

– Change the shift rail.

– Check shift rails for scoring, signs of corrosion and stiffness in the shift fork.

» If there is scoring or corrosion, or if the shift fork is stiff:

– Change the shift rail.

– Check sliding plate in contact areas for wear.

» If the sliding plate is worn:

– Change the sliding plate.

– Check return surface on the sliding plate for wear.

» If deep notches are present:


– Check guide pin for looseness and wear.

» If the guide pin is loose and/or worn:


20.25Preassembling the shift shaft

0011

0022

00330044

0055

0066 200175-01

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

Guideline

Use soft jaws.

– Mount sliding plate with the guide pin facing down and attach the guide pin tothe shift quadrant.

– Mount preload spring .

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

– Mount stop disk .

20.26Dismantling the main shaft

0011

0022

003300440055

0066

00blbl 00bkbk 0099

00880077

200460-01

– Fix the main shaft in the vise with the geared end facing downward.

Guideline

Use soft jaws.

PartS

hark

.com

877-

999-

5686


– Remove stop disk and second-gear fixed gear .

– Remove the sixth-gear idler gear .

– Remove needle bearing and stop disk .

– Remove the third/fourth-gear sliding gear .


– Remove stop disk and the fifth-gear idler gear .

– Remove needle bearing .

– Remove needle bearing using a suitable tool.

InfoIt only needs to be removed if worn.

20.27Dismantling the countershaft

0022

0011

0033 0044 0055

00660077 0088

0099 00bkbk00blbl 00bmbm00bnbn 00bobo

00bpbp00bqbq 00brbr

00bsbs

200462-01

– Fix the countershaft in the vise with the geared end facing downward.

Guideline

Use soft jaws

– Remove stop disk and the first-gear idler gear .


– Remove the fifth-gear sliding gear and lock ring .

– Remove stop disk and the fourth-gear idler gear .

– Remove needle bearing and the third-gear idler gear .


– Remove lock ring and the sixth-gear sliding gear .

– Remove lock ring and stop disk .

– Remove the second-gear idler gear and needle bearing .

PartS

hark

.com

877-

999-

5686


20.28Checking the transmission

0011

0011

0011

00110011

0011

0022

0033

0044

0044

0044

0044

0055

0055

0055

0055

0066

0066

0066

0066

0066

0066

0066

0066

0077

00770077

0077

00440088

200461-01

– Check needle bearing for damage and wear.



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


– Change the main shaft and/or countershaft.

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


– Change the main shaft and/or countershaft.

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


– Change the idler/fixed gear pair.

– Check the shift dogs of idler gears and fixed gears for damage and wear.



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



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



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

» If the fixed gear does not move easily:

– Change the fixed gear or the main shaft.

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

» If the fixed gear does not move easily:

– Change the fixed gear or the countershaft.

– Check stop disks for damage and wear.


– Change the stop disk.

– Use new lock rings in every repair job.

– Check needle bushing for damage and wear.


PartS

hark

.com

877-

999-

5686



20.29Assembling the main shaft

InfoUse new lock rings and new stop disks with every repair.

– Oil all parts carefully before assembling.

– Check the transmission. ( p. 160)

00bl

bl

0

0bk

bk

0

09

90

08

80

07

7

0

06

6

0

01

1 0

02

2 0

03

3

0

04

40

05

5

200460-02

– Fix the main shaft in the vise with the geared end facing downward.

Guideline

Use soft jaws

– If removed, mount a new needle bushing using a suitable tool.

– Mount needle bearing and put on the fifth-gear idler gear with the shifting claws facing upward.

– Mount stop disk and a new lock ring .

– Mount the third/fourth-gear sliding gear with the small gear wheel facing upward.

– Mount stop disk and needle bearing .

– Put on the sixth-gear idler gear with the shifting claws facing downward.

– Mount the second-gear fixed gear with the collar facing downward and mount stop disk .

– Finally, check all gear wheels for smooth operation.

20.30Assembling the countershaft

InfoUse new lock rings and new stop disks with every repair.

– Oil all parts carefully before assembling.

– Check the transmission. ( p. 160)

PartS

hark

.com

877-

999-

5686


00brbr

00bsbs

00bqbq 00bpbp 00bobo

00bnbn00bmbm 00blbl

00bkbk 0099008800770066 0055

00440033 0022

0011

200462-02

– Fix the countershaft in the vise with the geared end facing downward.

Guideline

Use soft jaws

– Mount needle bearing and the second-gear idler gear on the countershaft with the protruding collar facing downward.


– Mount the sixth-gear sliding gear with the shift groove facing upward.

– Mount a new lock ring and stop disk .

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

– Mount needle bearing and the fourth-gear idler gear with the collar facing downward.


– Mount the fifth-gear sliding gear with the shift groove facing downward and stop disk .

– Mount needle bearing , first-gear idler gear with the groove facing downward and stop disk .

– Finally, check all gear wheels for smooth operation.

PartS

hark

.com

877-

999-

5686

30/ASSEMBLING THE ENGINE 163

21.1Installing the timing chain rails of the left engine case section

200447-11

– Position timing chain guide rail . Mount and tighten screw .

Guideline

Screw, timing chain guiderail

M8 15 Nm(11.1 lbf ft)

Loctite® 243™

InfoEnsure that there is no thread locking material at the collar of the screw;otherwise, the timing chain guide rail could lock and break.

– Position timing chain tensioning rail . Mount and tighten screw .

Guideline

Screw, timing chain ten-sioning rail

M8 15 Nm(11.1 lbf ft)

Loctite® 243™

InfoEnsure that there is no thread locking material at the collar of the screw;otherwise, the timing chain tension rail could lock and break.

– Check both timing chain rails for freedom of motion.

21.2Installing the timing chain rails of the right engine case section

200434-10

– Position timing chain guide rail . Mount and tighten screw .

Guideline

Screw, timing chain guiderail

M8 15 Nm(11.1 lbf ft)

Loctite® 243™

InfoEnsure that there is no thread locking material at the collar of the screw;otherwise, the timing chain guide rail could lock and break.

– Position timing chain tensioning rail . Mount and tighten screw .

Guideline

Screw, timing chain ten-sioning rail

M8 15 Nm(11.1 lbf ft)

Loctite® 243™

InfoEnsure that there is no thread locking material at the collar of the screw;otherwise, the timing chain tension rail could lock and break.

– Check both timing chain rails for freedom of motion.PartS

hark

.com

877-

999-

5686


21.3Installing the oil spray tube

200433-01

– Mount new O-rings on oil spray tube .

– Mount the oil spray tube.

Pin must engage in recess .

21.4Installing the transmission shaft

200431-10

– Clamp the right section of the engine case.

Engine work stand (61229001000) ( p. 443)

Engine holder (61229002000) ( p. 443)

– Assemble the two transmission shafts and slide them into the bearing seatstogether.

200430-11

– Mount stop disk and lock ring of the countershaft.

200429-11

– Tilt the engine.

– Mount shift forks with shift rollers .

InfoUse a small amount of grease to fix the shift rollers to the shift forks.

PartS

hark

.com

877-

999-

5686


200428-11

– Swing shift forks to one side.

InfoWatch out for the shift rollers .

– Insert shift drum into the bearing seat.

– Let the shift forks engage in the shift grooves.

200427-11

– Mount shift rails with the pressure springs.

InfoUse a small amount of grease to fix the pressure springs in the shift rails.

– Check the transmission for smooth operation.

21.5Installing the middle suction pump

200426-11

– Mount external rotor with the marking facing downward.

The marking is not visible after mounting.

– Mount pin into the third hole of oil pump shaft after shaft keyway .

– Slide internal rotor over the pin.

200425-11

– Mount oil pump shaft with internal rotor .

Marking of the internal rotor is visible after mounting while that of the exter-nal rotor is not.

– Oil the parts.

21.6Installing the crankshaft

301423-10

– Slide the crankshaft into the bearing seat.

InfoPosition the connecting rod as shown in the photo.

PartS

hark

.com

877-

999-

5686


21.7Installing the left engine case

301422-11

– Mount dowels .

– Mount gasket .

– Check that dowel is correctly seated.

400481-01

– Degrease the sealing area and coat thinly with sealant.

Loctite® 5910

InfoOnly coat the sealing area around the outside (see figure).

200421-11

– Attach the left engine case, using a plastic hammer if necessary to seat it properly.

InfoDo not tighten the engine case sections using the screws.


Guideline

Screw, engine case M8 18 Nm (13.3 lbf ft)


Guideline

Screw, engine case M6x60 10 Nm (7.4 lbf ft)


Guideline



Guideline


PartS

hark

.com

877-

999-

5686


InfoScrews must always be replaced with new screws.

– Mount screw .

21.8Installing the locking lever

200420-11

– Position locking lever with sleeve and spring .


Guideline

Screw, locking lever M6 10 Nm(7.4 lbf ft)

Loctite® 243™

21.9Installing the shift drum locating

301417-10

– Press locking lever down and position shift drum locating .

InfoThe flat surfaces of the shift drum locating are not symmetric.

– Release the locking lever.

301414-11


Guideline

Screw, shift drum locating M6 10 Nm(7.4 lbf ft)

Loctite® 243™

21.10Installing the shift shaft

301413-11

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

– Push sliding plate away from the shift drum locating .

– Insert the shift shaft all the way.

– Let the sliding plate engage in the shift drum locating.

– Shift through the transmission.

PartS

hark

.com

877-

999-

5686


21.11Installing the force pump

301416-10

– Mount pin .

InfoEnsure that pins are seated correctly.

– Mount internal rotor and external rotor .


– Oil the parts.

301411-11

– Position the oil pump cover. Mount and tighten screws .

Guideline

Screw, oil pump cover M6 10 Nm(7.4 lbf ft)

Loctite® 243™

– Mount washer and pin .

301410-11

– Mount oil pump gear wheel , washer and lock washer .

PartS

hark

.com

877-

999-

5686


21.12Installing the left suction pump

301405-10

– Mount pin .

– Mount internal rotor and external rotor .


– Oil the parts.

301406-10

– Insert new gasket into the oil pump cover.

– Position oil pump cover . Mount and tighten screws .

Guideline

Screw, oil pump cover M6 10 Nm(7.4 lbf ft)

Loctite® 243™

– Turn the oil pump gear wheel and check the oil pumps for smooth operation.

21.13Setting the engine to ignition top dead center of the rear cylinder

301382-10

– Set the crankshaft to top dead center of the rear cylinder.

The position notch of the crankshaft is visible in the hole.



PartS

hark

.com

877-

999-

5686


21.14Installing the primary gear

200412-11

– Ensure that the spring washer is seated properly.

– Mount primary gear .

– Mount the washer and nut and tighten the nut.

Guideline

Nut, primary gear M33LHx1.5 130 Nm(95.9 lbf ft)

Loctite® 243™

21.15Installing the outer clutch hub

301404-11

– Mount washer and needle bearing .

301403-11

– Mount outer clutch hub and washer .

InfoTurn the outer clutch hub and oil pump gear wheel back and forth slightlyto help them mesh more easily.

200411-10

– Position inner clutch hub in outer clutch hub .

– Place the outer component of the clutch pressure booster into the inner clutchhub.

Projections engage in recesses .

– Mount inner component of the clutch pressure booster.

Markings and are adjacent to each other.

PartS

hark

.com

877-

999-

5686


200408-11

– Insert special tool .

Clutch holder (61229003000) ( p. 443)

– Mount the washer and nut and tighten the nut.

Guideline

Nut, inner clutch hub M22x1.5 130 Nm(95.9 lbf ft)

Loctite® 243™

21.16Installing the clutch facing

200407-10

– Mount support ring and pretension ring .

The pretension ring rests on the inside of the support ring, with the outsidefacing away from the support ring.

3

3

4

4

6

6

5

5

200408-01

– Oil the clutch facing discs well.

– Mount clutch facing disc with the larger inside diameter.

– Alternately mount nine intermediate discs and eight identical clutch facingdiscs .

200406-11

– Mount the outermost clutch facing disc with the wider elements offset by onecontact .

200405-11

– Mount push rod .

– Attach pressure cap , mount all screws with spring washers and springs, andtighten them in a crisscross pattern.

Guideline

Screw, clutch spring M6 12 Nm(8.9 lbf ft)

Loctite® 243™

PartS

hark

.com

877-

999-

5686


21.17Installing the idler and timing chain on the right

200404-10

– Position timing chain according to the direction of travel.

– Place the timing chain over the toothing of idler . Align markings and .

– Slide on the idler.

21.18Installing the clutch cover

200401-11

– Mount dowels and the clutch cover seal.

– Mount check valve .

200402-10

– Slide special tool onto the water pump shaft.

Mounting sleeve (61229005000) ( p. 444)

200399-11

– Mount the clutch cover. Mount and tighten screws and .

Guideline

Screw, clutch cover M6 10 Nm (7.4 lbf ft)


PartS

hark

.com

877-

999-

5686


21.19Installing the water pump wheel

200398-11

– Mount the washer and water pump wheel.


Guideline

Screw, water pump wheel M6 10 Nm(7.4 lbf ft)

Loctite® 243™

– Mount dowels .

– Replace the seal.

301394-11

– Mount the water pump cover.


Guideline

Screw, water pump cover M6 10 Nm (7.4 lbf ft)

21.20Installing the gear position sensor

301399-11

– Mount the contact springs and contact bolt .

The contact bolts are mounted with the flat side forward; the rounded sidesface the sensor.

301398-11

– Mount gear position sensor with the O-ring. Mount and tighten the screws.

Guideline

Screw, gear sensor M5 3 Nm(2.2 lbf ft)

Loctite® 243™

21.21Installing the drive wheel of the balancer shaft

200400-10

– Heat the drive wheel of the balancer shaft.

Guideline

200 °C (392 °F)

– Ensure that the spring washer is seated properly. Mount the drive wheel of the bal-ancer shaft with the beveled edge facing forward.

Pressure bell (61229016000) ( p. 445)

The markings are visible after mounting.

PartS

hark

.com

877-

999-

5686


21.22Installing the balancer shaft

200357-10

– Mount the rear washer and needle bearing.

– Mount balancer shaft .

Markings and are aligned.

– Mount washer .

21.23Installing the idler and timing chain on the left

301445-10

– Mount the rear washer.

– Position timing chain in the engine case in accordance with the direction oftravel.

200355-10

– Place timing chain over the toothing of the idler.

Markings and are aligned.

– Slide on idler .

– Mount the needle bearing.

– Mount washer .

PartS

hark

.com

877-

999-

5686


21.24Installing the oil filter

301395-10

– Tilt the engine sideways and fill the oil filter housing to about ⅓ full with engineoil.

– Insert oil filter .

– Lubricate the O-ring of oil filter cover . Mount the oil filter cover.


Guideline


21.25Installing the rotor

200351-10

– Turn the free-wheel-gear counterclockwise and mount it in rotor .

200352-10

– Ensure that spring washer is seated properly.

– Mount the rotor.

200348-11

– Thoroughly clean the oil jet of the rotor screw and blow it out with compressed air.

– Mount and tighten rotor screw .

Guideline

Rotor screw M12x1.5 90 Nm(66.4 lbf ft)

– Position freewheel holder . Mount and tighten the screws.

Guideline

Screw, freewheel holder M6 10 Nm(7.4 lbf ft)

Loctite® 243™

PartS

hark

.com

877-

999-

5686


21.26Installing the torque limiter and idler

200347-11

– Mount the rear washer, needle bearing, idler and front washer.

– Mount torque limiter with the rear washer.

21.27Installing the ignition pulse generator

200346-10

– Position the ignition pulse generator .

– Mount and tighten the screws.

Guideline

Screw, pulse generator M5 10 Nm(7.4 lbf ft)

Loctite® 243™

– Position the cable, thinly coat cable support sleeve with the sealing compoundand insert it in the engine case.

Loctite® 5910

– Check the distance between the ignition pulse generator and rotor.

Guideline

Crankshaft position sensor/rotor - gap 0.70 mm (0.0276 in)

21.28Installing the generator cover

301392-10

– Mount the new generator cover seal and dowels.

– Position the generator cover.


Guideline


21.29Installing the oil drain plug

200480-10

– Mount the new O-rings.

– Mount and tighten oil drain plug with the magnet, O-rings and oil screen.

Guideline

Oil drain plug M20x1.5 20 Nm(14.8 lbf ft)

PartS

hark

.com

877-

999-

5686


21.30Installing the rear piston

200329-10

– Shift the joint of the piston rings by 120°.

– Place the oiled piston on the cylinder. Tighten the piston rings using the specialtool.

Piston ring mounting tool (60029015000) ( p. 441)

200330-10

– Using a hammer, lightly strike the special tool from above until it is flush with thecylinder.

The special tool must squeeze the piston rings together well and lie flushagainst the cylinder.

200331-10

– Carefully tap the piston into the cylinder using the hammer shaft.

The piston rings should not become caught; otherwise, they may be damaged.

200339-10

– Position the new cylinder base gasket .

301365-10

– Ensure that piston marking faces the outfeed side.

301367-10

– Cover the engine case opening with a cloth. Thread the timing chain through thechain shaft. Mount the piston pin.

PartS

hark

.com

877-

999-

5686


200084-10

– Position the new piston pin retainer.

InfoFor clarity, the following steps are illustrated using a disassembled piston.

– Insert the special tool and firmly press it toward the piston.

– Turn the special tool counterclockwise, thereby pressing the piston pin retainer intothe groove.

Piston pin lock ring insert (75029035000) ( p. 447)

– Ensure that the piston pin retainer is correctly seated on both sides.

301354-10

– Remove the cloth.

– Keep the timing chain tensioned. Push the cylinder down carefully and let thedowel pins engage.

21.31Installing the rear cylinder head

301369-10

– Mount the new cylinder head gasket.

– Position the cylinder head and mount and tighten the new cylinder head screws .

Guideline

Cylinder head screw M11x1.5 Tighteningsequence:Using a criss-cross patternStep 115 Nm(11.1 lbf ft)Step 230 Nm(22.1 lbf ft)Step 390°Step 490°

lubricated withengine oil

– Mount and tighten nuts with the washers.

Guideline

Nut, cylinder head M6 10 Nm (7.4 lbf ft)

PartS

hark

.com

877-

999-

5686


21.32Installing the rear camshaft

301370-10

– Pull up the timing chain and insert intake camshaft .

InfoThe intake camshaft is labeled with eh.

– Place the timing chain over the rear sprocket of the intake camshaft.

Marking is aligned.

– Ensure that bleeder is seated correctly.

– Position exhaust camshaft .

InfoThe exhaust camshaft is labeled with ah.

– Place the timing chain over the rear sprocket and position the camshaft in thebearing seat.

Marking is aligned.

301371-10

– Thoroughly clean all oil jets and blow them out with compressed air.

– Position the camshaft bearing bridge.

– Mount screws and tighten them from the outside to the inside.

Guideline

Screw, camshaft bearing support M6 10 Nm (7.4 lbf ft)

Screw, camshaft bearing support M8 Step 110 Nm (7.4 lbf ft)Step 218 Nm(13.3 lbf ft)

– Grease the O-rings and mount spark plug shaft insert .

21.33Installing the rear timing chain tensioner

301372-10

– After it has been positioned in the installation location, insert timing chain ten-sioner with a new O-ring.

– Mount and tighten plug with the new seal ring .

Guideline

Plug, timing-chain tensioner M24x1.5 25 Nm(18.4 lbf ft)

301373-10

– Remove screw and use the special tool to push the timing chain tensionertoward the timing chain.

Release device for timing chain tensioner (61229021000) ( p. 445)

The timing chain tensioner unlocks.


Guideline

Screw, timing chain tensioner release M10x1 10 Nm (7.4 lbf ft)

PartS

hark

.com

877-

999-

5686


21.34Setting the engine to ignition top dead center of the front cylinder

301382-10

– Remove special tool .

– Keep the timing chain tensioned.

– Turn the crankshaft counterclockwise by the specified value.

Guideline

1 turn

200333-10

– Turn the crankshaft counterclockwise by the specified value .

Guideline

75°

The position notch of the crankshaft is visible in the hole.



21.35Installing the front piston

200329-10

– Shift the joint of the piston rings by 120°.

– Place the oiled piston on the cylinder. Tighten the piston rings using the specialtool.

Piston ring mounting tool (60029015000) ( p. 441)

200330-10

– Using a hammer, lightly strike the special tool from above until it is flush with thecylinder.

The special tool must squeeze the piston rings together well and lie flushagainst the cylinder.

200331-10

– Carefully knock the piston into the cylinder using the hammer shaft.

The piston rings should not become caught; otherwise, they may be damaged.

PartS

hark

.com

877-

999-

5686


301383-10

– Position the new cylinder base gasket .

301365-10

– Ensure that piston marking faces the outfeed side.

301374-10

– Cover the engine case opening with a cloth. Thread the timing chain through thechain shaft. Mount the piston pin.

200084-10

– Position the new piston pin retainer.

InfoFor clarity, the following steps are illustrated using a disassembled piston.

– Insert the special tool and firmly press it toward the piston.

– Turn the special tool counterclockwise, thereby pressing the piston pin retainer intothe groove.

Piston pin lock ring insert (75029035000) ( p. 447)

– Ensure that the piston pin retainer is correctly seated on both sides.

PartS

hark

.com

877-

999-

5686


301375-10

– Remove the cloth.

– Keep the timing chain tensioned. Push the cylinder down carefully and let thedowel pins engage.

21.36Installing the front cylinder head

301376-10

– Mount the new cylinder head gasket.

– Mount the cylinder head. Mount and tighten the new cylinder head screws .

Guideline

Cylinder head screw M11x1.5 Tighteningsequence:Using a criss-cross patternStep 115 Nm(11.1 lbf ft)Step 230 Nm(22.1 lbf ft)Step 390°Step 490°

lubricated withengine oil

– Mount and tighten nuts with the washers.

Guideline

Nut, cylinder head M6 10 Nm (7.4 lbf ft)

21.37Installing the front camshafts

301377-10


InfoThe intake camshaft is labeled with ev.


Marking is aligned.


InfoThe exhaust camshaft is labeled with av.


Marking is aligned.

PartS

hark

.com

877-

999-

5686


301378-10

– Thoroughly clean all oil jets and blow them out with compressed air.



Guideline

Screw, camshaft bearing support M6 10 Nm (7.4 lbf ft)

Screw, camshaft bearing support M8 Step 110 Nm (7.4 lbf ft)Step 218 Nm(13.3 lbf ft)

– Grease the O-rings and mount spark plug shaft insert .

21.38Installing the front timing chain tensioner

301379-10


– Mount and tighten plug with the new seal ring .

Guideline


301380-10



The timing chain tensioner is unlocked.


Guideline


21.39Installing the heat exchanger

301366-11

– Oil and mount O-rings .

– Mount sleeves .

– Mount gasket .

301350-11

– Position the heat exchanger.


Guideline



Guideline

Screw, heat exchanger M8 15 Nm(11.1 lbf ft)

PartS

hark

.com

877-

999-

5686


21.40Installing the oil filler tube

301349-10

– Mount the oil filler tube with the O-ring.


Guideline


21.41Installing the starter motor

301384-10

– Grease O-ring . Mount the starter motor.


301348-11

– Mount and tighten screw with the ground wire.

Guideline

Screw, starter motor M6 10 Nm (7.4 lbf ft)

21.42Checking the rear cylinder control time

301389-10

– Check the markings of the camshaft.

InfoThe markings are shown with the camshafts removed for purposes of illus-tration.

Align center marking of the camshaft with marking of the camshaft gear.

» If the markings do not align:

– Adjust the rear cylinder control time. ( p. 184)

21.43Adjusting the rear cylinder control time

301343-10



PartS

hark

.com

877-

999-

5686


301342-10

– Turn the engine one crankshaft turn in a counterclockwise direction.

Marking faces outward and is flush with the edge of the cylinder head.

– Remove screws .

– Mount the new screws but do not tighten them yet.

301344-10


Marking is aligned and flush with the edge of the cylinder head.

– Mount special tool .


– Remove screws .


301464-10


Adjustment gauge, control time, cylinder 1 (69129130000) ( p. 447)


Guideline

Screw, special tool M6 3 Nm (2.2 lbf ft)


Guideline

Camshaft drive sprocket bolt M6 13 Nm (9.6 lbf ft)

– Remove screws .





301342-10




Guideline


21.44Checking the rear valve clearance

301382-10


– Crank the engine several times.

– Set the engine to ignition top dead center of the rear cylinder. ( p. 123)

PartS

hark

.com

877-

999-

5686


301385-10

– On all valves, check the valve clearance between the camshaft and cam lever.

Guideline

Valve clearance

Exhaust at: 20 °C (68 °F) 0.25… 0.30 mm (0.0098…0.0118 in)

Intake at: 20 °C (68 °F) 0.10… 0.15 mm (0.0039…0.0059 in)

Feeler gauge (59029041100) ( p. 441)

» If valve clearance does not meet specifications:

– Adjust the rear valve clearance. ( p. 186)

21.45Adjusting the rear valve clearance– Remove the rear timing chain tensioner. ( p. 124)

– Remove the rear camshaft. ( p. 125)

301386-10

– Swing up cam lever .

– Remove shims and set them down according to the installation position.

– Correct the shims as indicated by the results of the valve clearance check.

– Insert suitable shims.

– Install the rear camshaft. ( p. 179)

– Install the rear timing chain tensioner. ( p. 179)

– Check the rear valve clearance. ( p. 185)

21.46Checking the front cylinder control time

301343-10



– Set the engine to ignition top dead center of the front cylinder. ( p. 126)

301389-10


InfoThe markings are shown with the camshafts removed for purposes of illus-tration.




21.47Adjusting the front cylinder control time

301343-10



PartS

hark

.com

877-

999-

5686


301342-10



– Remove screws .


301344-10





– Remove screws .


301463-10




Guideline



Guideline


– Remove screws .



301342-10




Guideline


21.48Checking the front valve clearanceConditionThe engine is positioned at ignition top dead center of the front cylinder

301388-10


Guideline

Valve clearance


Intake at: 20 °C (68 °F) 0.10… 0.15 mm (0.0039…0.0059 in)

Feeler gauge (59029041100) ( p. 441)


– Adjust the front valve clearance. ( p. 188)

PartS

hark

.com

877-

999-

5686


21.49Adjusting the front valve clearance– Remove the front timing chain tensioner. ( p. 126)

– Remove the front camshafts. ( p. 126)

301387-10

– Swing up cam lever .


– Correct the shims as indicated by the results of the valve clearance check.

– Insert suitable shims.

– Install the front camshafts. ( p. 182)

– Install the front timing chain tensioner. ( p. 183)

– Check the front valve clearance. ( p. 187)

301338-11

– Mount and tighten the screw of generator cover .

Guideline

Screw in generator cover M24x1.5 8 Nm (5.9 lbf ft)

301340-11

– Remove special tool . Mount and tighten screw .

Guideline

Plug, crankshaft retainer M8 15 Nm(11.1 lbf ft)

21.50Installing the front valve cover

301336-11

– Position the valve cover seal.

– Put the valve cover in place with the seal. Mount and tighten screws .

Guideline

Screw, valve cover M6 10 Nm (7.4 lbf ft)

InfoThe front valve cover is not equipped with a connector for the engine vent.

– Mount and tighten the spark plug using a special tool.


– Mount ignition coil .

21.51Installing the rear valve cover

301337-11


– Put the valve cover in place with the seal. Mount and tighten screws .

Guideline


InfoThe rear valve cover is equipped with a connector for the engine vent.



PartS

hark

.com

877-

999-

5686


– Mount ignition coil .

21.52Mounting the engine bracket

301345-10

– Position the engine bracket.

– Mount and tighten screws and .

Guideline

Screw, engine console M8 20 Nm(14.8 lbf ft)

Loctite® 243™

301346-10

– Position the engine bracket.

– Mount and tighten screws and .

Guideline

Screw, engine console M8 20 Nm(14.8 lbf ft)

Loctite® 243™

21.53Dismounting the engine from the work stand

301334-10

– Remove the screw connections.

– Dismount the engine from the work stand.

InfoHave an assistant help you or use a crane.

PartS

hark

.com

877-

999-

5686

31/SECONDARY AIR SYSTEM 190

22.1Exhaust air injection

900012-60

Installation location– The exhaust air injection valve is located under the air filter box.

Exhaust air injection valve, connector FE ( p. 403) pin assignment

Function description– The exhaust air injection valve injects purified fresh air into the exhaust port to

improve exhaust emissions as long as closed loop control is not yet active.

PartS

hark

.com

877-

999-

5686

32/CLUTCH 191

23.1Checking fluid level of hydraulic clutch

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

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

100752-01

– Check the fluid level.

The fluid level must be between the MIN and MAX markings.

» If the coolant level does not meet specifications:

– Correct the fluid level of the hydraulic clutch. ( p. 191)

23.2Correcting fluid level of hydraulic clutch

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

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

100753-01

– Remove screw cover with membrane.

– Correct the fuel level.

Guideline

The fluid level must be between the MIN and MAX markings.

Hydraulic fluid (15) ( p. 437)


PartS

hark

.com

877-

999-

5686

34/SHIFT MECHANISM 192

24.1Adjusting shift lever stub

100703-10

– Remove the screw with the shift lever stub.

– Position the shift lever stub with the screw in one of the holes according to thedesired lever length.

Guideline

Standard Central hole

– Tighten screw.

Guideline

Screw, shift lever stub M6 10 Nm(7.4 lbf ft)

Loctite® 243™

24.2Adjusting shift lever

InfoThe footrest system offers many ways of adjusting the shift lever to your riding style and requirements.

100704-10

– Remove screws and take off the shift rod.

– The length of the shift rod can be adjusted by means of the screw thread.

Guideline

Shift rod 115… 130 mm (4.53… 5.12 in)

– Loosen the counter nuts .

– Adjust the shift shaft.

InfoMake the same adjustments on both sides.After the counter nuts have been tightened, the bearings of the shift shaftmust be central and aligned identically to each other in order to ensure free-dom of movement in the bearing shells.At least 5 screw threads must be screwed into the seating.

– Tighten the counter nuts.PartS

hark

.com

877-

999-

5686

34/SHIFT MECHANISM 193

00AA

00BB

00CC

400479-10

– The shift rod can be mounted both on the shift lever variably at an upper or lowerposition, and on the reverse gear change of the shift shaft in two different posi-tions.

Guideline

Standard Shift lever: lower drill hole,shift shaft: lower drill hole

Shift power low, long shift travel Shift lever: lower drill hole,shift shaft: upper drill hole

Shift power high, short shift travel Shift lever: upper drill hole,shift shaft: lower drill hole

– Position the shift rod.

– Tighten the screws.

Guideline

Screw, shift rod M6 12 Nm(8.9 lbf ft)

Loctite® 243™

100705-10

– The position of the shift lever can be greatly varied, depending on the length of theshift rod and the drill holes selected. As seen from the footrest, there is either ahigh position of the shift lever or a low position of the shift lever .

InfoIf you turn the reverse shift shaft 2 teeth on the serration of the shift shaft,you can adjust the footrest system optimally for the upper footrest position.

– After adjusting the shift lever, check its operation. There must be a minimum dis-tance between the moving parts of the shift lever and other parts of the vehicle.

Guideline

Minimum clearance 5 mm (0.2 in)

PartS

hark

.com

877-

999-

5686

35/WATER PUMP, COOLING SYSTEM 194

25.1Checking the coolant level

WarningScalding hazard During motorcycle operation, the coolant gets very hot and is under pressure.

– Do not open the radiator, radiator hoses and other components of the cooling system while the engine is warm. Let theengine and cooling system cool down first. If you get scalded, immediately flush the affected areas with lukewarm water.

100750-01

ConditionThe engine is cold.The radiator is completely full.

– Rest the motorcycle on its side stand on a horizontal surface.

– Check the coolant level in the compensating tank.

The coolant level must be between MIN and MAX.

» If there is no coolant in the compensating tank:


InfoDo not operate the motorcycle!

– Add coolant/bleed the cooling system. ( p. 196)

» If the coolant level in the compensating tank does not meet specifications,but the tank is not empty:


– Fill the cooling system compensating tank. ( p. 197)

25.2Checking the antifreeze



WarningDanger of poisoning Coolants are poisonous and a health hazard.

– Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water andcontact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctorimmediately. Change clothes that have come into contact with coolants. Keep coolants out of the reach of children.

ConditionThe engine is cold.

– Rest the motorcycle on its side stand on a horizontal surface.

– Remove the right side covers.

200535-11

– Remove plug from the compensating tank and radiator cap .

– Check the coolant antifreeze.

−25… −45 °C (−13… −49 °F)

» If the coolant antifreeze does not meet specifications:

– Correct the coolant antifreeze.

– Add coolant to the specified level.

Guideline

The radiator must be completely filled.


– Replace the compensating tank cap and the radiator cap.

– Install the right side covers.

PartS

hark

.com

877-

999-

5686


25.3Removing the radiator– Remove the exhaust cover completely. ( p. 63)

– Remove the inside cover. ( p. 75)

200505-10

– Remove the drain plug of water pump and of radiator . Completely drain thecoolant.

– Mount and tighten the drain plug of water pump and radiator .

Guideline


200504-10

– Loosen the hose clamps. Detach radiator hoses .

– Push back the cover. Unplug the connector of thermoswitch .

– Unplug connector of the radiator fan.

– Unplug the connector of ignition pulse generator .

– Unplug the connector of horn .

200506-10

– Loosen hose clamps . Remove the radiator hose.

– Remove screw .

200507-10

– Remove screw . Take off the radiator.

25.4Installing the radiator

200507-11

– Position the radiator. Mount and tighten screw .

Guideline


PartS

hark

.com

877-

999-

5686


200506-11


Guideline


– Mount the radiator hose. Position and tighten hose clamps .

200504-11

– Mount radiator hoses . Position and tighten the hose clamps.

– Plug in the connector of thermoswitch . Mount the cover.

– Plug in connector of the radiator fan.

– Plug in the connector of ignition pulse generator .

– Plug in the connector of horn .

– Add coolant/bleed the cooling system. ( p. 196)

– Install the inside cover. ( p. 76)

– Install the exhaust cover completely. ( p. 63)

25.5Adding coolant/bleeding the cooling system



ConditionThe side cover has been removed.

400494-10

– Position the vehicle as shown and secure it against rolling. Height difference must be reached.

Guideline

Height difference 50 cm (19.7 in)

200534-10

– Remove radiator cap and bleeder screw of the radiator.

200536-10

– Remove bleeder screw of the cylinder heads.

– Add coolant until it exits from the vent hole without bubbles.

Coolant 2.60 l (2.75 qt.) Coolant ( p. 436)

Coolant (mixed ready to use)( p. 436)

– Mount and tighten the bleeder screws with the seal rings.

Guideline



PartS

hark

.com

877-

999-

5686


200535-10

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

– Position the vehicle on a level surface.

– Remove the cap of the compensating tank.

– Add coolant to the compensating tank until the coolant reaches the specified level.

Guideline


– Mount the cap of the compensating tank.

25.6Filling the cooling system compensating tank





NoteEngine damage Impaired cooling efficiency due to air trapped in the cooling system.

– After draining coolant and refilling the cooling system, the motorcycle must be raised at the front according to the model type.This is the only way of ensuring that the cooling system is filled without air bubbles.

100750-10


– Remove the cap of the compensating tank.

– Top up with coolant until the specified coolant level is reached.

Guideline


Alternative 1

Coolant ( p. 436)

Alternative 2

Coolant (mixed ready to use) ( p. 436)

– Mount the cap of the compensating tank.PartS

hark

.com

877-

999-

5686

36/CYLINDER HEAD 198

26.1Engine coolant temperature sensor cylinder 1

900017-01

Installation location– The engine coolant temperature sensor for cylinder 1 is located on the left-hand

side of the rear cylinder head.

400539-60

Component description– The engine coolant temperature sensor is a negative temperature coefficient ther-

mistor (NTC resistor). Resistance falls when the temperature increases in an NTCresistor; the "nil" value, however, is never reached. When the temperature decreasesthe resistance increases; however, the "infinite" value is never reached.

600853-10

Pin overview

1 Signal wire

2 Sensor ground

Function description– The signal from engine coolant temperature sensor for cylinder 1 is transmitted to

the EFI control unit.

Engine coolant temperature sensor

Resistance at: −30 °C(−22 °F)

22.86… 27.94 kΩ


13.50… 16.50 kΩ

Resistance at: −10 °C(14 °F)

8.24… 10.08 kΩ


5.17… 6.31 kΩ


3.33… 4.07 kΩ


2.21… 2.70 kΩ


1.49… 1.83 kΩ


1.04… 1.27 kΩ


730… 892 Ω


526… 642 Ω


385… 471 Ω


286… 350 Ω


216… 264 Ω


165… 202 Ω


128… 156 Ω

PartS

hark

.com

877-

999-

5686



100… 122 Ω

26.2Engine coolant temperature sensor for cylinder 2

900018-01

Installation location– The engine coolant temperature sensor for cylinder 2 is located on the right-hand

side of the front cylinder head.

400539-60

Component description– The coolant temperature sensor is an NTC thermistor. In NTC thermistors the

resistance decreases with increasing temperature; however, the "nil" value is neverreached. When the temperature decreases the resistance increases; however, the"infinite" value is never reached.

600853-10

Pin overview

1 Signal wire

2 Sensor ground

Function description– The signal from engine coolant temperature sensor for cylinder 2 is transmitted to

the combination instrument.



22.86… 27.94 kΩ


13.50… 16.50 kΩ

Resistance at: −10 °C(14 °F)

8.24… 10.08 kΩ


5.17… 6.31 kΩ


3.33… 4.07 kΩ


2.21… 2.70 kΩ


1.49… 1.83 kΩ


1.04… 1.27 kΩ


730… 892 Ω


526… 642 Ω


385… 471 Ω


286… 350 Ω


216… 264 Ω


165… 202 Ω

PartS

hark

.com

877-

999-

5686



128… 156 Ω


100… 122 Ω

26.3Checking the valve clearance– Remove the filter box bottom. ( p. 67)

– Remove the side covers. ( p. 75)

200538-10

– Detach connector of the ignition coil.

– Remove the ignition coil.

– Remove screws and take off the valve cover.



– Repeat these steps on the second cylinder.

– Set the engine to ignition top dead center of the rear cylinder. ( p. 120)

301434-10


Guideline

Valve clearance


Intake at: 20 °C (68 °F) 0.10… 0.15 mm (0.0039…0.0059 in)

Feeler gauge (59029041100) ( p. 441)


– Adjust the rear valve clearance. ( p. 201)

– Set the engine to ignition top dead center of the front cylinder. ( p. 121)

301435-10


Guideline

Valve clearance


Intake at: 20 °C (68 °F) 0.10… 0.15 mm (0.0039…0.0059 in)

Feeler gauge (59029041100) ( p. 441)


– Adjust the front valve clearance. ( p. 202)

PartS

hark

.com

877-

999-

5686


200540-10


– Crank the engine several times. Check the valve clearance and correct it if neces-sary.

– Remove special tool and screw in and tighten screw .

Guideline

Plug, crankshaft retainer M8 15 Nm(11.1 lbf ft)

200539-10

– Mount and tighten the screw of generator cover .

Guideline

Screw in generator cover M24x1.5 8 Nm (5.9 lbf ft)

200538-10




InfoThe rear valve cover is equipped with a connector for the engine vent.The front valve cover is not equipped with a connector for the engine vent.

– Position the valve cover with the seal. Mount and tighten screws .

Guideline


– Mount the ignition coil.

– Attach connector of the ignition coil.

– Repeat these steps on the second cylinder.

– Install the filter box bottom. ( p. 68)


26.4Adjusting the rear valve clearance– Remove the rear camshaft. ( p. 205)

200546-10

– Raise cam lever on the outside.


– Correct and insert the shims as indicated by the results of the valve clearancecheck.

– Install the rear camshaft. ( p. 205)

PartS

hark

.com

877-

999-

5686


26.5Adjusting the front valve clearance– Remove the front camshafts. ( p. 206)

200552-10

– Raise cam lever on the outside.


– Correct and insert the shims as indicated by the results of the valve clearancecheck.

– Install the front camshafts. ( p. 206)

26.6Checking the rear cylinder control timeConditionThe valve cover has been removed.

301389-10


InfoThe markings are shown with the camshafts removed for purposes of illus-tration.Removal is not necessary.




26.7Checking the front cylinder control timeConditionThe valve cover has been removed.

301343-10



– Set the engine to the ignition top dead center of the front cylinder and screw inspecial tool .

301389-10


InfoThe markings are shown with the camshafts removed for purposes of illus-tration.Removal is not necessary.




PartS

hark

.com

877-

999-

5686


26.8Adjusting the rear cylinder control time– Set the engine to ignition top dead center of the rear cylinder. ( p. 120)

301343-10



InfoFor purposes of illustration, the following operations are shown with theengine deinstalled.Removal is not necessary.

301342-10



– Remove screws .


301344-10





– Remove screws .


301464-10




Guideline



Guideline


– Remove screws .





301342-10




Guideline


PartS

hark

.com

877-

999-

5686


26.9Adjusting the front cylinder control time– Set the engine to ignition top dead center of the front cylinder. ( p. 121)

301343-10



InfoFor purposes of illustration, the following operations are shown with theengine deinstalled.Removal is not necessary.

301342-10



– Remove screws .


301344-10





– Remove screws .


301463-10




Guideline



Guideline


– Remove screws .





301342-10




Guideline


PartS

hark

.com

877-

999-

5686


26.10Removing the rear camshaftConditionThe engine is positioned at ignition top dead center of the rear cylinder

200549-10

– Remove screw with the O-ring.


301436-10






26.11Installing the rear camshaft

301438-10


InfoThe intake camshaft is labeled with eh.


– Ensure that bleeder is seated correctly.


InfoThe exhaust camshaft is labeled with ah.


Markings must be flush with the edge of the cylinder head.



Guideline

Screw, camshaft bearingsupport


–


M8 Step 110 Nm(7.4 lbf ft)Step 218 Nm(13.3 lbf ft)

–


M8 Step 18.5 Nm(6.27 lbf ft)Step 214.5 Nm(10.7 lbf ft)

Only applies whenusing:Hex key bit(61229025000)( p. 446)

Hex key bit (61229025000) ( p. 446)

– Grease the O-rings and mount the spark plug shaft insert.

– Install the rear timing chain tensioner. ( p. 207)

PartS

hark

.com

877-

999-

5686


26.12Removing the front camshaftsConditionThe engine is positioned at ignition top dead center of the front cylinder

200550-10

– Remove screw with the O-ring.


301439-10






26.13Installing the front camshafts

301440-10


InfoThe intake camshaft is labeled with ev.



InfoThe exhaust camshaft is labeled with av.


Markings must be flush with the edge of the cylinder head.



Guideline



–


M8 Step 110 Nm(7.4 lbf ft)Step 218 Nm(13.3 lbf ft)

–


M8 Step 18.5 Nm(6.27 lbf ft)Step 214.5 Nm(10.7 lbf ft)

Only applies whenusing:Hex key bit(61229025000)( p. 446)

Hex key bit (61229025000) ( p. 446)

– Grease the O-rings and mount the spark plug shaft insert.

– Install the front timing chain tensioner. ( p. 207)

PartS

hark

.com

877-

999-

5686


26.14Installing the rear timing chain tensioner– Prepare the timing chain tensioner for installation. ( p. 154)

200549-11


– Mount and tighten plug with a new seal ring.

Guideline


200554-10



The timing chain tensioner unlocks.


Guideline


26.15Installing the front timing chain tensioner– Prepare the timing chain tensioner for installation. ( p. 154)

200550-11


– Mount and tighten plug with a new seal ring.

Guideline


200555-10



The timing chain tensioner is unlocked.


Guideline

Screw, timing chain tensioner release M10x1 10 Nm (7.4 lbf ft)PartS

hark

.com

877-

999-

5686

38/LUBRICATION SYSTEM 208

27.1Oil circuit

400492-60

Oil circuit of middle suction pump

1 Oil screen of oil drain plug in gearbox

2 Middle suction pump

3 Heat exchanger

4 Oil exit in oil tank

Oil circuit of left suction pump

5 Crankcase

6 Left suction pump

7 Lubricating slots in gearbox

Oil circuit of force pump

8 Oil screen of oil drain plug in oil tank

9 Force pump

10 Oil pressure regulator valve

11 Oil filter

12 Crankshaft

13 Oil jet for generator cooling

14 Timing chain tensioner

15 Camshaft lubrication/oil jets for valve gear lubrication

16 Oil jets for piston cooling

17 Oil spray tube

18 Oil jet for clutch lubrication

19 Clutch

PartS

hark

.com

877-

999-

5686


27.2Checking the engine oil level

InfoThe engine oil level must be checked at normal engine operating temperature.

– Stand the motorcycle upright on a horizontal surface.

100769-10

– Remove oil dipstick . Check the engine oil level in the measurement range.

InfoAfter switching off the engine, wait one minute before checking the level.

The engine oil level must be in the middle of the measurement range of theoil dipstick.

» If the engine oil level is not at the specified level:

– Add engine oil. ( p. 213)

– Replace the oil dipstick.

27.3Changing the engine oil and filter, cleaning the oil screens

500281-01

– Drain the engine oil and clean the oil screens. ( p. 209)

– Fill up with engine oil. ( p. 212)

27.4Draining engine oil, cleaning oil screens

WarningDanger of scalding Engine oil and gear oil get very hot when the motocycle is driven.

– Wear suitable protective clothing and protective gloves. If you get scalded, immediately flush the affected areas with luke-warm water.



InfoDrain the engine oil only when the engine is warm.Par

tSha

rk.c

om

877-

999-

5686


100771-10

– Remove screws .

– Take off the left exhaust cover .

100772-10

– Stand the motorcycle on its side stand on a horizontal surface.

– Place a suitable container under the engine.

– Remove oil drain plug with the magnet, O-rings and oil screen.

– Remove the oil filter. ( p. 211)


100773-10

– Thoroughly clean the magnet and oil screen of the oil drain plug.

100772-11

– Mount and tighten the oil drain plugs with the magnet, O-rings and oil screen.

Guideline

Oil drain plug M20x1.5 20 Nm(14.8 lbf ft)

– Install the oil filter. ( p. 212)

PartS

hark

.com

877-

999-

5686


100771-10

– Position the left exhaust cover .


Guideline


27.5Removing the oil filter






100774-10

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

100775-10

– Pull oil filter out of the oil filter housing.



– Clean the parts and the sealing area thoroughly.

PartS

hark

.com

877-

999-

5686


27.6Installing the oil filter

100776-10

– Insert oil filter .

– Lubricate the O-ring of the oil filter cover. Mount oil filter cover .


Guideline


27.7Filling up with engine oil

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

100777-10

– The oil must be topped up in two steps.

Engine oil 3.60 l (3.8 qt.) External tem-perature: ≥ 0 °C(≥ 32 °F)

Engine oil(SAE 10W/50)( p. 436)

External tem-perature: < 0 °C(< 32 °F)


– Remove the dipstick and top up the engine oil.

Engine oil (1stquantity)

3.00 l (3.17 qt.) External tem-perature: ≥ 0 °C(≥ 32 °F)




– Replace the oil dipstick .



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

– Remove the dipstick and pour in the remaining engine oil.

Engine oil (2ndquantity)

0.60 l (0.63 qt.) External tem-perature: ≥ 0 °C(≥ 32 °F)




– Replace the oil dipstick .





PartS

hark

.com

877-

999-

5686


27.8Adding engine oil

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


100777-10

– Remove the dipstick and add engine oil.

ConditionExternal temperature: ≥ 0 °C (≥ 32 °F)

Engine oil (SAE 10W/50) ( p. 436)

ConditionExternal temperature: < 0 °C (< 32 °F)

Engine oil (SAE 5W/40) ( p. 436)

InfoFor optimal performance of the engine oil, do not mix different types ofengine oil.If appropriate, change the engine oil.

– Replace oil dipstick .





27.9Checking the engine oil pressure





– Jack up the motorcycle at the rear. ( p. 13)Par

tSha

rk.c

om

877-

999-

5686


100771-10

– Remove screws .

– Take off the left exhaust cover .

200557-10


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

– Remove oil filter .


200558-10

– Position the special tool with the O-ring. Mount and tighten the screws.

Guideline


Oil pressure testing adapter (75029094000) ( p. 448)

– Connect the pressure testing tool to the special tool without the t-plate.





– Start the engine and let it warm up.

– Check the engine oil pressure.

Engine oil pressure

PartS

hark

.com

877-

999-

5686


Coolant temperature: ≥ 70 °C(≥ 158 °F)Engine speed: 1,500 rpm

1.3… 2.3 bar (19… 33 psi)

Coolant temperature: ≥ 70 °C(≥ 158 °F)Engine speed: 5,000 rpm

3.0… 4.0 bar (44… 58 psi)


– Check the oil pumps for wear. Check that all oil holes are free of blockages.

– Switch off the engine.

WarningDanger of burns Some vehicle components get very hot when the machineis driven.

– Wear appropriate protective clothing and safety gloves. In case of burns,rinse immediately with lukewarm water.

– Remove the special tools.

– Insert the new oil filter.

– Lubricate the O-ring of the oil filter cover. Mount the oil filter cover.


Guideline


100771-10

– Position the left exhaust cover .


Guideline




27.10Removing the oil jet for the clutch lubrication

301426-10

– Remove screws .

– Take off the engine sprocket cover.

PartS

hark

.com

877-

999-

5686


301427-10

– Remove plug .

301429-11

– Remove oil jet .

27.11Checking / cleaning the oil jet for clutch lubrication– Remove the oil jet for the clutch lubrication. ( p. 215)

301428-10

– Check the oil jet for clutch lubrication is not blocked.

» If the oil jet is blocked:

– Clean the oil jet and change as necessary.

– Install the oil jet for the clutch lubrication. ( p. 216)

27.12Installing the oil jet for the clutch lubrication

301429-10

– Mount and tighten oil jet .

Guideline

Oil jet for clutch lubrication M6x0.75 4 Nm (3 lbf ft)

301427-10

– Mount and tighten plugs .

Guideline

Plug, clutch lubrication M10x1 15 Nm(11.1 lbf ft)

PartS

hark

.com

877-

999-

5686


301426-11

– Position the engine sprocket cover.


Guideline


PartS

hark

.com

877-

999-

5686

39/IGNITION SYSTEM 218

28.1Crankshaft position sensor

900001-01

Installation location– The crankshaft position sensor is located below the generator cover on the left-hand

side of the engine.

Component description– The crankshaft position sensor consists of a permanent magnet and an induction

coil with a soft iron core. The counter part to the crankshaft position sensor is atrigger wheel whose 22 teeth are evenly spaced, but one of the teeth has a widergap. The trigger wheel is installed on the generator rotor which is attached to thecrankshaft. There is a small air gap between the crankshaft position sensor and thetoothed wheel.

Crankshaft position sensor, connector AT ( p. 395) pin assignment

900010-01

Description of function– Magnetic flow through the induction coil depends on whether a gap or a tooth is

opposite the crankshaft position sensor. A tooth focuses the magnetic leakage fluxof the permanent magnet while a gap weakens the magnetic flux. When the rotor(and trigger wheel) starts to turn, the teeth pass the sensor, thus altering the mag-netic field strength. The alteration of the magnetic field created in the inductioncoil generates an alternating voltage. The number of pulses per second is equiv-alent to the rotor speed. The larger gap between the teeth on the trigger wheel isintended so that the EFI control unit can identify the position of the crankshaft.The gap cannot be altered.

Crankshaft position sen-sor/rotor - gap

0.70 mm (0.0276 in)

Crankshaft position sensor


80… 120 Ω

28.2Ignition coil

900022-61

Installation location– The ignition coil for cylinder 1 is located on the rear cylinder head.

The ignition coil for cylinder 2 is located on the front cylinder head.

600851-10

Pin overview

1 Control wire

2 System voltage

Ignition coil

Primary winding resis-tance at: 20 °C (68 °F)

1.105… 1.495 Ω

Secondary windingresistance at: 20 °C(68 °F)

16.2… 10.8 kΩ

PartS

hark

.com

877-

999-

5686

41/THROTTLE VALVE BODY 219

29.1Throttle position sensor circuit A

900019-60

Installation location– Throttle position sensor circuit A, is located on the throttle valve body for cylinder

2, on the right-hand side of the engine.

900020-10

Component description– The throttle position sensor has a linear characteristic line and works like a variable

resistor.

– As shown in the diagram, the output voltage correlates to a throttle position.

Throttle position sensor circuit A, connector AM ( p. 391) pin assignment

Function description– The output voltage of the throttle position sensor is dependent on the opening

angle of the throttle valve and is sent via the signal wire to determine the throttlevalve position.

Throttle position sensor cir-cuit A voltage "(THAD)"

0.56… 4.20 V

Throttle position sensor cir-cuit A, signal "ATP"

0… 100 %

29.2Throttle position sensor circuit A - checking in the "zero" positionConditionThe ignition is on.The diagnostic tool is connected and running.

400687-60










– Read the information page on the KTM diagnostics tool and using "Continue" startthe calibration process.

InfoThe motor drive moves the throttle valve in circuit A to the "zero" position(throttle valve fully closed position).

Throttle position sensor circuit A voltage "(THAD)"

In "zero" position 0.56… 0.64 V

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

– Adjust the position of the throttle position sensor in circuit A. ( p. 220)

PartS

hark

.com

877-

999-

5686


29.3Adjusting the position of the throttle position sensor in circuit AConditionThe ignition is on.The diagnostic tool is connected and running.

– Remove the throttle valve body to adjust. ( p. 221)

400680-10










– Read the information page on the KTM diagnostics tool and using "Continue" start the calibration process.

InfoThe motor drive moves the throttle valve in circuit A to the "zero" position (throttle valve fully closed position).




– Loosen screw .

– Turn the throttle position sensor to adjust it to the specified value.

Guideline



– Tighten screw .

– Open and close the throttle grip fully ten times.

– Check the voltage again and readjust if necessary.

– Reinstall the throttle valve body when the adjustments have been made. ( p. 222)

PartS

hark

.com

877-

999-

5686


29.4Removing the throttle valve body to adjust– Remove the air filter. ( p. 67)

200498-10

– Unplug the connector of the manifold absolute pressure sensor .

– Take the manifold absolute pressure sensor out of the holder but do not detach thevacuum hoses.


– Take plug-in connector out of the holding bracket.

200499-10

– Remove screws . Take off the retaining plates and holding brackets.

– Remove screw . Remove the cover.

200500-10

– Loosen hose clamps .

200501-10

– Loosen the spring-loaded band-type clamp using the special tool. Pull off thefuel hose.


– Pull up the throttle valve body and remove connector with the seal.

– Pull the throttle cables out of the filter box bottom with guide piece .

– Remove the throttle valve body.

PartS

hark

.com

877-

999-

5686


29.5Reinstalling the throttle valve body when the adjustments have been made

200501-11

– Mount connector with the seal.

– Connect the fuel hose. Mount the spring-loaded band-type clamp using the spe-cial tool.


InfoThe fuel hose must have a minimum distance of 4 mm to the throttle link-age in all operating positions.

– Position the throttle cables with guide piece .

– Slide the throttle valve body into the rubber sleeves.

200500-11

– Position and tighten upper hose clamps .

Guideline


200499-11

– Mount the cover. Mount and tighten screw .

– Position the retaining plates and holding brackets. Mount and tighten screws .

200498-11

– Fix plug-in connector with the holding bracket.

– Connect plug-in connector .

– Mount manifold absolute pressure sensor and plug in the connector.


PartS

hark

.com

877-

999-

5686


29.6Throttle position sensor circuit B

900025-60

Installation location– Throttle position sensor circuit B is located on the throttle valve body for cylinder 1

on the right-hand side of the engine.

900047-10

Component description– The throttle position sensor has a linear characteristic line and works like a variable

resistor.

– As shown in the diagram, the voltage can be correlated to a throttle position.

Throttle position sensor circuit B, connector AR ( p. 394) pin assignment

Description of function– The EFI control unit utilizes the signal from the throttle position sensor in circuit B

to set the opening angle of the second throttle valve. The second throttle valveenables smoother power delivery from the engine and it is used as part of the elec-tronic power control (EPC).

Position 2. Throttlevalve "2ndTHAngle"

0… 100 %

Throttle position sensor cir-cuit B, voltage "TAPAD"

0.156… 4.824 V

29.7Manifold absolute pressure sensor

900003-61

Installation location– The manifold absolute pressure sensor cylinder 1 is located on the right-hand

rear side of the air filter box and is connected to the induction manifold by a hose.The manifold absolute pressure sensor cylinder 2 is located on the front right-hand rear side of the air filter box and is connected to the induction manifold by ahose.

Component description– The processing electronics and a measuring cell are located in the housing of the

manifold absolute pressure sensor. In the measuring cell a diaphragm encloses areference pressure chamber. When the shape of the diaphragm is altered by exte-rior pressure, the conductivity of the measuring resistors is altered and thus themeasured voltage. The measured voltage is prepared by the processing electronicsand sent on to the EFI control unit.

400659-10

Pin overview

1 System voltage

2 Sensor ground

3 Signal wire

600725-10

Function description– The output voltage of the manifold absolute pressure sensor depends on the man-

ifold pressure and is sent via the signal wire. The voltage signal drops when pres-sure decreases. This means that when the throttle valve is closed with resulting lowmanifold pressure (due to the suction effect of the engine), a low voltage signal isemitted from the manifold absolute pressure sensor. When the throttle valve is fullyopen, the manifold pressure is roughly equal to the ambient air pressure and thevoltage signal is high.

Manifold absolute pressure sensor cylinder 1, voltage "PM1AD"

at: 350 mbar (5.08 psi) 1.62… 1.68 V

PartS

hark

.com

877-

999-

5686


at: 400 mbar (5.8 psi) 1.77… 1.83 V

at: 450 mbar (6.53 psi) 1.92… 1.98 V

at: 800 mbar (11.6 psi) 2.97… 3.03 V

at: 850 mbar(12.33 psi)

3.12… 3.18 V

at: 900 mbar(13.05 psi)

3.27… 3.33 V

at: 950 mbar(13.78 psi)

3.42… 3.48 V

at: 1,000 mbar(14.5 psi)

3.57… 3.63 V

at: 1,050 mbar(15.23 psi)

3.72… 3.78 V


at: 350 mbar (5.08 psi) 1.62… 1.68 V

at: 400 mbar (5.8 psi) 1.77… 1.83 V

at: 450 mbar (6.53 psi) 1.92… 1.98 V

at: 800 mbar (11.6 psi) 2.97… 3.03 V

at: 850 mbar(12.33 psi)

3.12… 3.18 V

at: 900 mbar(13.05 psi)

3.27… 3.33 V

at: 950 mbar(13.78 psi)

3.42… 3.48 V

at: 1,000 mbar(14.5 psi)

3.57… 3.63 V

at: 1,050 mbar(15.23 psi)

3.72… 3.78 V

29.8Connecting the vacuum hand pump to the manifold absolute pressure sensor– Remove the filter box bottom. ( p. 67)

600856-10

Connecting to the manifold absolute pressure sensor cylinder 1:– Pull off vacuum hose .

– Connect the vacuum hand pump to the vacuum hose of the manifold absolutepressure sensor cylinder 1.

600856-11

Connecting to the manifold absolute pressure sensor cylinder 2:– Pull off vacuum hose .

– Connect the vacuum hand pump to the vacuum hose of the manifold absolutepressure sensor cylinder 2.

PartS

hark

.com

877-

999-

5686


29.9Ambient air pressure sensor

900006-60

Installation location– The ambient air pressure sensor is located on the right-hand side of the frame.

Component description– The processing electronics and a measuring cell are located in the housing of the

ambient air pressure sensor. In the measuring cell a diaphragm encloses a refer-ence pressure chamber. When the shape of the diaphragm is altered by externalpressure, the conductivity of the measuring resistors is altered and thus the mea-sured voltage. The measured voltage is prepared by the processing electronics andsent on to the EFI control unit.

400659-10

Pin overview

1 System voltage

2 Sensor ground

3 Signal wire

600725-10

Function description– The output voltage of the ambient air pressure sensor depends on the ambient air

pressure and is sent via the signal wire. The voltage signal rises when ambient airpressure increases.

Ambient air pressure sensor voltage "PAAD"

at: 800 mbar (11.6 psi) 2.97… 3.03 V

at: 850 mbar(12.33 psi)

3.12… 3.18 V

at: 900 mbar(13.05 psi)

3.27… 3.33 V

at: 950 mbar(13.78 psi)

3.42… 3.48 V

at: 1,000 mbar(14.5 psi)

3.57… 3.63 V

at: 1,050 mbar(15.23 psi)

3.72… 3.78 V

29.10Injector

900027-61

Installation location– Injector cylinder 1 is located on the rear throttle valve body.

Injector cylinder 2 is located on the front throttle valve body.

Component description– The injector consists of a solenoid, a spring loaded plunger, a needle valve and a

filter. When current flows through the coil in the solenoid, a magnetic field is gen-erated which attracts the plunger, overcoming the spring force; this lifts the nee-dle valve off its seat. Fuel is discharged through eight holes and forms two conicaljets. When the current is switched off, the magnetic field collapses and the springcloses the needle valve. The filter keeps any contamination out of the holes.

400598-10

Pin overview

1 Control wire

2 System voltage

PartS

hark

.com

877-

999-

5686


Function description– The injector is supplied with battery voltage by the power relay. The EFI control

unit calculates the amount of fuel required and grounds the injector via the amplifi-cation stage in the EFI control unit. The longer the injector is connected to ground,the greater the amount of fuel injected.

Injector


10.5… 13.0 Ω

29.11Rollover sensor

900002-60

Installation location– The rollover sensor is located on the base of the air filter box.

900004-10

Rollover sensor construction

1 Pendulum with a magnet

2 Circuit board with a Hall sensor

3 Housing

4 Spacer

5 Retainer for the connector seal

6 Connector seal

A Normal position, left-hand corner

B Normal position, right-hand corner

Component description– The sensor makes use of the Hall effect. A pendulum with a magnet attached is

fitted in the rollover sensor. The pendulum passes a Hall element. The evaluationelectronics of the rollover sensor calculates the Hall voltage and activates the signalvoltage.

400660-10

Pin overview

4 Sensor ground

5 Signal wire

6 System voltage

Description of function– The rollover sensor is connected in series to a sensing resistor (on feed side and

ground side) located in the EFI control unit. The evaluation electronics of therollover sensor switches the signal voltage, depending on the inclination of thevehicle, via a resistor to voltage or to ground. Using the voltage value from thesignal wire, the EFI control unit can determine the inclination of the vehicle.

Rollover sensor

Voltage (Rollover AD)"no fall detected"

0.4… 1.4 V

Voltage (Rollover AD)"fall detected"

3.7… 4.1 V

PartS

hark

.com

877-

999-

5686


29.12EFI control unit

900038-60

Installation location– The EFI control unit is located behind the right-hand side cover.

InfoWhen an EFI control unit from the spare parts warehouse is initiallyprogrammed, it is given an identity. This means that when writing to the EFIcontrol unit, e.g., using the flash container KM690EU0802001 (1190 RC8series), the EFI control unit is defined as a 690 version, and can from then ononly be used on 690 models (specifically installed control unit).After programming is complete, the VIN must be entered into the EFI controlunit using the "Coding" function!

– Connector CO ( p. 397) pin assignment

– Connector AO ( p. 392) pin assignment

29.13Requesting the EFI control unit activation codeConditionAn exchanged EFI control unit is connected.The ignition is on.The diagnostic tool is connected and running.The "ECU Flashing" process is complete.

400687-60








– Select "Change VIN - New identity".


– Read the information page on the KTM diagnostics tool and using "Continue" startthe coding process.

– Overwrite the entry under the "Please enter VIN:" heading.


– Select "Code form".

– Press "Print".

The protocol is being printed out.

– Fill out the protocol and send to "[email protected]".

29.14Coding the EFI control unitConditionThe ignition is on.The diagnostic tool is connected and running.

– Request the EFI control unit activation code. ( p. 227)

400687-60








– Select "Change VIN - New identity".


– Read the information page on the KTM diagnostics tool and using "Continue" startthe coding process.

PartS

hark

.com

877-

999-

5686


– Overwrite the entry under the "Please enter VIN:" heading.


– Select "Code entry".

– "Please enter the Code"


The new VIN is written to the EFI control unit.

– Switch to the main menu.

– Select "Show identification".

– Compare the old VIN to the new VIN.

The new VIN is shown.

29.15Flashing the EFI control unitConditionThe ignition is on.The diagnostic tool is connected and running.

400687-60





– Select "ECU Flashing".



– Read the safety information and set up the required conditions.

– Confirm the instruction by clicking on "OK".

– Press "Select file" and select the new mapping.

Info"The BLZ file and the exhaust system must match!"

– Press the "ECU flash process" button.

– Read the safety notice and confirm with "OK".

The new mapping is loaded.

PartS

hark

.com

877-

999-

5686

IMMOBILIZER BLINK CODE 229

Blink code of immobilizer indi-cator lamp

12 Immobilizer indicator lamp flashes 1x short, 1 second pause, 2x short

Possible cause Ignition keys (all) have not been activated ( p. 229)

Ignition keys (all) have not been activated– Activate/deactivate the ignition key. ( p. 102)

PartS

hark

.com

877-

999-

5686




Possible cause ICU antenna - value not plausible ( p. 230)

ICU antenna - coil antenna has an open ( p. 230)

Last measure if none of the doc-umented causes leads to elimi-nation of the fault

– Change the immobilizer control unit.

ICU antenna - value not plausibleConditionThe imobilizer control unit antenna coil is disconnected. ( p. 102)

400685-10

ICU antenna - checking the resistance– Measure the resistance between the specified points.

ICU antenna connector EL pin 1 – ICU antenna connector EL pin 2

ICU antenna 13.917… 15.383 Ω

» If the specifications have not been met:

– Change the ICU antenna.

» If the specifications have been met:

– Check the next possible cause:ICU antenna - coil antenna has an open ( p. 230)

ICU antenna - coil antenna has an openConditionThe immobilizer control unit is disconnected. ( p. 102)The imobilizer control unit antenna coil is connected. ( p. 102)

400657-10

ICU antenna - checking the coil antenna for opens– Measure the resistance between the specified points.

Immobilizer control unit, connector DO pin 1 – Immobilizer control unit,connector DO pin 2

ICU antenna 13.917… 15.383 Ω


– Check connector DO pin 1 and pin 2.

– Check connector DV ( p. 401) pin 1 and pin 2.

– Check the cable from connector DO pin 1 to connector DV ( p. 401) pin 1 foropens.

– Check the cable from connector DO pin 2 to connector DV ( p. 401) pin 2 foropens.

– Disconnect connector DV ( p. 401) of the ICU antenna. Check the cablesfrom connector DO pin 1 and pin 2 to connector DV pin 1 and pin 2 for mutualshort circuits.



PartS

hark

.com

877-

999-

5686




Possible cause Malfunction in transponder of black ignition key ( p. 231)

Malfunction in transponder of black ignition key– Use spare black ignition key.

– Order a new black ignition key according to the key number on the KEYCODECARD.

– Activate/deactivate the ignition key. ( p. 102)

PartS

hark

.com

877-

999-

5686




Possible cause Ignition key has not been activated ( p. 232)

Ignition key has not been activated– Activate/deactivate the ignition key. ( p. 102)

PartS

hark

.com

877-

999-

5686




Possible cause Malfunction, encryption, immobilizer control unit to black ignition key ( p. 233)


– Activate/deactivate the ignition key. ( p. 102)

Malfunction, encryption, immobilizer control unit to black ignition key– Use the black ignition key belonging to the vehicle.

Last measure if none of the documented causes leads to elimination of the fault– Activate/deactivate the ignition key. ( p. 102)

PartS

hark

.com

877-

999-

5686




Possible cause Immobilizer control unit not activated ( p. 234)

Immobilizer control unit not activated– Activate the ICU. ( p. 104)

PartS

hark

.com

877-

999-

5686




Possible cause Malfunction, encryption query from EFI control unit to immobilizer control unit ( p. 235)

Malfunction, encryption query from EFI control unit to immobilizer control unit– Flash the EFI control unit. ( p. 228)

PartS

hark

.com

877-

999-

5686




Possible cause Malfunction in CAN bus communication ( p. 236)

Malfunction in CAN bus communication– Read out the trouble code memory using the KTM diagnostics tool.

PartS

hark

.com

877-

999-

5686



60 Immobilizer indicator lamp flashes 6x short

Possible cause E²PROM malfunction ( p. 237)

E²PROM malfunction– Change the immobilizer control unit.

PartS

hark

.com

877-

999-

5686

ENGINE CONTROL TROUBLE CODE 238

Blink code EFI warninglamp (MIL)

45 EFI warning lamp (MIL) flashes 4x long, 5x short

Display on diagnostic tool P0031"Lambda sensor heater cylinder 1, sensor 1""Short circuit to ground or open circuit"

Error level condition Circuit fault: ≥ 3 s

Function check Checking the lambda sensor heater cylinder 1 ( p. 238)

Possible cause Lambda sensor heater cylinder 1 - value not plausible ( p. 238)

Lambda sensor heater cylinder 1 - the power supply is faulty ( p. 239)

Lambda sensor heater cylinder 1 - the control wire has an open ( p. 239)

Lambda sensor heater cylinder 1 - the control wire has a short circuit to sensor ground ( p. 240)

Lambda sensor heater cylinder 1 - the control wire has a short circuit to ground (terminal 31)( p. 240)


– Contact customer service.

Checking the lambda sensor heater cylinder 1ConditionThe ignition is on.The diagnostics tool is connected and active.





– Select "Actuator Test".



– Select "Lambda sensor heater cylinder 1".


– In the KTM diagnostics tool, read the information page and start the actuator test with "Continue".

Lambda sensor

Lambda sensor cylinder 1 voltage "HEGO1AD" at test start 5 V

Lambda sensor

Lambda sensor cylinder 1 voltage "HEGO1AD" at test end ≤ 0.5 V

» If the displayed value corresponds to the nominal value:


– Take a test ride.



– Check the next possible cause:Lambda sensor heater cylinder 1 - value not plausible ( p. 238)

Lambda sensor heater cylinder 1 - value not plausibleConditionThe ignition is off.Lambda sensor for cylinder 1 is disconnected. ( p. 62)

PartS

hark

.com

877-

999-

5686


400647-10

Lambda sensor heater cylinder 1 - check the resistance– Measure the resistance between the specified points.

Lambda sensor cylinder 1, connector CE pin 1 – Lambda sensor cylinder 1,connector CE pin 2


Resistance at: 20 °C (68 °F) 11.7… 14.3 Ω


– Replace the lambda sensor cylinder 1.


– Check the next possible cause:Lambda sensor heater cylinder 1 - the power supply is faulty ( p. 239)

Lambda sensor heater cylinder 1 - the power supply is faultyConditionThe ignition is on.EFI control unit is connected. ( p. 227)Lambda sensor for cylinder 1 is disconnected. ( p. 62)

400646-10 400658-10

Lambda sensor heater cylinder 1 - check the power supply– Measure the voltage between the specified points.

Lambda sensor cylinder 1, connector CA pin 1 – Measuring point Ground (−)

InfoWhen taking measurements, the measurement locations must be loaded with a 12V/21W bulb.

The value may not differ from the battery voltage "VBAT" by more than 1 V.


– Check connector CA pin 1.

– Check the cable from connector CA pin 1 to the next node in the wiring harness for opens.


– Check the next possible cause:Lambda sensor heater cylinder 1 - the control wire has an open ( p. 239)

Lambda sensor heater cylinder 1 - the control wire has an openConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Lambda sensor for cylinder 1 is disconnected. ( p. 62)

PartS

hark

.com

877-

999-

5686


600850-12 400646-10

Lambda sensor heater cylinder 1 - check the control wire for opens– Measure the resistance between the specified points.

Break out box CO pin 33 – Lambda sensor cylinder 1, connector CA pin 2

Resistance ≤ 0.6 Ω


– Check EFI control unit connector CO ( p. 397) pin 33 and connector CA pin 2.

– Check the cable from EFI control unit connector CO ( p. 397) pin 33 to connector CA pin 2 for opens.


– Check the next possible cause:Lambda sensor heater cylinder 1 - the control wire has a short circuit to sensor ground ( p. 240)

Lambda sensor heater cylinder 1 - the control wire has a short circuit to sensor groundConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Lambda sensor for cylinder 1 is disconnected. ( p. 62)

600850-11 600850-12

Lambda sensor heater cylinder 1 - checking the control wire for a short circuit to sensor ground– Measure the resistance between the specified points.

Break Out Box AO pin 7 – Break out box CO pin 33

Resistance ∞ Ω


– Check the cable from EFI control unit connector CO ( p. 397) pin 33 to connector CA ( p. 396) pin 2 for a short circuit tosensor ground.


– Check the next possible cause:Lambda sensor heater cylinder 1 - the control wire has a short circuit to ground (terminal 31) ( p. 240)

Lambda sensor heater cylinder 1 - the control wire has a short circuit to ground (terminal 31)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Lambda sensor for cylinder 1 is disconnected. ( p. 62)

PartS

hark

.com

877-

999-

5686


600850-12 400658-10

Lambda sensor heater cylinder 1 - checking the control wire for a short circuit to ground (terminal 31)– Measure the resistance between the specified points.

Break out box CO pin 33 – Measuring point Ground (−)

Resistance ∞ Ω


– Check the cable from EFI control unit connector CO ( p. 397) pin 33 to connector CA ( p. 396) pin 2 for a short circuit toground (terminal 31).



PartS

hark

.com

877-

999-

5686




Display on diagnostic tool P0032"Lambda sensor heater cylinder 1, sensor 1""Input signal too high"




Lambda sensor heater cylinder 1 - the signal wire has a short circuit to plus (terminal 30)( p. 243)

Lambda sensor heater cylinder 1 - the signal wire has a short circuit to ignition plus (terminal 15)( p. 243)














Lambda sensor

Lambda sensor cylinder 1 voltage "HEGO1AD" at test start 5 V

Lambda sensor

Lambda sensor cylinder 1 voltage "HEGO1AD" at test end ≤ 0.5 V








400647-10

Lambda sensor heater cylinder 1 - check the resistance– Measure the resistance between the specified points.




PartS

hark

.com

877-

999-

5686





– Check the next possible cause:Lambda sensor heater cylinder 1 - the signal wire has a short circuit to plus(terminal 30) ( p. 243)

Lambda sensor heater cylinder 1 - the signal wire has a short circuit to plus (terminal 30)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Lambda sensor for cylinder 1 is disconnected. ( p. 62)

600850-12 400658-10

Lambda sensor heater cylinder 1 - checking the signal wire for a short circuit to plus (terminal 30)– Measure the voltage between the specified points.


Voltage < 0.1 V


– Check the cable from EFI control unit connector CO ( p. 397) pin 33 to connector CA ( p. 396) pin 2 for a short circuit toplus (terminal 30).


– Check the next possible cause:Lambda sensor heater cylinder 1 - the signal wire has a short circuit to ignition plus (terminal 15) ( p. 243)

Lambda sensor heater cylinder 1 - the signal wire has a short circuit to ignition plus (terminal 15)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Lambda sensor for cylinder 1 is disconnected. ( p. 62)

600850-12 600850-11

Lambda sensor heater cylinder 1 - check the signal wire for a short circuit to ignition plus (terminal 15).– Measure the resistance between the specified points.

Break out box CO pin 33 – Break Out Box AO pin 20

Resistance ∞ Ω


– Check the cable from EFI control unit connector CO ( p. 397) pin 33 to connector CA ( p. 396) pin 2 for a short circuit toignition plus (terminal 15).

PartS

hark

.com

877-

999-

5686




PartS

hark

.com

877-

999-

5686




Display on diagnostic tool P0051"Lambda sensor heater cylinder 2, sensor 1""Short circuit to ground or open circuit"




Lambda sensor heater cylinder 2 - the power supply is faulty ( p. 246)

Lambda sensor heater cylinder 2 - the control wire has an open ( p. 246)

Lambda sensor heater cylinder 2 - the control wire has a short circuit to sensor ground ( p. 247)

Lambda sensor heater cylinder 2 - the control wire has a short circuit to ground (terminal 31)( p. 247)














Lambda sensor

Lambda sensor cylinder 2 voltage "HEGO2AD" at the teststart

5 V

Lambda sensor

Lambda sensor cylinder 2 voltage "HEGO2AD" at the testend

≤ 0.5 V








PartS

hark

.com

877-

999-

5686


400647-10

Lambda sensor heater cylinder 2 - check the resistance.– Measure the resistance between the specified points.





– Change the lambda sensor cylinder 2.


– Check the next possible cause:Lambda sensor heater cylinder 2 - the power supply is faulty ( p. 246)

Lambda sensor heater cylinder 2 - the power supply is faultyConditionThe ignition is on.The diagnostics tool is connected and active.Lambda sensor for cylinder 2 is disconnected. ( p. 62)

400646-10 400658-10

Lambda sensor heater cylinder 2 - checking the power supply– Measure the voltage between the specified points.

Lambda sensor cylinder 2, connector CA pin 1 – Measuring point Ground (−)

InfoFor measurement the measuring points must be subjected to a 12V/21W bulb load.



– Check connector CA pin 1.

– Check the cable from connector CA pin 1 to the next node in the wiring harness for opens.


– Check the next possible cause:Lambda sensor heater cylinder 2 - the control wire has an open ( p. 246)

Lambda sensor heater cylinder 2 - the control wire has an openConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Lambda sensor for cylinder 2 is disconnected. ( p. 62)

PartS

hark

.com

877-

999-

5686


600850-12 400646-10

Lambda sensor heater cylinder 2 - checking the control wire for opens– Measure the resistance between the specified points.

Break out box CO pin 15 – Lambda sensor cylinder 2, connector CA pin 2



– Check EFI control unit connector CO ( p. 397) pin 15 and connector CA pin 2.

– Check the cable from EFI control unit connector CO ( p. 397) pin 15 to connector CA pin 2 for opens.


– Check the next possible cause:Lambda sensor heater cylinder 2 - the control wire has a short circuit to sensor ground ( p. 247)

Lambda sensor heater cylinder 2 - the control wire has a short circuit to sensor groundConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Lambda sensor for cylinder 2 is disconnected. ( p. 62)

600850-11 600850-12

Lambda sensor heater cylinder 2 - checking the control wire for a short circuit to sensor ground– Measure the resistance between the specified points.

Break Out Box AO pin 7 – Break out box CO pin 15

Resistance ∞ Ω


– Check the cable from EFI control unit connector CO ( p. 397) pin 15 to connector CA ( p. 396) pin 2 for a short circuit tosensor ground.


– Check the next possible cause:Lambda sensor heater cylinder 2 - the control wire has a short circuit to ground (terminal 31) ( p. 247)

Lambda sensor heater cylinder 2 - the control wire has a short circuit to ground (terminal 31)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Lambda sensor for cylinder 2 is disconnected. ( p. 62)

PartS

hark

.com

877-

999-

5686


600850-12 400658-10

Lambda sensor heater cylinder 2 - checking the control wire for a short circuit to ground (terminal 31)– Measure the resistance between the specified points.


Resistance ∞ Ω


– Check the cable from EFI control unit connector CO ( p. 397) pin 15 to connector CA ( p. 396) pin 2 for a short circuit toground (terminal 31).



PartS

hark

.com

877-

999-

5686




Display on diagnostic tool P0052"Lambda sensor heater cylinder 2, sensor 1""Input signal too high"




Lambda sensor heater cylinder 2 - the signal wire has a short circuit to plus (terminal 30)( p. 250)

Lambda sensor heater cylinder 2 - the signal wire has a short circuit to ignition plus (terminal 15)( p. 250)














Lambda sensor

Lambda sensor cylinder 2 voltage "HEGO2AD" at the teststart

5 V

Lambda sensor

Lambda sensor cylinder 2 voltage "HEGO2AD" at the testend

≤ 0.5 V








PartS

hark

.com

877-

999-

5686


400647-10

Lambda sensor heater cylinder 2 - check the resistance.– Measure the resistance between the specified points.







– Check the next possible cause:Lambda sensor heater cylinder 2 - the signal wire has a short circuit to plus(terminal 30) ( p. 250)

Lambda sensor heater cylinder 2 - the signal wire has a short circuit to plus (terminal 30)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Lambda sensor for cylinder 2 is disconnected. ( p. 62)

600850-12 400658-10

Lambda sensor heater cylinder 2 - checking the signal wire for a short circuit to plus (terminal 30)– Measure the voltage between the specified points.


Voltage < 0.1 V


– Check the cable from EFI control unit connector CO ( p. 397) pin 15 to connector CA ( p. 396) pin 2 for a short circuit toplus (terminal 30).


– Check the next possible cause:Lambda sensor heater cylinder 2 - the signal wire has a short circuit to ignition plus (terminal 15) ( p. 250)

Lambda sensor heater cylinder 2 - the signal wire has a short circuit to ignition plus (terminal 15)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Lambda sensor for cylinder 2 is disconnected. ( p. 62)

600850-12 600850-11

Lambda sensor heater cylinder 2 - check the signal wire for a short circuit to ignition plus (terminal 15).– Measure the resistance between the specified points.


PartS

hark

.com

877-

999-

5686


Resistance ∞ Ω


– Check the cable from EFI control unit connector CO ( p. 397) pin 15 to connector CA ( p. 396) pin 2 for a short circuit toignition plus (terminal 15).



PartS

hark

.com

877-

999-

5686



09 EFI warning lamp (MIL) flashes 9x short

Display on diagnostic tool P0107"Manifold absolute pressure sensor cylinder 1""Input signal too low"

Error level condition Manifold absolute pressure sensor cylinder 1, voltage "PM1AD": ≤ 0.508 VTime: ≥ 1 sSubstitute value: 700 mbar (10.15 psi)

Function check Manifold absolute pressure sensor cylinder 1 - checking the voltage ( p. 252)

Possible cause Manifold absolute pressure sensor cylinder 1 - the signal wire has a short circuit to sensor ground( p. 253)

Manifold absolute pressure sensor cylinder 1 - the signal wire has a short circuit to ground (termi-nal 31) ( p. 253)

Manifold absolute pressure sensor cylinder 1 - the power supply is interrupted ( p. 253)


– Replace the manifold absolute pressure sensor cylinder 1.

Manifold absolute pressure sensor cylinder 1 - checking the voltageConditionThe ignition is on.The diagnostic tool is connected and running.The engine is switched off.





– Select "Measured Values".

– Highlight "Fuel management general".


– Highlight "Manifold absolute pressure sensor cylinder 1 voltage" and deselect the other parameters with "Select live data".


at: 350 mbar (5.08 psi) 1.62… 1.68 V

at: 400 mbar (5.8 psi) 1.77… 1.83 V

at: 450 mbar (6.53 psi) 1.92… 1.98 V

at: 800 mbar (11.6 psi) 2.97… 3.03 V

at: 850 mbar (12.33 psi) 3.12… 3.18 V

at: 900 mbar (13.05 psi) 3.27… 3.33 V

at: 950 mbar (13.78 psi) 3.42… 3.48 V

at: 1,000 mbar (14.5 psi) 3.57… 3.63 V

at: 1,050 mbar (15.23 psi) 3.72… 3.78 V





» If the displayed value is below the nominal value:

– Check the next possible cause:Manifold absolute pressure sensor cylinder 1 - the signal wire has a short circuit to sensor ground ( p. 253)

PartS

hark

.com

877-

999-

5686


Manifold absolute pressure sensor cylinder 1 - the signal wire has a short circuit to sensor groundConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)Manifold absolute pressure sensor cylinder 1 is disconnected. ( p. 223)

400590-10

Manifold absolute pressure sensor cylinder 1 - check the signal wire for a short circuit tosensor ground– Measure the resistance between the specified points.

Manifold absolute pressure sensor cylinder 1, connector DP pin 2 – Mani-fold absolute pressure sensor cylinder 1, connector DP pin 3

Resistance ∞ Ω


– Check the cable from connector DP pin 3 to the EFI control unit connector AO( p. 392) pin 3 for a short circuit to sensor ground.


– Check the next possible cause:Manifold absolute pressure sensor cylinder 1 - the signal wire has a short cir-cuit to ground (terminal 31) ( p. 253)

Manifold absolute pressure sensor cylinder 1 - the signal wire has a short circuit to ground (terminal 31)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)Manifold absolute pressure sensor cylinder 1 is disconnected. ( p. 223)

400590-10 400658-10

Manifold absolute pressure sensor cylinder 1 - check the signal wire for a short circuit to ground (terminal 31)– Measure the resistance between the specified points.

Manifold absolute pressure sensor cylinder 1, connector DP pin 3 – Measuring point Ground (−)

Resistance ∞ Ω


– Check the cable from connector DP pin 1 to EFI control unit connector AO ( p. 392) pin 3 for a short circuit to ground (ter-minal 31).


– Check the next possible cause:Manifold absolute pressure sensor cylinder 1 - the power supply is interrupted ( p. 253)

Manifold absolute pressure sensor cylinder 1 - the power supply is interruptedConditionThe ignition is on.EFI control unit is connected. ( p. 227)Manifold absolute pressure sensor cylinder 1 is disconnected. ( p. 223)

PartS

hark

.com

877-

999-

5686


400590-10 400658-10

Manifold absolute pressure sensor cylinder 1 - checking the power supply– Measure the voltage between the specified points.

Manifold absolute pressure sensor cylinder 1, connector DP pin 1 – Measuring point Ground (−)

Voltage 4.9… 5.1 V


– Check connector DP pin 1.

– Check the cable from connector DP pin 1 to the next node in the wiring harness for opens.



PartS

hark

.com

877-

999-

5686




Display on diagnostic tool P0108"Manifold absolute pressure sensor cylinder 1""Input signal too high"

Error level condition Manifold absolute pressure sensor cylinder 1, voltage "PM1AD": ≥ 4.922 VTime: ≥ 1 sSubstitute value: 700 mbar (10.15 psi)


Possible cause Manifold absolute pressure sensor cylinder 1 - the signal wire has an open ( p. 256)

Manifold absolute pressure sensor cylinder 1 - the ground wire has an open ( p. 256)

Manifold absolute pressure sensor cylinder 1 - the signal wire has a short circuit to plus (termi-nal 30) ( p. 257)

Manifold absolute pressure sensor cylinder 1 - the signal wire has a short circuit to ignition plus(terminal 15) ( p. 257)

Manifold absolute pressure sensor cylinder 1 - the signal wire has a short circuit to the sensorpower supply ( p. 257)













at: 350 mbar (5.08 psi) 1.62… 1.68 V

at: 400 mbar (5.8 psi) 1.77… 1.83 V

at: 450 mbar (6.53 psi) 1.92… 1.98 V

at: 800 mbar (11.6 psi) 2.97… 3.03 V

at: 850 mbar (12.33 psi) 3.12… 3.18 V

at: 900 mbar (13.05 psi) 3.27… 3.33 V

at: 950 mbar (13.78 psi) 3.42… 3.48 V

at: 1,000 mbar (14.5 psi) 3.57… 3.63 V

at: 1,050 mbar (15.23 psi) 3.72… 3.78 V





» If the displayed value is above the nominal value:

– Check the next possible cause:Manifold absolute pressure sensor cylinder 1 - the signal wire has an open ( p. 256)

PartS

hark

.com

877-

999-

5686


Manifold absolute pressure sensor cylinder 1 - the signal wire has an openConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Manifold absolute pressure sensor cylinder 1 is disconnected. ( p. 223)

600850-11 400590-10

Manifold absolute pressure sensor cylinder 1 - check the signal wire for opens– Measure the resistance between the specified points.

Break Out Box AO pin 3 – Manifold absolute pressure sensor cylinder 1, connector DP pin 3



– Check EFI control unit connector AO ( p. 392) pin 3 and connector DP pin 3.

– Check the cable from EFI control unit connector AO ( p. 392) pin 3 to connector DP pin 3 for opens.


– Check the next possible cause:Manifold absolute pressure sensor cylinder 1 - the ground wire has an open ( p. 256)

Manifold absolute pressure sensor cylinder 1 - the ground wire has an openConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Manifold absolute pressure sensor cylinder 1 is disconnected. ( p. 223)

600850-11 400590-10

Manifold absolute pressure sensor cylinder 1 - check the ground wire for opens– Measure the resistance between the specified points.

Break Out Box AO pin 7 – Manifold absolute pressure sensor cylinder 1, connector DP pin 2






– Check the next possible cause:Manifold absolute pressure sensor cylinder 1 - the signal wire has a short circuit to plus (terminal 30) ( p. 257)

PartS

hark

.com

877-

999-

5686


Manifold absolute pressure sensor cylinder 1 - the signal wire has a short circuit to plus (terminal 30)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Manifold absolute pressure sensor cylinder 1 is disconnected. ( p. 223)

600850-11 400658-10

Manifold absolute pressure sensor cylinder 1 - check the signal wire for a short circuit to plus (terminal 30)– Measure the voltage between the specified points.

Break Out Box AO pin 3 – Measuring point Ground (−)

Voltage < 0.1 V


– Check the cable from EFI control unit connector AO ( p. 392) pin 3 to connector DP ( p. 400) pin 3 for a short circuit toplus (terminal 30).


– Check the next possible cause:Manifold absolute pressure sensor cylinder 1 - the signal wire has a short circuit to ignition plus (terminal 15) ( p. 257)

Manifold absolute pressure sensor cylinder 1 - the signal wire has a short circuit to ignition plus (terminal 15)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Manifold absolute pressure sensor cylinder 1 is disconnected. ( p. 223)

600850-11

Manifold absolute pressure sensor cylinder 1 - check the signal wire for a short circuit toignition plus (terminal 15)– Measure the resistance between the specified points.

Break Out Box AO pin 3 – Break Out Box AO pin 20

Resistance ∞ Ω


– Check the cable from EFI control unit connector AO ( p. 392) pin 3 to con-nector DP ( p. 400) pin 3 for a short circuit to ignition plus (terminal 15).


– Check the next possible cause:Manifold absolute pressure sensor cylinder 1 - the signal wire has a short cir-cuit to the sensor power supply ( p. 257)

Manifold absolute pressure sensor cylinder 1 - the signal wire has a short circuit to the sensor power supplyConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Manifold absolute pressure sensor cylinder 1 is disconnected. ( p. 223)

PartS

hark

.com

877-

999-

5686


600850-11

Manifold absolute pressure sensor cylinder 1 - check the signal wire for a short circuit to thesensor power supply– Measure the resistance between the specified points.


Resistance ∞ Ω


– Check the cable from EFI control unit connector AO ( p. 392) pin 3 to con-nector DP ( p. 400) pin 3 for a short circuit to the sensor power supply.



PartS

hark

.com

877-

999-

5686




Display on diagnostic tool P0112"Intake air temperature sensor""Input signal too low"

Error level condition Intake air temperature sensor "TAAD": ≤ 0.156 VTime: ≥ 3 sSubstitute value: 25 °C (77 °F)

Function check Intake air temperature sensor - checking the voltage ( p. 259)

Possible cause Intake air temperature sensor - value not plausible ( p. 259)

Intake air temperature sensor - the signal wire has a short circuit to ground (terminal 31)( p. 260)



Intake air temperature sensor - checking the voltageConditionThe ignition is on.The diagnostic tool is connected and running.








– Highlight "Intake air temperature sensor voltage (TAAD)" and deselect the other parameters with "Select live data".

Intake air temperature sensor "TAAD" 0.157… 4.843 V






– Check the next possible cause:Intake air temperature sensor - value not plausible ( p. 259)

Intake air temperature sensor - value not plausibleConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.

600850-11

Intake air temperature sensor - check the resistance– Measure the resistance between the specified points.


Intake air temperature sensor

Resistance at: −20 °C (−4 °F) 18.80 kΩ

Resistance at: 20 °C (68 °F) 2.942 kΩ




– Check the next possible cause:Intake air temperature sensor - the signal wire has a short circuit to sensorground ( p. 260)

PartS

hark

.com

877-

999-

5686


– Replace the intake air temperature sensor.


– Check the next possible cause:Intake air temperature sensor - the signal wire has a short circuit to ground (ter-minal 31) ( p. 260)

Intake air temperature sensor - the signal wire has a short circuit to sensor groundConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.The intake air temperature sensor is disconnected.

600850-11

Intake air temperature sensor - check the signal wire for a short circuit to sensor ground– Measure the resistance between the specified points.


Resistance ∞ Ω


– Check the cable from EFI control unit connector AO ( p. 392) pin 22 to con-nector CM ( p. 397) pin 2 for a short circuit to sensor ground.



Intake air temperature sensor - the signal wire has a short circuit to ground (terminal 31)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.

600850-11 400658-10

Intake air temperature sensor - check the signal wire for a short circuit to ground (terminal 31)– Measure the resistance between the specified points.


Resistance ∞ Ω


– Check the cable from EFI control unit connector AO ( p. 392) pin 22 to connector CM ( p. 397) pin 2 for a short circuit toground (terminal 31).



PartS

hark

.com

877-

999-

5686




Display on diagnostic tool P0113"Intake air temperature sensor""Input signal too high"

Error level condition Intake air temperature sensor "TAAD": ≥ 4.844 VTime: ≥ 3 sSubstitute value: 25 °C (77 °F)

Function check Intake air temperature sensor - checking the voltage ( p. 261)

Possible cause Intake air temperature sensor - the signal wire has a short circuit to plus (terminal 30) ( p. 261)

Intake air temperature sensor - the signal wire has a short circuit to ignition plus (terminal 15)( p. 262)

Intake air temperature sensor - the signal wire has a short circuit to the sensor power supply( p. 262)

Intake air temperature sensor - the signal wire has an open ( p. 263)

Intake air temperature sensor - the ground wire has an open ( p. 263)

Intake air temperature sensor - value not plausible ( p. 264)



Intake air temperature sensor - checking the voltageConditionThe ignition is on.The diagnostic tool is connected and running.








– Highlight "Intake air temperature sensor voltage (TAAD)" and deselect the other parameters with "Select live data".

Intake air temperature sensor "TAAD" 0.157… 4.843 V






– Check the next possible cause:Intake air temperature sensor - the signal wire has a short circuit to plus (terminal 30) ( p. 261)

Intake air temperature sensor - the signal wire has a short circuit to plus (terminal 30)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.

PartS

hark

.com

877-

999-

5686


600850-11 400658-10

Intake air temperature sensor - check the signal wire for a short circuit to plus (terminal 30)– Measure the voltage between the specified points.


Voltage ≤ 0.1 V


– Check the cable from EFI control unit connector AO ( p. 392) pin 22 to connector CM ( p. 397) pin 2 for a short circuit toplus (terminal 30).


– Check the next possible cause:Intake air temperature sensor - the signal wire has a short circuit to ignition plus (terminal 15) ( p. 262)

Intake air temperature sensor - the signal wire has a short circuit to ignition plus (terminal 15)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.

600850-11

Intake air temperature sensor - check the signal wire for a short circuit to ignition plus(terminal 15)– Measure the resistance between the specified points.


Resistance ∞ Ω


– Check the cable from EFI control unit connector AO ( p. 392) pin 22 to con-nector CM ( p. 397) pin 2 for a short circuit to ignition plus (terminal 15).


– Check the next possible cause:Intake air temperature sensor - the signal wire has a short circuit to the sensorpower supply ( p. 262)

Intake air temperature sensor - the signal wire has a short circuit to the sensor power supplyConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.

600850-11

Intake air temperature sensor - check the signal wire for a short circuit to the sensor powersupply– Measure the resistance between the specified points.


Resistance ∞ Ω


– Check the cable from EFI control unit connector AO ( p. 392) pin 22 to con-nector CM ( p. 397) pin 2 for a short circuit to the sensor power supply.


– Check the next possible cause:Intake air temperature sensor - the signal wire has an open ( p. 263)

PartS

hark

.com

877-

999-

5686


Intake air temperature sensor - the signal wire has an openConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.

600850-11 400650-10

Intake air temperature sensor - check the signal wire for opens– Measure the resistance between the specified points.

Break Out Box AO pin 22 – Connector CM pin 2



– Check EFI control unit connector AO ( p. 392) pin 22 and connector CM pin 2.

– Check the cable from EFI control unit connector AO ( p. 392) pin 22 to connector CM pin 2 for opens.


– Check the next possible cause:Intake air temperature sensor - the ground wire has an open ( p. 263)

Intake air temperature sensor - the ground wire has an openConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.

600850-11 400650-10

Intake air temperature sensor - check the ground wire for opens– Measure the resistance between the specified points.

Break Out Box AO pin 7 – Connector CM pin 1



– Check EFI control unit connector AO ( p. 392) pin 7 and connector CM pin 1.

– Check the cable from EFI control unit connector AO ( p. 392) pin 7 to connector CM pin 1 for opens.


– Check the next possible cause:Intake air temperature sensor - value not plausible ( p. 264)

PartS

hark

.com

877-

999-

5686


Intake air temperature sensor - value not plausibleConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.

600850-11

Intake air temperature sensor - check the resistance– Measure the resistance between the specified points.


Intake air temperature sensor

Resistance at: −20 °C (−4 °F) 18.80 kΩ





– Replace the intake air temperature sensor.



PartS

hark

.com

877-

999-

5686




Display on diagnostic tool P0117"Engine coolant temperature sensor""Input signal too low"

Error level condition Engine coolant temperature sensor voltage "TWAD": ≤ 0.156 VTime: ≥ 3 sSubstitute value: 80 °C (176 °F)

Function check Engine coolant temperature sensor cylinder 1 - checking the voltage ( p. 265)

Possible cause Cylinder 1 coolant temperature sensor - value not plausible ( p. 265)

Engine coolant temperature sensor cylinder 1 - the signal wire has a short circuit to ground (termi-nal 31) ( p. 266)

Engine coolant temperature sensor cylinder 1 - the signal wire has a short circuit to sensor ground( p. 266)



Engine coolant temperature sensor cylinder 1 - checking the voltageConditionThe ignition is on.The diagnostic tool is connected and running.








– Highlight "Engine coolant temperature sensor voltage (TWAD)" and deselect the other parameters with "Select live data".

Engine coolant temperature sensor voltage "TWAD" 0.157… 4.843 V






– Check the next possible cause:Cylinder 1 coolant temperature sensor - value not plausible ( p. 265)

Cylinder 1 coolant temperature sensor - value not plausibleConditionThe ignition is off.Engine coolant temperature sensor for cylinder 1 is disconnected. ( p. 198)

600853-10

Cylinder 1 coolant temperature sensor - check the resistance– Measure the resistance between the specified points.

Engine coolant temperature sensor cylinder 1 pin 1 – Engine coolant tem-perature sensor cylinder 1 pin 2


Resistance at: −30 °C (−22 °F) 22.86… 27.94 kΩ


Resistance at: −10 °C (14 °F) 8.24… 10.08 kΩ

Resistance at: 0 °C (32 °F) 5.17… 6.31 kΩ




PartS

hark

.com

877-

999-

5686



Resistance at: 50 °C (122 °F) 730… 892 Ω









– Change the engine coolant temperature sensor cylinder 1.


– Check the next possible cause:Engine coolant temperature sensor cylinder 1 - the signal wire has a short cir-cuit to ground (terminal 31) ( p. 266)

Engine coolant temperature sensor cylinder 1 - the signal wire has a short circuit to ground (terminal 31)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Engine coolant temperature sensor for cylinder 1 is disconnected. ( p. 198)

600850-11 400658-10

Engine coolant temperature sensor cylinder 1 - check the signal wire for a short circuit to ground (terminal 31)– Measure the resistance between the specified points.


Resistance ∞ Ω


– Check the cable from EFI control unit connector AO ( p. 392) pin 9 to connector AX ( p. 395) pin 2 for a short circuit toground (terminal 31).


– Check the next possible cause:Engine coolant temperature sensor cylinder 1 - the signal wire has a short circuit to sensor ground ( p. 266)

Engine coolant temperature sensor cylinder 1 - the signal wire has a short circuit to sensor groundConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Engine coolant temperature sensor for cylinder 1 is disconnected. ( p. 198)

600850-11

Engine coolant temperature sensor cylinder 1 - check the signal wire for a short circuit tosensor ground– Measure the resistance between the specified points.


Resistance ∞ Ω


PartS

hark

.com

877-

999-

5686


– Check the cable from EFI control unit connector AO ( p. 392) pin 9 to con-nector AX ( p. 395) pin 2 for a short circuit to sensor ground.



PartS

hark

.com

877-

999-

5686




Display on diagnostic tool P0118"Engine coolant temperature sensor""Input signal too high"

Error level condition Engine coolant temperature sensor voltage "TWAD": ≥ 4.844 VTime: ≥ 3 sSubstitute value: 80 °C (176 °F)

Function check Engine coolant temperature sensor cylinder 1 - checking the voltage ( p. 268)

Possible cause Cylinder 1 coolant temperature sensor - value not plausible ( p. 268)

Engine coolant temperature sensor cylinder 1 - the signal wire has a short circuit to plus (termi-nal 30) ( p. 269)

Engine coolant temperature sensor cylinder 1 - the signal wire has a short circuit to ignition plus(terminal 15) ( p. 269)

Engine coolant temperature sensor cylinder 1 - the signal wire has a short circuit to the sensorpower supply ( p. 270)

Engine coolant temperature sensor cylinder 1 - the signal wire has an open ( p. 270)

Engine coolant temperature sensor cylinder 1 - the ground wire has an open ( p. 271)



Engine coolant temperature sensor cylinder 1 - checking the voltageConditionThe ignition is on.The diagnostic tool is connected and running.








– Highlight "Engine coolant temperature sensor voltage (TWAD)" and deselect the other parameters with "Select live data".

Engine coolant temperature sensor voltage "TWAD" 0.157… 4.843 V






– Check the next possible cause:Cylinder 1 coolant temperature sensor - value not plausible ( p. 268)

Cylinder 1 coolant temperature sensor - value not plausibleConditionThe ignition is off.Engine coolant temperature sensor for cylinder 1 is disconnected. ( p. 198)

600853-10

Cylinder 1 coolant temperature sensor - check the resistance– Measure the resistance between the specified points.

Engine coolant temperature sensor cylinder 1 pin 1 – Engine coolant tem-perature sensor cylinder 1 pin 2




Resistance at: −10 °C (14 °F) 8.24… 10.08 kΩ

PartS

hark

.com

877-

999-

5686
















– Change the engine coolant temperature sensor cylinder 1.


– Check the next possible cause:Engine coolant temperature sensor cylinder 1 - the signal wire has a short cir-cuit to plus (terminal 30) ( p. 269)

Engine coolant temperature sensor cylinder 1 - the signal wire has a short circuit to plus (terminal 30)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Engine coolant temperature sensor for cylinder 1 is disconnected. ( p. 198)

600850-11 400658-10

Engine coolant temperature sensor cylinder 1 - check the signal wire for a short circuit to plus (terminal 30)– Measure the voltage between the specified points.


Voltage ≤ 0.1 V


– Check the cable from EFI control unit connector AO ( p. 392) pin 9 to connector AX ( p. 395) pin 2 for a short circuit toplus (terminal 30).


– Check the next possible cause:Engine coolant temperature sensor cylinder 1 - the signal wire has a short circuit to ignition plus (terminal 15) ( p. 269)

Engine coolant temperature sensor cylinder 1 - the signal wire has a short circuit to ignition plus (terminal 15)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Engine coolant temperature sensor for cylinder 1 is disconnected. ( p. 198)

PartS

hark

.com

877-

999-

5686


600850-11

Engine coolant temperature sensor cylinder 1 - check the signal wire for a short circuit toignition plus (terminal 15)– Measure the resistance between the specified points.


Resistance ∞ Ω


– Check the cable from EFI control unit connector AO ( p. 392) pin 9 to con-nector AX ( p. 395) pin 2 for a short circuit to ignition plus (terminal 15).


– Check the next possible cause:Engine coolant temperature sensor cylinder 1 - the signal wire has a short cir-cuit to the sensor power supply ( p. 270)

Engine coolant temperature sensor cylinder 1 - the signal wire has a short circuit to the sensor power supplyConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Engine coolant temperature sensor for cylinder 1 is disconnected. ( p. 198)

600850-11

Engine coolant temperature sensor cylinder 1 - check the signal wire for a short circuit to thesensor power supply– Measure the resistance between the specified points.


Resistance ∞ Ω


– Check the cable from EFI control unit connector AO ( p. 392) pin 9 to con-nector AX ( p. 395) pin 2 for a short circuit to the sensor power supply.


– Check the next possible cause:Engine coolant temperature sensor cylinder 1 - the signal wire has an open( p. 270)

Engine coolant temperature sensor cylinder 1 - the signal wire has an openConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Engine coolant temperature sensor for cylinder 1 is disconnected. ( p. 198)

600850-11 400586-10

Engine coolant temperature sensor cylinder 1 - check the signal wire for opens– Measure the resistance between the specified points.

Break Out Box AO pin 9 – Engine coolant temperature sensor cylinder 1 connector AX pin 2



– Check EFI control unit connector AO ( p. 392) pin 9 and connector AX pin 2.

– Check the cable from EFI control unit connector AO ( p. 392) pin 9 to connector AX pin 2 for opens.


PartS

hark

.com

877-

999-

5686


– Check the next possible cause:Engine coolant temperature sensor cylinder 1 - the ground wire has an open ( p. 271)

Engine coolant temperature sensor cylinder 1 - the ground wire has an openConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Engine coolant temperature sensor for cylinder 1 is disconnected. ( p. 198)

600850-11 400586-10

Engine coolant temperature sensor cylinder 1 - check the ground wire for opens– Measure the resistance between the specified points.

Break Out Box AO pin 7 – Engine coolant temperature sensor cylinder 1 connector AX pin 1



– Check EFI control unit connector AO ( p. 392) pin 7 and connector AX pin 1.

– Check the cable from EFI control unit connector AO ( p. 392) pin 7 to connector AX pin 1 for opens.



PartS

hark

.com

877-

999-

5686




Display on diagnostic tool P0122"Throttle position sensor circuit A""Input signal too low"

Error level condition Throttle position sensor circuit A voltage "(THAD)": ≤ 0.156 VTime: ≥ 3 sSubstitute value: 100 %

Function check Throttle position sensor circuit A - checking the voltage ( p. 272)

Possible cause Throttle position sensor circuit A - the power supply is interrupted ( p. 272)

Throttle position sensor circuit A - the signal wire has a short circuit to ground (terminal 31)( p. 273)

Throttle position sensor circuit A - the signal wire has a short circuit to sensor ground ( p. 274)

Throttle position sensor circuit A - the signal wire has an open ( p. 274)



Throttle position sensor circuit A - checking the voltageConditionThe ignition is on.The diagnostic tool is connected and running.








– Highlight "Throttle position sensor voltage circuit A (THAD)" and deselect the other parameters with "Select live data".

Throttle position sensor circuit A voltage "(THAD)" 0.56… 4.20 V






– Check the next possible cause:Throttle position sensor circuit A - the power supply is interrupted ( p. 272)

Throttle position sensor circuit A - the power supply is interruptedConditionThe ignition is on.The diagnostics tool is connected and active.EFI control unit is connected. ( p. 227)Throttle position sensor circuit A is disconnected. ( p. 219)

PartS

hark

.com

877-

999-

5686


400584-10 400658-10

Throttle position sensor circuit A - check the power supply– Measure the voltage between the specified points.

Throttle position sensor circuit A, connector AR pin 1 – Measuring point Ground (−)



– Check connector AR pin 1 and connector CP ( p. 398) pin 2.14.

– Check the cable from connector AR pin 1 to connector CP ( p. 398) pin 2.14 for opens.

– Check connector CQ ( p. 398) pin 14 and EFI control unit connector AO ( p. 392) pin 1.

– Check the cable from connector CQ ( p. 398) pin 14 to EFI control unit connector AO ( p. 392) pin 1 for opens.


– Check the next possible cause:Throttle position sensor circuit A - the signal wire has a short circuit to ground (terminal 31) ( p. 273)

Throttle position sensor circuit A - the signal wire has a short circuit to ground (terminal 31)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Throttle position sensor circuit A is disconnected. ( p. 219)

600850-11 400658-10

Throttle position sensor circuit A - check the signal wire for a short circuit to ground (terminal 31)– Measure the resistance between the specified points.


Resistance ∞ Ω


– Check the cable from EFI control unit connector AO ( p. 392) pin 10 to connector CQ ( p. 398) pin 6 for a short circuit toground (terminal 31).

– Check the cable from connector CP ( p. 398) pin 2.6 to connector AR ( p. 393) pin 2 for a short circuit to ground (termi-nal 31).


– Check the next possible cause:Throttle position sensor circuit A - the signal wire has a short circuit to sensor ground ( p. 274)

PartS

hark

.com

877-

999-

5686


Throttle position sensor circuit A - the signal wire has a short circuit to sensor groundConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Throttle position sensor circuit A is disconnected. ( p. 219)

600850-11

Throttle position sensor circuit A - check the signal wire for a short circuit to sensor ground– Measure the resistance between the specified points.


Resistance ∞ Ω


– Check the cable from EFI control unit connector AO ( p. 392) pin 10 to con-nector CQ ( p. 398) pin 6 for a short circuit to sensor ground.

– Check the cable from connector CP ( p. 398) pin 2.6 to connector AR( p. 393) pin 2 for a short circuit to sensor ground.


– Check the next possible cause:Throttle position sensor circuit A - the signal wire has an open ( p. 274)

Throttle position sensor circuit A - the signal wire has an openConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Throttle position sensor circuit A is disconnected. ( p. 219)

600850-11 400584-10

Throttle position sensor circuit A - check the signal wire for opens– Measure the resistance between the specified points.

Break Out Box AO pin 10 – Throttle position sensor circuit A, connector AR pin 2



– Check EFI control unit connector AO ( p. 392) pin 10 and connector CQ ( p. 398) pin 6.

– Check the cable from EFI control unit connector AO ( p. 392) pin 10 to connector CQ ( p. 398) pin 6 for opens.

– Check connector CP ( p. 398) pin 2.6 and connector AR pin 2.

– Check the cable from connector CP ( p. 398) pin 2.6 to connector AR pin 2 for opens.



PartS

hark

.com

877-

999-

5686




Display on diagnostic tool P0123"Throttle position sensor circuit A""Input signal too high"

Error level condition Throttle position sensor circuit A voltage "(THAD)": ≥ 4.824 VTime: ≥ 3 sSubstitute value: 100 %

Function check Throttle position sensor circuit A - checking the voltage ( p. 275)

Possible cause Throttle position sensor circuit A - the signal wire has a short circuit to plus (terminal 30)( p. 275)

Throttle position sensor circuit A - the signal wire has a short circuit to ignition plus (terminal 15)( p. 276)

Throttle position sensor circuit A - the signal wire has a short circuit to the sensor power supply( p. 276)

Throttle position sensor circuit A - the ground wire has an open ( p. 277)



Throttle position sensor circuit A - checking the voltageConditionThe ignition is on.The diagnostic tool is connected and running.








– Highlight "Throttle position sensor voltage circuit A (THAD)" and deselect the other parameters with "Select live data".

Throttle position sensor circuit A voltage "(THAD)" 0.56… 4.20 V






– Check the next possible cause:Throttle position sensor circuit A - the signal wire has a short circuit to plus (terminal 30) ( p. 275)

Throttle position sensor circuit A - the signal wire has a short circuit to plus (terminal 30)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Throttle position sensor circuit A is disconnected. ( p. 219)

PartS

hark

.com

877-

999-

5686


600850-11 400658-10

Throttle position sensor circuit A - check the signal wire for a short circuit to plus (terminal 30)– Measure the voltage between the specified points.


Voltage ≤ 0.1 V


– Check the cable from EFI control unit connector AO ( p. 392) pin 10 to connector CQ ( p. 398) pin 6 for a short circuit toplus (terminal 30).

– Check the cable from connector CP ( p. 398) pin 2.6 to connector AR ( p. 393) pin 2 for a short circuit to plus (termi-nal 30).


– Check the next possible cause:Throttle position sensor circuit A - the signal wire has a short circuit to ignition plus (terminal 15) ( p. 276)

Throttle position sensor circuit A - the signal wire has a short circuit to ignition plus (terminal 15)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Throttle position sensor circuit A is disconnected. ( p. 219)

600850-11

Throttle position sensor circuit A - check the signal wire for a short circuit to ignition plus(terminal 15)– Measure the resistance between the specified points.


Resistance ∞ Ω


– Check the cable from EFI control unit connector AO ( p. 392) pin 10 to con-nector CQ ( p. 398) pin 6 for a short circuit to ignition plus (terminal 15).

– Check the cable from connector CP ( p. 398) pin 2.6 to connector AR( p. 393) pin 2 for a short circuit to ignition plus (terminal 15).


– Check the next possible cause:Throttle position sensor circuit A - the signal wire has a short circuit to the sen-sor power supply ( p. 276)

Throttle position sensor circuit A - the signal wire has a short circuit to the sensor power supplyConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Throttle position sensor circuit A is disconnected. ( p. 219)

600850-11

Throttle position sensor circuit A - check the signal wire for a short circuit to the sensorpower supply– Measure the resistance between the specified points.


Resistance ∞ Ω


PartS

hark

.com

877-

999-

5686


– Check the cable from EFI control unit connector AO ( p. 392) pin 10 to con-nector CQ ( p. 398) pin 6 for a short circuit to the sensor power supply.

– Check the cable from connector CP ( p. 398) pin 2.6 to connector AR( p. 393) pin 2 for a short circuit to the sensor power supply.


– Check the next possible cause:Throttle position sensor circuit A - the ground wire has an open ( p. 277)

Throttle position sensor circuit A - the ground wire has an openConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Throttle position sensor circuit A is disconnected. ( p. 219)

600850-11 400584-10

Throttle position sensor circuit A - check the ground wire for opens– Measure the resistance between the specified points.

Break Out Box AO pin 7 – Throttle position sensor circuit A, connector AR pin 3





– Check connector CP ( p. 398) pin 2.2 and connector AR pin 3.

– Check the cable from connector CP ( p. 398) pin 2.2 to connector AR pin 3 for opens.



PartS

hark

.com

877-

999-

5686




Display on diagnostic tool P0130"Lambda sensor cylinder 1, sensor 1""Circuit fault"


Function check Lambda sensor cylinder 1 - checking the voltage ( p. 278)

Possible cause Lambda sensor cylinder 1 - value not plausible ( p. 278)

Lambda sensor heater cylinder 1 - the signal wire has a short circuit to ground (terminal 31)( p. 279)

Lambda sensor cylinder 1 - the signal wire has a short circuit to sensor ground ( p. 279)

Lambda sensor cylinder 1 - the signal wire has a short circuit to plus (terminal 30) ( p. 280)

Lambda sensor cylinder 1 - the signal wire has a short circuit to ignition plus (terminal 15)( p. 280)

Lambda sensor cylinder 1 - the signal wire has a short circuit to the sensor power supply( p. 280)

Lambda sensor cylinder 1 - the signal wire has an open ( p. 281)

Lambda sensor cylinder 1 - the ground wire has an open ( p. 281)



Lambda sensor cylinder 1 - checking the voltageConditionThe engine is running at idle speed.The diagnostic tool is connected and running.The engine is at operating temperature.






– Mark "Lambda values".


– Highlight "Lambda sensor cylinder 1 voltage (HEGO1AD)" and deselect the other parameters with "Select live data".

Lambda sensor

Lambda sensor cylinder 1 voltage "HEGO1AD" 0.2… 0.8 V






– Check the next possible cause:Lambda sensor cylinder 1 - value not plausible ( p. 278)

Lambda sensor cylinder 1 - value not plausibleConditionThe ignition is on.The engine is running at idle speed.The engine is at operating temperature.Lambda sensor for cylinder 1 is connected. ( p. 62)

PartS

hark

.com

877-

999-

5686


400686-10

Lambda sensor cylinder 1 - check the voltage– Measure the voltage between the specified points.

Lambda sensor connector CE‑CA pin 3 – Lambda sensor connector CE‑CApin 4

Lambda sensor

Lambda sensor cylinder 1 voltage"HEGO1AD"

0.2… 0.8 V




– Check the next possible cause:Lambda sensor heater cylinder 1 - the signal wire has a short circuit to ground(terminal 31) ( p. 279)

Lambda sensor heater cylinder 1 - the signal wire has a short circuit to ground (terminal 31)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Lambda sensor for cylinder 1 is disconnected. ( p. 62)

600850-11 400658-10

Lambda sensor cylinder 1 - check the signal wire for a short circuit to ground (terminal 31).– Measure the resistance between the specified points.


Resistance ∞ Ω


– Check the cable from EFI control unit connector AO ( p. 392) pin 11 to connector CA ( p. 396) pin 4 for a short circuit toground (terminal 31).


– Check the next possible cause:Lambda sensor cylinder 1 - the signal wire has a short circuit to sensor ground ( p. 279)

Lambda sensor cylinder 1 - the signal wire has a short circuit to sensor groundConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Lambda sensor for cylinder 1 is disconnected. ( p. 62)

600850-11

Lambda sensor cylinder 1 - check the signal wire for a short circuit to sensor ground.– Measure the resistance between the specified points.


Resistance ∞ Ω


– Check the cable from EFI control unit connector AO ( p. 392) pin 11 to con-nector CA ( p. 396) pin 4 for a short circuit to sensor ground.


– Check the next possible cause:Lambda sensor cylinder 1 - the signal wire has a short circuit to plus (termi-nal 30) ( p. 280)

PartS

hark

.com

877-

999-

5686


Lambda sensor cylinder 1 - the signal wire has a short circuit to plus (terminal 30)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Lambda sensor for cylinder 1 is disconnected. ( p. 62)

600850-11 400658-10

Lambda sensor cylinder 1 - check the signal wire for a short circuit to plus (terminal 30).– Measure the voltage between the specified points.


Voltage < 0.1 V


– Check the cable from EFI control unit connector AO ( p. 392) pin 11 to connector CA ( p. 396) pin 4 for a short circuit toplus (terminal 30).


– Check the next possible cause:Lambda sensor cylinder 1 - the signal wire has a short circuit to ignition plus (terminal 15) ( p. 280)

Lambda sensor cylinder 1 - the signal wire has a short circuit to ignition plus (terminal 15)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Lambda sensor for cylinder 1 is disconnected. ( p. 62)

600850-11

Lambda sensor cylinder 1 - check the signal wire for a short circuit to ignition plus(terminal 15).– Measure the resistance between the specified points.


Resistance ∞ Ω


– Check the cable from EFI control unit connector AO ( p. 392) pin 11 to con-nector CA ( p. 396) pin 4 for a short circuit to ignition plus (terminal 15).


– Check the next possible cause:Lambda sensor cylinder 1 - the signal wire has a short circuit to the sensorpower supply ( p. 280)

Lambda sensor cylinder 1 - the signal wire has a short circuit to the sensor power supplyConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Lambda sensor for cylinder 1 is disconnected. ( p. 62)

PartS

hark

.com

877-

999-

5686


600850-11

Lambda sensor cylinder 1 - check the signal wire for a short circuit to the sensor powersupply.– Measure the resistance between the specified points.


Resistance ∞ Ω


– Check the cable from EFI control unit connector AO ( p. 392) pin 11 to con-nector CA ( p. 396) pin 4 for a short circuit to the sensor power supply.


– Check the next possible cause:Lambda sensor cylinder 1 - the signal wire has an open ( p. 281)

Lambda sensor cylinder 1 - the signal wire has an openConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Lambda sensor for cylinder 1 is disconnected. ( p. 62)

600850-11 400646-10

Lambda sensor cylinder 1 - check the signal wire for opens.– Measure the resistance between the specified points.

Break Out Box AO pin 11 – Lambda sensor cylinder 1, connector CA pin 4



– Check EFI control unit connector AO ( p. 392) pin 11 and connector CA pin 4.

– Check the cable from EFI control unit connector AO ( p. 392) pin 11 to connector CA pin 4 for opens.


– Check the next possible cause:Lambda sensor cylinder 1 - the ground wire has an open ( p. 281)

Lambda sensor cylinder 1 - the ground wire has an openConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Lambda sensor for cylinder 1 is disconnected. ( p. 62)

600850-11 400646-10

Lambda sensor cylinder 1 - check the ground wire for opens.– Measure the resistance between the specified points.



PartS

hark

.com

877-

999-

5686







PartS

hark

.com

877-

999-

5686




Display on diagnostic tool P0150"Lambda sensor cylinder 2, sensor 1""Circuit fault"


Function check Lambda sensor cylinder 2 - checking the voltage ( p. 283)

Possible cause Lambda sensor cylinder 2 - value not plausible ( p. 283)

Lambda sensor cylinder 2 - the signal wire has a short circuit to ground (terminal 31) ( p. 284)

Lambda sensor cylinder 2 - the signal wire has a short circuit to sensor ground ( p. 284)

Lambda sensor cylinder 2 - the signal wire has a short circuit to plus (terminal 30) ( p. 285)

Lambda sensor cylinder 2 - the signal wire has a short circuit to ignition plus (terminal 15)( p. 285)

Lambda sensor cylinder 2 - the signal wire has a short circuit to the sensor power supply( p. 285)

Lambda sensor cylinder 2 - the signal wire has an open ( p. 286)

Lambda sensor cylinder 2 - the ground wire has an open ( p. 286)



Lambda sensor cylinder 2 - checking the voltageConditionThe engine is running at idle speed.The diagnostic tool is connected and running.The engine is at operating temperature.






– Mark "Lambda values".


– Highlight "Lambda sensor cylinder 2 voltage (HEGO2AD)" and deselect the other parameters with "Select live data".

Lambda sensor

Lambda sensor cylinder 2 voltage "HEGO2AD" 0.2… 0.8 V






– Check the next possible cause:Lambda sensor cylinder 2 - value not plausible ( p. 283)

Lambda sensor cylinder 2 - value not plausibleConditionThe ignition is on.The engine is running at idle speed.The engine is at operating temperature.Lambda sensor for cylinder 2 is connected. ( p. 62)

PartS

hark

.com

877-

999-

5686


400686-10

Lambda sensor cylinder 2 - check the voltage– Measure the voltage between the specified points.

Lambda sensor connector CE‑CA pin 3 – Lambda sensor connector CE‑CApin 4

Lambda sensor

Lambda sensor cylinder 2 voltage"HEGO2AD"

0.2… 0.8 V




– Check the next possible cause:Lambda sensor cylinder 2 - the signal wire has a short circuit to ground (termi-nal 31) ( p. 284)

Lambda sensor cylinder 2 - the signal wire has a short circuit to ground (terminal 31)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Lambda sensor for cylinder 2 is disconnected. ( p. 62)

600850-11 400658-10

Lambda sensor cylinder 2 - check the signal wire for a short circuit to ground (terminal 31).– Measure the resistance between the specified points.


Resistance ∞ Ω


– Check the cable from EFI control unit connector AO ( p. 392) pin 12 to connector CA ( p. 396) pin 4 for a short circuit toground (terminal 31).


– Check the next possible cause:Lambda sensor cylinder 2 - the signal wire has a short circuit to sensor ground ( p. 284)

Lambda sensor cylinder 2 - the signal wire has a short circuit to sensor groundConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Lambda sensor for cylinder 2 is disconnected. ( p. 62)

600850-11

Lambda sensor cylinder 2 - check the signal wire for a short circuit to sensor ground.– Measure the resistance between the specified points.


Resistance ∞ Ω


– Check the cable from EFI control unit connector AO ( p. 392) pin 12 to con-nector CA ( p. 396) pin 4 for a short circuit to sensor ground.


– Check the next possible cause:Lambda sensor cylinder 2 - the signal wire has a short circuit to plus (termi-nal 30) ( p. 285)

PartS

hark

.com

877-

999-

5686


Lambda sensor cylinder 2 - the signal wire has a short circuit to plus (terminal 30)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Lambda sensor for cylinder 2 is disconnected. ( p. 62)

600850-11 400658-10

Lambda sensor cylinder 2 - check the signal wire for a short circuit to plus (terminal 30).– Measure the voltage between the specified points.


Voltage < 0.1 V


– Check the cable from EFI control unit connector AO ( p. 392) pin 12 to connector CA ( p. 396) pin 4 for a short circuit toplus (terminal 30).


– Check the next possible cause:Lambda sensor cylinder 2 - the signal wire has a short circuit to ignition plus (terminal 15) ( p. 285)

Lambda sensor cylinder 2 - the signal wire has a short circuit to ignition plus (terminal 15)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Lambda sensor for cylinder 2 is disconnected. ( p. 62)

600850-11

Lambda sensor cylinder 2 - check the signal wire for a short circuit to ignition plus(terminal 15).– Measure the resistance between the specified points.


Resistance ∞ Ω


– Check the cable from EFI control unit connector AO ( p. 392) pin 12 to con-nector CA ( p. 396) pin 4 for a short circuit to ignition plus (terminal 15).


– Check the next possible cause:Lambda sensor cylinder 2 - the signal wire has a short circuit to the sensorpower supply ( p. 285)

Lambda sensor cylinder 2 - the signal wire has a short circuit to the sensor power supplyConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Lambda sensor for cylinder 2 is disconnected. ( p. 62)

PartS

hark

.com

877-

999-

5686


600850-11

Lambda sensor cylinder 2 - check the signal wire for a short circuit to the sensor powersupply.– Measure the resistance between the specified points.


Resistance ∞ Ω


– Check the cable from EFI control unit connector AO ( p. 392) pin 12 to con-nector CA ( p. 396) pin 4 for a short circuit to the sensor power supply.


– Check the next possible cause:Lambda sensor cylinder 2 - the signal wire has an open ( p. 286)

Lambda sensor cylinder 2 - the signal wire has an openConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Lambda sensor for cylinder 2 is disconnected. ( p. 62)

600850-11 400646-10

Lambda sensor cylinder 2 - check the signal wire for opens.– Measure the resistance between the specified points.







– Check the next possible cause:Lambda sensor cylinder 2 - the ground wire has an open ( p. 286)

Lambda sensor cylinder 2 - the ground wire has an openConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Lambda sensor for cylinder 2 is disconnected. ( p. 62)

600850-11 400646-10

Lambda sensor cylinder 2 - check the ground wire for opens.– Measure the resistance between the specified points.



PartS

hark

.com

877-

999-

5686







PartS

hark

.com

877-

999-

5686




Display on diagnostic tool P0201"Injector cylinder 1""Circuit fault"

Error level condition Circuit fault: ≥ 0.5 s

Function check Injector cylinder 1 - checking the control ( p. 288)

Possible cause Cylinder 1 injector - value not plausible ( p. 288)

Injector cylinder 1 - there is a power supply fault ( p. 289)

Injector cylinder 1 - the control wire has a short circuit to plus (terminal 30) ( p. 289)

Injector cylinder 1 - the control wire has a short circuit to ignition plus (terminal 15) ( p. 290)

Injector cylinder 1 - the control wire has a short circuit to the sensor power supply ( p. 290)

Injector cylinder 1 - the control wire has an open. ( p. 291)

Injector cylinder 1 - the control wire has a short circuit to ground (terminal 31) ( p. 291)

Injector cylinder 1 - the control wire has a short circuit to sensor ground ( p. 292)



Injector cylinder 1 - checking the controlConditionThe ignition is on.The diagnostic tool is connected and running.








– Select "Injector cylinder 1".



Injector Operating noise






– Check the next possible cause:Cylinder 1 injector - value not plausible ( p. 288)

Cylinder 1 injector - value not plausibleConditionThe ignition is off.Injector cylinder 1 is disconnected. ( p. 225)

400598-10

Cylinder 1 injector - check the resistance– Measure the resistance between the specified points.

Injector pin 1 – Injector pin 2

Injector



PartS

hark

.com

877-

999-

5686


– Replace the injector cylinder 1.


– Check the next possible cause:Injector cylinder 1 - there is a power supply fault ( p. 289)

Injector cylinder 1 - there is a power supply faultConditionThe ignition is on.Injector cylinder 1 is disconnected. ( p. 225)

400591-10 400658-10

Injector cylinder 1 - check the power supply– Measure the voltage between the specified points.

Injector cylinder 1 connector DQ pin 1 – Measuring point Ground (−)




– Check connector DQ pin 1 and connector CP ( p. 398) pin 2.13.

– Check the cable from connector DQ pin 1 to connector CP ( p. 398) pin 2.13 for opens.

– Check the cable from connector CQ ( p. 398) pin 13 to the next node in the wiring harness for opens.


– Check the next possible cause:Injector cylinder 1 - the control wire has a short circuit to plus (terminal 30) ( p. 289)

Injector cylinder 1 - the control wire has a short circuit to plus (terminal 30)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Injector cylinder 1 is disconnected. ( p. 225)

600850-12 400658-10

Injector cylinder 1 - check the control wire for a short circuit to plus (terminal 30).– Measure the voltage between the specified points.


Voltage < 0.1 V


– Check the cable from EFI control unit connector CO ( p. 397) pin 5 to connector CQ ( p. 398) pin 5 for a short circuit toplus (terminal 30).

PartS

hark

.com

877-

999-

5686


– Check the cable from connector CP ( p. 398) pin 2.5 to connector DQ ( p. 400) pin 2 for a short circuit to plus (termi-nal 30).


– Check the next possible cause:Injector cylinder 1 - the control wire has a short circuit to ignition plus (terminal 15) ( p. 290)

Injector cylinder 1 - the control wire has a short circuit to ignition plus (terminal 15)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Injector cylinder 1 is disconnected. ( p. 225)

600850-12 600850-11

Injector cylinder 1 - check the control wire for a short circuit to ignition plus (terminal 15).– Measure the resistance between the specified points.


Resistance ∞ Ω


– Check the cable from EFI control unit connector CO ( p. 397) pin 5 to connector CQ ( p. 398) pin 5 for a short circuit toignition plus (terminal 15).

– Check the cable from connector CP ( p. 398) pin 2.5 to connector DQ ( p. 400) pin 2 for a short circuit to ignition plus(terminal 15).


– Check the next possible cause:Injector cylinder 1 - the control wire has a short circuit to the sensor power supply ( p. 290)

Injector cylinder 1 - the control wire has a short circuit to the sensor power supplyConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Injector cylinder 1 is disconnected. ( p. 225)

600850-12 600850-11

Injector cylinder 1 - check the control wire for a short circuit to the sensor power supply– Measure the resistance between the specified points.


Resistance ∞ Ω


– Check the cable from EFI control unit connector CO ( p. 397) pin 5 to connector CQ ( p. 398) pin 5 for a short circuit tothe sensor power supply.

PartS

hark

.com

877-

999-

5686


– Check the cable from connector CP ( p. 398) pin 2.5 to connector DQ ( p. 400) pin 2 for a short circuit to the sensorpower supply.


– Check the next possible cause:Injector cylinder 1 - the control wire has an open. ( p. 291)

Injector cylinder 1 - the control wire has an open.ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Injector cylinder 1 is disconnected. ( p. 225)

600850-12 400591-10

Injector cylinder 1 - check the control wire for opens– Measure the resistance between the specified points.

Break out box CO pin 5 – Injector cylinder 1 connector DQ pin 2



– Check EFI control unit connector CO ( p. 397) pin 5 and connector CQ ( p. 398) pin 5.

– Check the cable from EFI control unit connector CO ( p. 397) pin 5 to connector CQ ( p. 398) pin 5 for opens.

– Check connector CP ( p. 398) pin 2.5 and connector DQ pin 2.

– Check the cable from connector CP ( p. 398) pin 2.5 to connector DQ pin 2 for opens.


– Check the next possible cause:Injector cylinder 1 - the control wire has a short circuit to ground (terminal 31) ( p. 291)

Injector cylinder 1 - the control wire has a short circuit to ground (terminal 31)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Injector cylinder 1 is disconnected. ( p. 225)

600850-12 400658-10

Injector cylinder 1 - check the control wire for a short circuit to ground (terminal 31).– Measure the resistance between the specified points.


Resistance ∞ Ω


– Check the cable from EFI control unit connector CO ( p. 397) pin 5 to connector CQ ( p. 398) pin 5 for a short circuit toground (terminal 31).

PartS

hark

.com

877-

999-

5686


– Check the cable from connector CP ( p. 398) pin 2.5 to connector DQ ( p. 400) pin 2 for a short circuit to ground (termi-nal 31).


– Check the next possible cause:Injector cylinder 1 - the control wire has a short circuit to sensor ground ( p. 292)

Injector cylinder 1 - the control wire has a short circuit to sensor groundConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Injector cylinder 1 is disconnected. ( p. 225)

600850-12 600850-11

Injector cylinder 1 - check the control wire for a short circuit to sensor ground.– Measure the resistance between the specified points.


Resistance ∞ Ω


– Check the cable from EFI control unit connector CO ( p. 397) pin 5 to connector CQ ( p. 398) pin 5 for a short circuit tosensor ground.

– Check the cable from connector CP ( p. 398) pin 2.5 to connector DQ ( p. 400) pin 2 for a short circuit to sensor ground.



PartS

hark

.com

877-

999-

5686




Display on diagnostic tool P0202"Injector cylinder 2""Circuit fault"

Error level condition Circuit fault: ≥ 0.5 s

Function check Injector cylinder 2 - checking the control ( p. 293)

Possible cause Injector cylinder 2 - value not plausible ( p. 293)

Injector cylinder 2 - the power supply is faulty ( p. 294)

Injector cylinder 2 - the control wire has a short circuit to plus (terminal 30) ( p. 294)

Injector cylinder 2 - the control wire has a short circuit to ignition plus (terminal 15) ( p. 295)

Injector cylinder 2 - the control wire has a short circuit to the sensor power supply ( p. 295)

Injector cylinder 2 - the control wire has an open. ( p. 296)

Injector cylinder 2 - the control wire has a short circuit to ground (terminal 31) ( p. 296)

Injector cylinder 2 - the control wire has a short circuit to sensor ground ( p. 297)



Injector cylinder 2 - checking the controlConditionThe ignition is on.The diagnostic tool is connected and running.








– Select "Injector cylinder 2".



Injector Operating noise






– Check the next possible cause:Injector cylinder 2 - value not plausible ( p. 293)

Injector cylinder 2 - value not plausibleConditionThe ignition is off.Injector cylinder 2 is disconnected. ( p. 225)

400598-10

Injector cylinder 2 - check the resistance– Measure the resistance between the specified points.

Injector pin 1 – Injector pin 2

Injector



PartS

hark

.com

877-

999-

5686


– Change the injector cylinder 2.


– Check the next possible cause:Injector cylinder 2 - the power supply is faulty ( p. 294)

Injector cylinder 2 - the power supply is faultyConditionThe ignition is on.Injector cylinder 1 is disconnected. ( p. 225)

400591-10 400658-10

Injector cylinder 2 - check the power supply– Measure the voltage between the specified points.

Injector cylinder 2 connector DQ pin 1 – Measuring point Ground (−)




– Check connector DQ pin 1 and connector CP ( p. 398) pin 2.13.

– Check the cable from connector DQ pin 1 to connector CP ( p. 398) pin 2.13 for opens.

– Check the cable from connector CQ ( p. 398) pin 13 to the next node in the wiring harness for opens.


– Check the next possible cause:Injector cylinder 2 - the control wire has a short circuit to plus (terminal 30) ( p. 294)

Injector cylinder 2 - the control wire has a short circuit to plus (terminal 30)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Injector cylinder 2 is disconnected. ( p. 225)

600850-12 400658-10

Injector cylinder 2 - check the control wire for a short circuit to plus (terminal 30).– Measure the voltage between the specified points.


Voltage < 0.1 V



PartS

hark

.com

877-

999-

5686


– Check the cable from connector CP ( p. 398) pin 2.9 to connector DQ ( p. 401) pin 2 for a short circuit to plus (termi-nal 30).


– Check the next possible cause:Injector cylinder 2 - the control wire has a short circuit to ignition plus (terminal 15) ( p. 295)

Injector cylinder 2 - the control wire has a short circuit to ignition plus (terminal 15)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Injector cylinder 2 is disconnected. ( p. 225)

600850-12 600850-11

Injector cylinder 2 - check the control wire for a short circuit to ignition plus (terminal 15).– Measure the resistance between the specified points.


Resistance ∞ Ω



– Check the cable from connector CP ( p. 398) pin 2.9 to connector DQ ( p. 401) pin 2 for a short circuit to ignition plus(terminal 15).


– Check the next possible cause:Injector cylinder 2 - the control wire has a short circuit to the sensor power supply ( p. 295)

Injector cylinder 2 - the control wire has a short circuit to the sensor power supplyConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Injector cylinder 2 is disconnected. ( p. 225)

600850-12 600850-11

Injector cylinder 2 - check the control wire for a short circuit to the sensor power supply– Measure the resistance between the specified points.


Resistance ∞ Ω


– Check the cable from EFI control unit connector CO ( p. 397) pin 6 to connector CQ ( p. 398) pin 9 for a short circuit tothe sensor power supply.

PartS

hark

.com

877-

999-

5686


– Check the cable from connector CP ( p. 398) pin 2.9 to connector DQ ( p. 401) pin 2 for a short circuit to the sensorpower supply.


– Check the next possible cause:Injector cylinder 2 - the control wire has an open. ( p. 296)

Injector cylinder 2 - the control wire has an open.ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Injector cylinder 2 is disconnected. ( p. 225)

600850-12 400591-10

Injector cylinder 2 - check the control wire for opens– Measure the resistance between the specified points.

Break out box CO pin 6 – Injector cylinder 2 connector DQ pin 2



– Check EFI control unit connector CO ( p. 397) pin 6 and connector CQ ( p. 398) pin 9.

– Check the cable from EFI control unit connector CO ( p. 397) pin 6 to connector CQ ( p. 398) pin 9 for opens.

– Check connector CP ( p. 398) pin 2.9 and connector DQ pin 2.

– Check the cable from connector CP ( p. 398) pin 2.9 to connector DQ pin 2 for opens.


– Check the next possible cause:Injector cylinder 2 - the control wire has a short circuit to ground (terminal 31) ( p. 296)

Injector cylinder 2 - the control wire has a short circuit to ground (terminal 31)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Injector cylinder 2 is disconnected. ( p. 225)

600850-12 400658-10

Injector cylinder 2 - check the control wire for a short circuit to ground (terminal 31).– Measure the resistance between the specified points.


Resistance ∞ Ω



PartS

hark

.com

877-

999-

5686


– Check the cable from connector CP ( p. 398) pin 2.9 to connector DQ ( p. 401) pin 2 for a short circuit to ground (termi-nal 31).


– Check the next possible cause:Injector cylinder 2 - the control wire has a short circuit to sensor ground ( p. 297)

Injector cylinder 2 - the control wire has a short circuit to sensor groundConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Injector cylinder 2 is disconnected. ( p. 225)

600850-12 600850-11

Injector cylinder 2 - check the control wire for a short circuit to sensor ground.– Measure the resistance between the specified points.


Resistance ∞ Ω



– Check the cable from connector CP ( p. 398) pin 2.9 to connector DQ ( p. 401) pin 2 for a short circuit to sensor ground.



PartS

hark

.com

877-

999-

5686




Display on diagnostic tool P0222"Throttle position sensor circuit B""Input signal too low"

Error level condition Throttle position sensor circuit B, voltage "TAPAD": ≤ 0.156 VTime: ≥ 3 sSubstitute value: 100 °C (212 °F)

Function check Throttle position sensor circuit B - checking the voltage ( p. 298)

Possible cause Throttle position sensor circuit B - the power supply is interrupted ( p. 298)

Throttle position sensor circuit B - the signal wire has a short circuit to ground (terminal 31)( p. 299)

Throttle position sensor circuit B - the signal wire has a short circuit to sensor ground ( p. 300)

Throttle position sensor circuit B - the signal wire has an open ( p. 300)



Throttle position sensor circuit B - checking the voltageConditionThe ignition is on.The diagnostic tool is connected and running.








– Highlight "Throttle position sensor voltage circuit B" and deselect the other parameters with "Select live data".

Throttle position sensor circuit B

Voltage "TAPAD" 0.156… 4.824 V






– Check the next possible cause:Throttle position sensor circuit B - the power supply is interrupted ( p. 298)

Throttle position sensor circuit B - the power supply is interruptedConditionThe ignition is on.The diagnostics tool is connected and active.EFI control unit is connected. ( p. 227)Throttle position sensor circuit B is disconnected. ( p. 223)

PartS

hark

.com

877-

999-

5686


400582-10 400658-10

Throttle position sensor circuit B - check the power supply– Measure the voltage between the specified points.

Throttle position sensor circuit B, connector AM pin 2 – Measuring point Ground (−)



– Check connector AM pin 2 and connector CP ( p. 398) pin 2.14.

– Check the cable from connector AM pin 2 to connector CP ( p. 398) pin 2.14 for opens.

– Check connector CQ ( p. 398) pin 14 and EFI control unit connector AO ( p. 392) pin 1.

– Check the cable from connector CQ ( p. 398) pin 14 to EFI control unit connector AO ( p. 392) pin 1 for opens.


– Check the next possible cause:Throttle position sensor circuit B - the signal wire has a short circuit to ground (terminal 31) ( p. 299)

Throttle position sensor circuit B - the signal wire has a short circuit to ground (terminal 31)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Throttle position sensor circuit B is disconnected. ( p. 223)

600850-11 400658-10

Throttle position sensor circuit B - check the signal wire for a short circuit to ground (terminal 31)– Measure the resistance between the specified points.


Resistance ∞ Ω


– Check the cable from EFI control unit connector AO ( p. 392) pin 2 to connector CQ ( p. 398) pin 10 for a short circuit toground (terminal 31).

– Check the cable from connector CP ( p. 398) pin 2.10 to connector AM ( p. 392) pin 1 for a short circuit to ground (termi-nal 31).


– Check the next possible cause:Throttle position sensor circuit B - the signal wire has a short circuit to sensor ground ( p. 300)

PartS

hark

.com

877-

999-

5686


Throttle position sensor circuit B - the signal wire has a short circuit to sensor groundConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Throttle position sensor circuit B is disconnected. ( p. 223)

600850-11

Throttle position sensor circuit B - check the signal wire for a short circuit to sensor ground– Measure the resistance between the specified points.


Resistance ∞ Ω


– Check the cable from EFI control unit connector AO ( p. 392) pin 2 to con-nector CQ ( p. 398) pin 10 for a short circuit to sensor ground.

– Check the cable from connector CP ( p. 398) pin 2.10 to connector AM( p. 392) pin 1 for a short circuit to sensor ground.


– Check the next possible cause:Throttle position sensor circuit B - the signal wire has an open ( p. 300)

Throttle position sensor circuit B - the signal wire has an openConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Throttle position sensor circuit B is disconnected. ( p. 223)

600850-11 400582-10

Throttle position sensor circuit B - check the signal wire for opens– Measure the resistance between the specified points.

Break Out Box AO pin 2 – Throttle position sensor circuit B, connector AM pin 1




– Check the cable from EFI control unit connector AO ( p. 392) pin 2 to connector CQ ( p. 398) pin 2.10 for opens.

– Check connector CP ( p. 398) pin 2.10 and connector AM pin 1.

– Check the cable from connector CP ( p. 398) pin 2.10 to connector AM pin 1 for opens.



PartS

hark

.com

877-

999-

5686




Display on diagnostic tool P0223"Throttle position sensor circuit B""Input signal too high"

Error level condition Throttle position sensor circuit B, voltage "TAPAD": ≥ 4.824 VTime: ≥ 3 sSubstitute value: 100 °C (212 °F)

Function check Throttle position sensor circuit B - checking the voltage ( p. 301)

Possible cause Throttle position sensor circuit B - the signal wire has a short circuit to plus (terminal 30)( p. 301)

Throttle position sensor circuit B - the signal wire has a short circuit to ignition plus (terminal 15)( p. 302)

Throttle position sensor circuit B - the signal wire has a short circuit to the sensor power supply( p. 302)

Throttle position sensor circuit B - the ground wire has an open ( p. 303)



Throttle position sensor circuit B - checking the voltageConditionThe ignition is on.The diagnostic tool is connected and running.








– Highlight "Throttle position sensor voltage circuit B" and deselect the other parameters with "Select live data".








– Check the next possible cause:Throttle position sensor circuit B - the signal wire has a short circuit to plus (terminal 30) ( p. 301)

Throttle position sensor circuit B - the signal wire has a short circuit to plus (terminal 30)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Throttle position sensor circuit B is disconnected. ( p. 223)

PartS

hark

.com

877-

999-

5686


600850-11 400658-10

Throttle position sensor circuit B - check the signal wire for a short circuit to plus (terminal 30)– Measure the voltage between the specified points.


Voltage ≤ 0.1 V


– Check the cable from EFI control unit connector AO ( p. 392) pin 2 to connector CQ ( p. 398) pin 10 for a short circuit toplus (terminal 30).

– Check the cable from connector CP ( p. 398) pin 2.10 to connector AM ( p. 392) pin 1 for a short circuit to plus (termi-nal 30).


– Check the next possible cause:Throttle position sensor circuit B - the signal wire has a short circuit to ignition plus (terminal 15) ( p. 302)

Throttle position sensor circuit B - the signal wire has a short circuit to ignition plus (terminal 15)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Throttle position sensor circuit B is disconnected. ( p. 223)

600850-11

Throttle position sensor circuit B - check the signal wire for a short circuit to ignition plus(terminal 15)– Measure the resistance between the specified points.


Resistance ∞ Ω


– Check the cable from EFI control unit connector AO ( p. 392) pin 2 to con-nector CQ ( p. 398) pin 10 for a short circuit to ignition plus (terminal 15).

– Check the cable from connector CP ( p. 398) pin 2.10 to connector AM( p. 392) pin 1 for a short circuit to ignition plus (terminal 15).


– Check the next possible cause:Throttle position sensor circuit B - the signal wire has a short circuit to the sen-sor power supply ( p. 302)

Throttle position sensor circuit B - the signal wire has a short circuit to the sensor power supplyConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Throttle position sensor circuit B is disconnected. ( p. 223)

600850-11

Throttle position sensor circuit B - check the signal wire for a short circuit to the sensorpower supply– Measure the resistance between the specified points.


Resistance ∞ Ω


PartS

hark

.com

877-

999-

5686


– Check the cable from EFI control unit connector AO ( p. 392) pin 2 to con-nector CQ ( p. 398) pin 10 for a short circuit to the sensor power supply.

– Check the cable from connector CP ( p. 398) pin 2.10 to connector AM( p. 392) pin 1 for a short circuit to the sensor power supply.


– Check the next possible cause:Throttle position sensor circuit B - the ground wire has an open ( p. 303)

Throttle position sensor circuit B - the ground wire has an openConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Throttle position sensor circuit B is disconnected. ( p. 223)

600850-11 400582-10

Throttle position sensor circuit B - check the ground wire for opens– Measure the resistance between the specified points.

Break Out Box AO pin 7 – Throttle position sensor circuit B, connector AM pin 3





– Check connector CP ( p. 398) pin 2.2 and connector AM pin 3.

– Check the cable from connector CP ( p. 398) pin 2.2 to connector AM pin 3 for opens.



PartS

hark

.com

877-

999-

5686




Display on diagnostic tool P0335"Circuit crankshaft position sensor""Circuit fault"

Error level condition The manifold absolute pressure sensor delivers a normal signal (engine running), while thecrankshaft position sensor does not generate any signal at all.The engine is switched off: ≥ 0.1 s

Function check Crankshaft position sensor - checking the signal ( p. 304)

Possible cause Crankshaft position sensor - value not plausible ( p. 304)

Crankshaft position sensor - the signal wire has an open ( p. 305)

Crankshaft position sensor - the signal wires have a short circuit to ground (terminal 31)( p. 305)

Crankshaft position sensor - the signal wires have a short circuit to sensor ground ( p. 306)

Crankshaft position sensor - the signal wires have a short circuit to plus (terminal 30) ( p. 306)

Crankshaft position sensor - the signal wires have a short circuit to ignition plus (terminal 15)( p. 307)

Crankshaft position sensor - the signal wire has a short circuit to the sensor power supply( p. 307)



Crankshaft position sensor - checking the signalConditionThe ignition is on.The diagnostic tool is connected and running.






– Highlight "electric starter".


– Highlight "Engine speed (NE)" and deselect the other parameters with "Select live data".

– Perform the start procedure.

"Engine speed (NE)" Starter rpm






– Check the next possible cause:Crankshaft position sensor - value not plausible ( p. 304)

Crankshaft position sensor - value not plausibleConditionThe ignition is off.The crankshaft position sensor is disconnected. ( p. 218)

PartS

hark

.com

877-

999-

5686


400585-10

Crankshaft position sensor - check the resistance– Measure the resistance between the specified points.

Crankshaft position sensor, connector AT pin 1 – Crankshaft position sensor,connector AT pin 2




– Replace the crankshaft position sensor.


– Check the next possible cause:Crankshaft position sensor - the signal wire has an open ( p. 305)

Crankshaft position sensor - the signal wire has an openConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.The crankshaft position sensor is connected. ( p. 218)

600850-11

Crankshaft position sensor - check the signal wire for opens– Measure the resistance between the specified points.





– Check EFI control unit connector AO ( p. 392) pin 14 and pin 13.

– Check connector AL ( p. 391) pin 2 and connector AL pin 1.

– Check the cable from EFI control unit connector AO ( p. 392) pin 14 to con-nector AL ( p. 391) pin 2 for opens.

– Check the cable from EFI control unit connector AO ( p. 392) pin 13 to con-nector AL ( p. 391) pin 1 for opens.


– Check the next possible cause:Crankshaft position sensor - the signal wires have a short circuit to ground (ter-minal 31) ( p. 305)

Crankshaft position sensor - the signal wires have a short circuit to ground (terminal 31)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.The crankshaft position sensor is connected. ( p. 218)

600850-11 400658-10

Crankshaft position sensor - check the signal wires for a short circuit to ground (terminal 31)– Measure the resistance between the specified points.


Resistance ∞ Ω


PartS

hark

.com

877-

999-

5686


– Check the cable from EFI control unit connector AO ( p. 392) pin 14 to connector AL ( p. 391) pin 2 for a short circuit toground (terminal 31).

– Check the cable from EFI control unit connector AO ( p. 392) pin 13 to connector AL ( p. 391) pin 1 for a short circuit toground (terminal 31).


– Check the next possible cause:Crankshaft position sensor - the signal wires have a short circuit to sensor ground ( p. 306)

Crankshaft position sensor - the signal wires have a short circuit to sensor groundConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.The crankshaft position sensor is connected. ( p. 218)

600850-11

Crankshaft position sensor - check the signal wires for a short circuit to sensor ground– Measure the resistance between the specified points.


Resistance ∞ Ω


– Check the cable from EFI control unit connector AO ( p. 392) pin 14 to con-nector AL ( p. 391) pin 2 for a short circuit to sensor ground.

– Check the cable from EFI control unit connector AO ( p. 392) pin 13 to con-nector AL ( p. 391) pin 1 for a short circuit to sensor ground.


– Check the next possible cause:Crankshaft position sensor - the signal wires have a short circuit to plus (termi-nal 30) ( p. 306)

Crankshaft position sensor - the signal wires have a short circuit to plus (terminal 30)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.The crankshaft position sensor is connected. ( p. 218)

600850-11 400658-10

Crankshaft position sensor - check the signal wires for a short circuit to plus (terminal 30)– Measure the voltage between the specified points.


Voltage < 0.1 V


– Check the cable from EFI control unit connector AO ( p. 392) pin 14 to connector AL ( p. 391) pin 2 for a short circuit toplus (terminal 30).

– Check the cable from EFI control unit connector AO ( p. 392) pin 13 to connector AL ( p. 391) pin 1 for a short circuit toplus (terminal 30).


– Check the next possible cause:Crankshaft position sensor - the signal wires have a short circuit to ignition plus (terminal 15) ( p. 307)

PartS

hark

.com

877-

999-

5686


Crankshaft position sensor - the signal wires have a short circuit to ignition plus (terminal 15)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.The crankshaft position sensor is connected. ( p. 218)

600850-11

Crankshaft position sensor - check the signal wire for a short circuit to ignition plus(terminal 15)– Measure the resistance between the specified points.


Resistance ∞ Ω


– Check the cable from EFI control unit connector AO ( p. 392) pin 14 to con-nector AL ( p. 391) pin 2 for a short circuit to ignition plus (terminal 15).

– Check the cable from EFI control unit connector AO ( p. 392) pin 13 to con-nector AL ( p. 391) pin 1 for a short circuit to ignition plus (terminal 15).


– Check the next possible cause:Crankshaft position sensor - the signal wire has a short circuit to the sensorpower supply ( p. 307)

Crankshaft position sensor - the signal wire has a short circuit to the sensor power supplyConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.The crankshaft position sensor is connected. ( p. 218)

600850-11

Crankshaft position sensor - check the signal wire for a short circuit to the sensor powersupply– Measure the resistance between the specified points.


Resistance ∞ Ω


– Check the cable from EFI control unit connector AO ( p. 392) pin 14 to con-nector AL ( p. 391) pin 2 for a short circuit to the sensor power supply.

– Check the cable from EFI control unit connector AO ( p. 392) pin 13 to con-nector AL ( p. 391) pin 1 for a short circuit to the sensor power supply.


– Contact customer service.PartS

hark

.com

877-

999-

5686




Display on diagnostic tool P0351"Ignition coil cylinder 1""Circuit fault"

Error level condition Circuit fault.The engine is switched off: ≥ 0.5 s

Function check Checking the ignition coil cylinder 1 ( p. 308)

Possible cause Ignition coil cylinder 1 - value not plausible ( p. 308)

Ignition coil cylinder 1 - the control wire has a short circuit to ground (terminal 31) ( p. 309)

Ignition coil cylinder 1 - the control wire has a short circuit to sensor ground ( p. 309)

Ignition coil cylinder 1 - the control wire has a short circuit to plus (terminal 30) ( p. 310)

Ignition coil cylinder 1 - the control wire has a short circuit to ignition plus (terminal 15)( p. 310)

Ignition coil cylinder 1 - the control wire has an open ( p. 311)

Ignition coil cylinder 1 - the power supply is interrupted ( p. 312)



Checking the ignition coil cylinder 1ConditionThe ignition is on.The diagnostic tool is connected and running.








– Select "Ignition cylinder 1".



Spark plug Operating noise






– Check the next possible cause:Ignition coil cylinder 1 - value not plausible ( p. 308)

Ignition coil cylinder 1 - value not plausibleConditionThe ignition is off.Ignition coil cylinder 1 is disconnected. ( p. 218)

PartS

hark

.com

877-

999-

5686


600851-10

Ignition coil cylinder 1 - check the resistance– Measure the resistance between the specified points.

Ignition coil pin 1 – Ignition coil pin 2

Ignition coil

Primary winding resistance at: 20 °C(68 °F)

1.105… 1.495 Ω


– Replace the ignition coil cylinder 1.


– Check the next possible cause:Ignition coil cylinder 1 - the control wire has a short circuit to ground (termi-nal 31) ( p. 309)

Ignition coil cylinder 1 - the control wire has a short circuit to ground (terminal 31)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Ignition coil cylinder 1 is disconnected. ( p. 218)

600850-12 400658-10

Ignition coil cylinder 1 - check the control wire for a short circuit to ground (terminal 31).– Measure the resistance between the specified points.


Resistance ∞ Ω


– Check the cable from EFI control unit connector CO ( p. 397) pin 29 to connector AS ( p. 394) pin 1 for a short circuit toground (terminal 31).


– Check the next possible cause:Ignition coil cylinder 1 - the control wire has a short circuit to sensor ground ( p. 309)

Ignition coil cylinder 1 - the control wire has a short circuit to sensor groundConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Ignition coil cylinder 1 is disconnected. ( p. 218)

PartS

hark

.com

877-

999-

5686


600850-12 600850-11

Ignition coil cylinder 1 - check the control wire for a short circuit to sensor ground.– Measure the resistance between the specified points.


Resistance ∞ Ω


– Check the cable from EFI control unit connector CO ( p. 397) pin 29 to connector AS ( p. 394) pin 1 for a short circuit tosensor ground.


– Check the next possible cause:Ignition coil cylinder 1 - the control wire has a short circuit to plus (terminal 30) ( p. 310)

Ignition coil cylinder 1 - the control wire has a short circuit to plus (terminal 30)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Ignition coil cylinder 1 is disconnected. ( p. 218)

600850-12 400658-10

Ignition coil cylinder 1 - check the control wire for a short circuit to plus (terminal 30).– Measure the voltage between the specified points.


Voltage < 0.1 V


– Check the cable from EFI control unit connector CO ( p. 397) pin 29 to connector AS ( p. 394) pin 1 for a short circuit toplus (terminal 30).


– Check the next possible cause:Ignition coil cylinder 1 - the control wire has a short circuit to ignition plus (terminal 15) ( p. 310)

Ignition coil cylinder 1 - the control wire has a short circuit to ignition plus (terminal 15)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Ignition coil cylinder 1 is disconnected. ( p. 218)

PartS

hark

.com

877-

999-

5686


600850-12 600850-11

Ignition coil cylinder 1 - check the control wire for a short circuit to ignition plus (terminal 15).– Measure the resistance between the specified points.


Resistance ∞ Ω


– Check the cable from EFI control unit connector CO ( p. 397) pin 29 to connector AS ( p. 394) pin 1 for a short circuit toignition plus (terminal 15).


– Check the next possible cause:Ignition coil cylinder 1 - the control wire has an open ( p. 311)

Ignition coil cylinder 1 - the control wire has an openConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Ignition coil cylinder 1 is disconnected. ( p. 218)

400644-10 400658-10

Ignition coil cylinder 1 - check the control wire for opens– Measure the voltage between the specified points.

Ignition coil cylinder 1 connector AS pin 1 – Measuring point Ground (−)

InfoEstablish a secure connection from the battery plus terminal to the break out box CO pin 29.For measurement the measuring points must be subjected to a 12V/21W bulb load.



– Check EFI control unit connector CO ( p. 397) pin 29 and connector AS pin 1.

– Check the cable from EFI control unit connector CO ( p. 397) pin 29 to connector AS pin 1 for opens.


– Check the next possible cause:Ignition coil cylinder 1 - the power supply is interrupted ( p. 312)

PartS

hark

.com

877-

999-

5686


Ignition coil cylinder 1 - the power supply is interruptedConditionThe ignition is on.The diagnostics tool is connected and active.EFI control unit is connected. ( p. 227)Ignition coil cylinder 1 is disconnected. ( p. 218)

400644-10 400658-10

Ignition coil cylinder 1 - check the power supply– Measure the voltage between the specified points.





– Check connector AS pin 2.

– Check the cable from connector AS pin 2 to the next node in the wiring harness for opens.



PartS

hark

.com

877-

999-

5686




Display on diagnostic tool P0352"Ignition coil cylinder 2""Circuit fault"

Error level condition Circuit fault.The engine is switched off: ≥ 0.5 s

Function check Checking the ignition coil cylinder 2 ( p. 313)

Possible cause Ignition coil cylinder 2 - value not plausible ( p. 313)

Ignition coil cylinder 2 - the control wire has a short circuit to ground (terminal 31) ( p. 314)

Ignition coil cylinder 2 - the control wire has a short circuit to sensor ground ( p. 314)

Ignition coil cylinder 2 - the control wire has a short circuit to plus (terminal 30) ( p. 315)

Ignition coil cylinder 2 - the control wire has a short circuit to ignition plus (terminal 15)( p. 315)

Ignition coil cylinder 2 - the control wire has an open ( p. 316)

Ignition coil cylinder 2 - the power supply is interrupted ( p. 317)



Checking the ignition coil cylinder 2ConditionThe ignition is on.The diagnostic tool is connected and running.








– Select "Ignition cylinder 2".



Spark plug Operating noise






– Check the next possible cause:Ignition coil cylinder 2 - value not plausible ( p. 313)

Ignition coil cylinder 2 - value not plausibleConditionThe ignition is off.Ignition coil cylinder 2 is disconnected. ( p. 218)

PartS

hark

.com

877-

999-

5686


600851-10

Ignition coil cylinder 2 - check the resistance– Measure the resistance between the specified points.

Ignition coil pin 1 – Ignition coil pin 2

Ignition coil

Primary winding resistance at: 20 °C(68 °F)

1.105… 1.495 Ω


– Change the ignition coil cylinder 2.


– Check the next possible cause:Ignition coil cylinder 2 - the control wire has a short circuit to ground (termi-nal 31) ( p. 314)

Ignition coil cylinder 2 - the control wire has a short circuit to ground (terminal 31)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Ignition coil cylinder 2 is disconnected. ( p. 218)

600850-12 400658-10

Ignition coil cylinder 2 - check the control wire for a short circuit to ground (terminal 31).– Measure the resistance between the specified points.


Resistance ∞ Ω


– Check the cable from EFI control unit connector CO ( p. 397) pin 26 to connector AS ( p. 394) pin 1 for a short circuit toground (terminal 31).


– Check the next possible cause:Ignition coil cylinder 2 - the control wire has a short circuit to sensor ground ( p. 314)

Ignition coil cylinder 2 - the control wire has a short circuit to sensor groundConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Ignition coil cylinder 2 is disconnected. ( p. 218)

PartS

hark

.com

877-

999-

5686


600850-12 600850-11

Ignition coil cylinder 2 - check the control wire for a short circuit to sensor ground.– Measure the resistance between the specified points.


Resistance ∞ Ω


– Check the cable from EFI control unit connector CO ( p. 397) pin 26 to connector AS ( p. 394) pin 1 for a short circuit tosensor ground.


– Check the next possible cause:Ignition coil cylinder 2 - the control wire has a short circuit to plus (terminal 30) ( p. 315)

Ignition coil cylinder 2 - the control wire has a short circuit to plus (terminal 30)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Ignition coil cylinder 2 is disconnected. ( p. 218)

600850-12 400658-10

Ignition coil cylinder 2 - check the control wire for a short circuit to plus (terminal 30).– Measure the voltage between the specified points.


Voltage < 0.1 V


– Check the cable from EFI control unit connector CO ( p. 397) pin 26 to connector AS ( p. 394) pin 1 for a short circuit toplus (terminal 30).


– Check the next possible cause:Ignition coil cylinder 2 - the control wire has a short circuit to ignition plus (terminal 15) ( p. 315)

Ignition coil cylinder 2 - the control wire has a short circuit to ignition plus (terminal 15)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Ignition coil cylinder 2 is disconnected. ( p. 218)

PartS

hark

.com

877-

999-

5686


600850-12 600850-11

Ignition coil cylinder 2 - check the control wire for a short circuit to ignition plus (terminal 15).– Measure the resistance between the specified points.


Resistance ∞ Ω


– Check the cable from EFI control unit connector CO ( p. 397) pin 26 to connector AS ( p. 394) pin 1 for a short circuit toignition plus (terminal 15).


– Check the next possible cause:Ignition coil cylinder 2 - the control wire has an open ( p. 316)

Ignition coil cylinder 2 - the control wire has an openConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Ignition coil cylinder 2 is disconnected. ( p. 218)

400644-10 400658-10

Ignition coil cylinder 2 - check the control wire for opens– Measure the voltage between the specified points.


InfoEstablish a protected connection from battery plus to break out box CO pin 26.For measurement the measuring points must be subjected to a 12V/21W bulb load.



– Check EFI control unit connector CO ( p. 397) pin 26 and connector AS pin 1.

– Check the cable from EFI control unit connector CO ( p. 397) pin 26 to connector AS pin 1 for opens.


– Check the next possible cause:Ignition coil cylinder 2 - the power supply is interrupted ( p. 317)

PartS

hark

.com

877-

999-

5686


Ignition coil cylinder 2 - the power supply is interruptedConditionThe ignition is on.The diagnostics tool is connected and active.EFI control unit is connected. ( p. 227)Ignition coil cylinder 2 is disconnected. ( p. 218)

400644-10 400658-10

Ignition coil cylinder 2 - check the power supply– Measure the voltage between the specified points.





– Check connector AS pin 2.

– Check the cable from connector AS pin 2 to the next node in the wiring harness for opens.



PartS

hark

.com

877-

999-

5686




Display on diagnostic tool P0413"Secondary air valve ""Short circuit to ground or open circuit"

Error level condition The control unit is active.Circuit fault: ≥ 3 s

Function check Checking the secondary air valve ( p. 318)

Possible cause Secondary air valve - value not plausible ( p. 318)

Secondary air valve - the control wire has a short circuit to ground (terminal 31) ( p. 319)

Secondary air valve - the control wire has an open ( p. 319)

Secondary air valve - the power supply is faulty ( p. 320)

Secondary air valve - the control wire has a short circuit to ground (terminal 31) ( p. 320)

Secondary air valve - the control wire has a short circuit to sensor ground ( p. 321)



Checking the secondary air valveConditionThe ignition is on.The diagnostic tool is connected and running.








– Select "Exhaust air injection valve SLS on/off".



Secondary air valve Operating noise






– Check the next possible cause:Secondary air valve - value not plausible ( p. 318)

Secondary air valve - value not plausibleConditionThe ignition is off.The exhaust air injection valve is disconnected. ( p. 190)

600854-10

Secondary air valve - check the resistance– Measure the resistance between the specified points.

Exhaust air injection valve, connector FE pin 1 – Exhaust air injection valve,connector FE pin 2

Secondary air valve

at: 20 °C (68 °F) 18.0… 22.0 Ω


PartS

hark

.com

877-

999-

5686


– Change the secondary air valve.


– Check the next possible cause:Secondary air valve - the control wire has a short circuit to ground (terminal 31)( p. 319)

Secondary air valve - the control wire has a short circuit to ground (terminal 31)ConditionThe ignition is off.The exhaust air injection valve is disconnected. ( p. 190)

600854-10 400658-10

Secondary air valve - check the control wire for a short circuit to ground (terminal 31)– Measure the resistance between the specified points.

Exhaust air injection valve, connector FE pin 2 – Measuring point Ground (−)

Resistance ∞ Ω




– Check the next possible cause:Secondary air valve - the control wire has an open ( p. 319)

Secondary air valve - the control wire has an openConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.The exhaust air injection valve is disconnected. ( p. 190)

600850-12 400648-10

Secondary air valve - check the control wire for opens– Measure the resistance between the specified points.

Break out box CO pin 13 – Secondary air valve connector CK pin 2



– Check EFI control unit connector CO ( p. 397) pin 13 and connector CK pin 2.

– Check the cable from EFI control unit connector CO ( p. 397) pin 13 to connector CK pin 2 for opens.


– Check the next possible cause:Secondary air valve - the power supply is faulty ( p. 320)

PartS

hark

.com

877-

999-

5686


Secondary air valve - the power supply is faultyConditionThe ignition is on.EFI control unit is connected. ( p. 227)The exhaust air injection valve is disconnected. ( p. 190)

400648-10 400658-10

Secondary air valve - check the power supply– Measure the voltage between the specified points.

Secondary air valve connector CK pin 1 – Measuring point Ground (−)




– Check connector CK pin 1.

– Check the cable from connector CK pin 1 to the next node in the wiring harness for opens.


– Check the next possible cause:Secondary air valve - the control wire has a short circuit to ground (terminal 31) ( p. 320)

Secondary air valve - the control wire has a short circuit to ground (terminal 31)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.The exhaust air injection valve is disconnected. ( p. 190)

400648-10 400658-10

Secondary air valve - check the control wire for a short circuit to ground (terminal 31)– Measure the resistance between the specified points.

Secondary air valve connector CK pin 2 – Measuring point Ground (−)

Resistance ∞ Ω


– Check the cable from EFI control unit connector CO ( p. 397) pin 13 to connector CK pin 2 for a short circuit to ground (ter-minal 31).


– Check the next possible cause:Secondary air valve - the control wire has a short circuit to sensor ground ( p. 321)

PartS

hark

.com

877-

999-

5686


Secondary air valve - the control wire has a short circuit to sensor groundConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.The exhaust air injection valve is disconnected. ( p. 190)

600850-12 600850-11

Secondary air valve - check the control wire for a short circuit to sensor ground.– Measure the resistance between the specified points.


Resistance ∞ Ω


– Check the cable from EFI control unit connector CO ( p. 397) pin 13 to connector CK ( p. 396) pin 2 for a short circuit tosensor ground.



PartS

hark

.com

877-

999-

5686




Display on diagnostic tool P0414"Secondary air valve ""Input signal too high"


Function check Checking the secondary air valve ( p. 322)

Possible cause Secondary air valve - value not plausible ( p. 322)

Secondary air valve - the signal wire has a short circuit to plus (terminal 30) ( p. 323)

Secondary air valve - the signal wire has a short circuit to ignition plus (terminal 15) ( p. 323)



Checking the secondary air valveConditionThe ignition is on.The diagnostic tool is connected and running.








– Select "Exhaust air injection valve SLS on/off".



Secondary air valve Operating noise






– Check the next possible cause:Secondary air valve - value not plausible ( p. 322)

Secondary air valve - value not plausibleConditionThe ignition is off.The exhaust air injection valve is disconnected. ( p. 190)

600854-10

Secondary air valve - check the resistance– Measure the resistance between the specified points.

Exhaust air injection valve, connector FE pin 1 – Exhaust air injection valve,connector FE pin 2

Secondary air valve

at: 20 °C (68 °F) 18.0… 22.0 Ω




– Check the next possible cause:Secondary air valve - the signal wire has a short circuit to plus (terminal 30)( p. 323)

PartS

hark

.com

877-

999-

5686


Secondary air valve - the signal wire has a short circuit to plus (terminal 30)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.The exhaust air injection valve is disconnected. ( p. 190)

600850-12 400658-10

Secondary air valve - check the signal wire for a short circuit to plus (terminal 30)– Measure the voltage between the specified points.


Voltage ≤ 0.1 V


– Check the cable from EFI control unit connector CO ( p. 397) pin 13 to connector CK ( p. 396) pin 2 for a short circuit toplus (terminal 30).


– Check the next possible cause:Secondary air valve - the signal wire has a short circuit to ignition plus (terminal 15) ( p. 323)

Secondary air valve - the signal wire has a short circuit to ignition plus (terminal 15)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.The exhaust air injection valve is disconnected. ( p. 190)

600850-12 600850-11

Secondary air valve - check the signal wire for a short circuit to ignition plus (terminal 15)– Measure the resistance between the specified points.


Resistance ∞ Ω


– Check the cable from EFI control unit connector CO ( p. 397) pin 13 to connector CK ( p. 396) pin 2 for a short circuit toignition plus (terminal 15).



PartS

hark

.com

877-

999-

5686




Display on diagnostic tool P0505"Circuit A of motor drive ""Circuit fault"


Function check Motor drive circuit A - checking the control ( p. 324)

Possible cause Motor drive circuit A phase A - value not plausible ( p. 325)

Motor drive circuit A phase B - value not plausible ( p. 325)

Motor drive circuit A phase A - the signal wire has an open ( p. 325)

Motor drive circuit A phase B - the signal wire has an open ( p. 326)

Motor drive circuit A phase A - the signal wire has a short circuit to ground (terminal 31)( p. 326)

Motor drive circuit A phase B - the signal wire has a short circuit to ground (terminal 31)( p. 327)

Motor drive circuit A phase A - the signal wire has a short circuit to sensor ground ( p. 328)

Motor drive circuit A phase B - the signal wire has a short circuit to sensor ground ( p. 328)

Motor drive circuit A phase A - the signal wire has a short circuit to plus (terminal 30) ( p. 329)

Motor drive circuit A phase B - the signal wire has a short circuit to plus (terminal 30) ( p. 329)

Motor drive circuit A phase A - the signal wire has a short circuit to ignition plus (terminal 15)( p. 330)

Motor drive circuit A phase B - the signal wire has a short circuit to ignition plus (terminal 15)( p. 330)



Motor drive circuit A - checking the controlConditionThe ignition is on.The diagnostic tool is connected and running.








– Select "motor drive circuit A".



Idle speed control Operating noise






– Check the next possible cause:Motor drive circuit A phase A - value not plausible ( p. 325)

PartS

hark

.com

877-

999-

5686


Motor drive circuit A phase A - value not plausibleConditionThe ignition is off.Connector CP is disconnected. ( p. 398)

400651-10

Motor drive circuit A phase A - check the resistance– Measure the resistance between the specified points.

Connector CP pin 2.12 – Connector CP pin 2.16

Motor drive circuit A

Phase A at: 20 °C (68 °F) 7.11… 8.68 Ω


– Check connector CP pin 2.12 and connector AE ( p. 391) pin 2.

– Check the connector from CP pin 2.12 to connector AE ( p. 391) pin 2 foropens.



– Disconnect connector CQ ( p. 398) from the throttle valve body. Check thecable from connector CP pin 2.12 to pin 2.16 for a mutual short circuit.

– Change the throttle valve body.


– Check the next possible cause:Motor drive circuit A phase B - value not plausible ( p. 325)

Motor drive circuit A phase B - value not plausibleConditionThe ignition is off.Connector CP is disconnected. ( p. 398)

400651-10

Motor drive circuit A phase B - check the resistance– Measure the resistance between the specified points.



Phase B at: 20 °C (68 °F) 7.11… 8.68 Ω






– Disconnect connector CQ ( p. 398) from the throttle valve body. Check thecable from connector CP pin 2.4 to pin 2.8 for a mutual short circuit.



– Check the next possible cause:Motor drive circuit A phase A - the signal wire has an open ( p. 325)

Motor drive circuit A phase A - the signal wire has an openConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Connector CP is connected. ( p. 398)

PartS

hark

.com

877-

999-

5686


600850-12

Motor drive circuit A phase A - check the signal wire for opens– Measure the resistance between the specified points.

Break out box CO pin 7 – Break out box CO pin 23


Phase A at: 20 °C (68 °F) 7.11… 8.68 Ω


– Check EFI control unit connector CO ( p. 397) pin 7 and connector CQ( p. 398) pin 12.

– Check the cable from EFI control unit connector CO ( p. 397) pin 7 to con-nector CQ ( p. 398) pin 12 for opens.



– Disconnect connector CQ ( p. 398) from the throttle valve body. Check thecable from EFI control unit connector CO ( p. 392) pin 7 to pin 23 for amutual short circuit.


– Check the next possible cause:Motor drive circuit A phase B - the signal wire has an open ( p. 326)

Motor drive circuit A phase B - the signal wire has an openConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Connector CP is connected. ( p. 398)

600850-12

Motor drive circuit A phase B - check the signal wire for opens– Measure the resistance between the specified points.



Phase B at: 20 °C (68 °F) 7.11… 8.68 Ω






– Disconnect connector CQ ( p. 398) from the throttle valve body. Check thecable from EFI control unit connector CO ( p. 397) pin 3 to pin 11 for amutual short circuit.


– Check the next possible cause:Motor drive circuit A phase A - the signal wire has a short circuit to ground (ter-minal 31) ( p. 326)

Motor drive circuit A phase A - the signal wire has a short circuit to ground (terminal 31)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.

PartS

hark

.com

877-

999-

5686


600850-12 400658-10

Motor drive circuit A phase A - check the signal wire for a short circuit to ground (terminal 31)– Measure the resistance between the specified points.


Resistance ∞ Ω



– Check the cable from connector CP ( p. 398) pin 2.16 to connector AE ( p. 391) pin 3 for a short circuit to ground (termi-nal 31).


– Check the cable from connector CP ( p. 398) pin 2.12 to connector AE ( p. 391) pin 2 for a short circuit to ground (termi-nal 31).


– Check the next possible cause:Motor drive circuit A phase B - the signal wire has a short circuit to ground (terminal 31) ( p. 327)

Motor drive circuit A phase B - the signal wire has a short circuit to ground (terminal 31)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.

600850-12 400658-10

Motor drive circuit A phase B - check the signal wire for a short circuit to ground (terminal 31)– Measure the resistance between the specified points.


Resistance ∞ Ω



– Check connector CP ( p. 398) pin 2.8 to connector AE ( p. 391) pin 1 for a short circuit to ground (terminal 31).


– Check connector CP ( p. 398) pin 2.4 to connector AE ( p. 391) pin 4 for a short circuit to ground (terminal 31).


– Check the next possible cause:Motor drive circuit A phase A - the signal wire has a short circuit to sensor ground ( p. 328)

PartS

hark

.com

877-

999-

5686


Motor drive circuit A phase A - the signal wire has a short circuit to sensor groundConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.

600850-12 600850-11

Motor drive circuit A phase A - check the signal wire for a short circuit to sensor ground– Measure the resistance between the specified points.


Resistance ∞ Ω



– Check the cable from connector CP ( p. 398) pin 2.16 to connector AE ( p. 391) pin 3 for a short circuit to sensor ground.


– Check the cable from connector CP ( p. 398) pin 2.12 to connector AE ( p. 391) pin 2 for a short circuit to sensor ground.


– Check the next possible cause:Motor drive circuit A phase B - the signal wire has a short circuit to sensor ground ( p. 328)

Motor drive circuit A phase B - the signal wire has a short circuit to sensor groundConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.

600850-12 600850-11

Motor drive circuit A phase B - check the signal wire for a short circuit to sensor ground– Measure the resistance between the specified points.


Resistance ∞ Ω



– Check connector CP ( p. 398) pin 2.8 to connector AE ( p. 391) pin 1 for a short circuit to sensor ground.


– Check connector CP ( p. 398) pin 2.4 to connector AE ( p. 391) pin 4 for a short circuit to sensor ground.

PartS

hark

.com

877-

999-

5686



– Check the next possible cause:Motor drive circuit A phase A - the signal wire has a short circuit to plus (terminal 30) ( p. 329)

Motor drive circuit A phase A - the signal wire has a short circuit to plus (terminal 30)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.

600850-12 400658-10

Motor drive circuit A phase A - check the signal wire for a short circuit to plus (terminal 30)– Measure the voltage between the specified points.


Voltage < 0.1 V



– Check the cable from connector CP ( p. 398) pin 2.16 to connector AE ( p. 391) pin 3 for a short circuit to plus (termi-nal 30).


– Check the cable from connector CP ( p. 398) pin 2.12 to connector AE ( p. 391) pin 2 for a short circuit to plus (termi-nal 30).


– Check the next possible cause:Motor drive circuit A phase B - the signal wire has a short circuit to plus (terminal 30) ( p. 329)

Motor drive circuit A phase B - the signal wire has a short circuit to plus (terminal 30)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.

600850-12 400658-10

Motor drive circuit A phase B - check the signal wire for a short circuit to plus (terminal 30)– Measure the voltage between the specified points.


Voltage < 0.1 V



PartS

hark

.com

877-

999-

5686


– Check connector CP ( p. 398) pin 2.8 to connector AE ( p. 391) pin 1 for a short circuit to plus (terminal 30).


– Check connector CP ( p. 398) pin 2.4 to connector AE ( p. 391) pin 4 for a short circuit to plus (terminal 30).


– Check the next possible cause:Motor drive circuit A phase A - the signal wire has a short circuit to ignition plus (terminal 15) ( p. 330)

Motor drive circuit A phase A - the signal wire has a short circuit to ignition plus (terminal 15)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.

600850-12 600850-11

Motor drive circuit A phase A - check the signal wire for a short circuit to ignition plus (terminal 15)– Measure the resistance between the specified points.


Resistance ∞ Ω



– Check the cable from connector CP ( p. 398) pin 2.16 to connector AE ( p. 391) pin 3 for a short circuit to ignition plus(terminal 15).


– Check the cable from connector CP ( p. 398) pin 2.12 to connector AE ( p. 391) pin 2 for a short circuit to ignition plus(terminal 15).


– Check the next possible cause:Motor drive circuit A phase B - the signal wire has a short circuit to ignition plus (terminal 15) ( p. 330)

Motor drive circuit A phase B - the signal wire has a short circuit to ignition plus (terminal 15)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.

600850-12 600850-11

Motor drive circuit A phase B - check the signal wire for a short circuit to ignition plus (terminal 15)– Measure the resistance between the specified points.


Resistance ∞ Ω

PartS

hark

.com

877-

999-

5686




– Check connector CP ( p. 398) pin 2.8 to connector AE ( p. 391) pin 1 for a short circuit to ignition plus (terminal 15).


– Check connector CP ( p. 398) pin 2.4 to connector AE ( p. 391) pin 4 for a short circuit to ignition plus (terminal 15).



PartS

hark

.com

877-

999-

5686




Display on diagnostic tool P0560"Power supply""Circuit fault"

Error level condition EFI control unit power supply: ≤ 0.977 VTime: ≥ 3 sEFI control unit power supply: ≤ 4.980 VTime: ≥ 3 s

Function check EFI control unit - checking the power supply ( p. 332)

Possible cause EFI control unit - the power supply is faulty ( p. 332)

EFI control unit - the ground wire (I) has an open ( p. 333)

EFI control unit - the ground wire (II) has an open ( p. 333)


– Change the ambient air pressure sensor.

EFI control unit - checking the power supplyConditionThe ignition is on.The diagnostic tool is connected and running.The engine is switched off.








– Highlight "Battery voltage (VBAT)" and deselect the other parameters with "Select live data".







– Check the next possible cause:EFI control unit - the power supply is faulty ( p. 332)

EFI control unit - the power supply is faultyConditionThe ignition is on.The break out box is connected to the EFI control unit and the wiring harness.

600850-11 400658-10

EFI control unit - check the power supply– Measure the voltage between the specified points.


PartS

hark

.com

877-

999-

5686





– Check connector AO ( p. 392) pin 20.

– Check the cable from connector AO ( p. 392) pin 20 to the next node in the wiring harness for opens.


– Check the next possible cause:EFI control unit - the ground wire (I) has an open ( p. 333)

EFI control unit - the ground wire (I) has an openConditionThe ignition is on.The break out box is connected to the EFI control unit and the wiring harness.

600850-12 400658-10

EFI control unit - the ground wire (I) has an open– Measure the voltage between the specified points.

Break out box CO pin 8 – Measuring point Plus (+)




– Check connector CO ( p. 397) pin 8.

– Check the cable from connector CO ( p. 397) pin 8 to the next node in the wiring harness for opens.


– Check the next possible cause:EFI control unit - the ground wire (II) has an open ( p. 333)

EFI control unit - the ground wire (II) has an openConditionThe ignition is on.The break out box is connected to the EFI control unit and the wiring harness.

600850-12 400658-10

EFI control unit - the ground wire (II) has an open– Measure the voltage between the specified points.

Break out box CO pin 9 – Measuring point Plus (+)

PartS

hark

.com

877-

999-

5686





– Check connector CO ( p. 397) pin 9.

– Check the cable from connector CO ( p. 397) pin 9 to the next node in the wiring harness for opens.



PartS

hark

.com

877-

999-

5686




Display on diagnostic tool P0603"E²PROM""Fault"

Error level condition Read data and write data differ.

Function check Flashing the EFI control unit ( p. 335)


– Change the EFI control unit.

Flashing the EFI control unitConditionThe ignition is on.The diagnostic tool is connected and running.

400687-60





– Select "ECU Flashing".



– Read the safety information and set up the required conditions.

– Confirm the instruction by clicking on "OK".

– Press "Select file" and select the new mapping.

Info"The BLZ file and the exhaust system must match!"

– Press the "ECU flash process" button.

– Read the safety notice and confirm with "OK".

The new mapping is loaded.

Last measure if none of the documented causes leads to elimination of the fault– Change the EFI control unit.

PartS

hark

.com

877-

999-

5686



50 EFI warning lamp (MIL) flashes 5x long

Display on diagnostic tool P0638"Throttle position sensor actuator circuit B""Circuit fault"

Error level condition Difference between calculated "2nd throttle target angle (STHTRG)" and actual "2nd throttle currentangle (2ndTHAngle)"Intake air temperature sensor "TA": > 1 °C (> 34 °F)≥ 25.5 s

Difference between calculated "2nd throttle target angle (STHTRG)" and actual "2nd throttle currentangle (2ndTHAngle)"Intake air temperature sensor "TA": ≤ 1 °C (≤ 34 °F)Engine coolant temperature sensor "TW": > 1 °C (> 34 °F)≥ 25.5 s

Function check Checking circuit B of the motor drive ( p. 336)

Possible cause Motor drive circuit B phase A - value not plausible ( p. 337)

Motor drive circuit B phase B - value not plausible ( p. 337)

Motor drive circuit B phase A - the signal wire has an open ( p. 338)

Motor drive circuit B phase B - the signal wire has an open ( p. 338)

Motor drive circuit B phase A - the signal wire has a short circuit to ground (terminal 31)( p. 339)

Motor drive circuit B phase B - the signal wire has a short circuit to ground (terminal 31)( p. 339)

Motor drive circuit B phase A - the signal wire has a short circuit to sensor ground ( p. 340)

Motor drive circuit B phase B - the signal wire has a short circuit to sensor ground ( p. 340)

Motor drive circuit B phase A - the signal wire has a short circuit to plus (terminal 30) ( p. 341)

Motor drive circuit B phase B - the signal wire has a short circuit to plus (terminal 30) ( p. 341)

Motor drive circuit B phase A - the signal wire has a short circuit to ignition plus (terminal 15)( p. 342)

Motor drive circuit B phase B - the signal wire has a short circuit to ignition plus (terminal 15)( p. 342)



Checking circuit B of the motor driveConditionThe ignition is on.The diagnostic tool is connected and running.








– Select "Motor drive circuit B".








PartS

hark

.com

877-

999-

5686




– Check the next possible cause:Motor drive circuit B phase A - value not plausible ( p. 337)

Motor drive circuit B phase A - value not plausibleConditionThe ignition is off.Connector CP is disconnected. ( p. 398)

400651-10

Motor drive circuit B phase A - check the resistance– Measure the resistance between the specified points.


Motor drive circuit B

Phase A at: 20 °C (68 °F) 5.85… 7.15 Ω


– Check connector CP pin 2.15 and connector CA ( p. 395) pin 1.

– Check the connector from CP pin 2.15 to connector CA ( p. 395) pin 1 foropens.



– Disconnect connector CA ( p. 395) from motor drive circuit B. Check thecable from connector CP pin 2.15 to pin 2.11 for a mutual short circuit.



– Check the next possible cause:Motor drive circuit B phase B - value not plausible ( p. 337)

Motor drive circuit B phase B - value not plausibleConditionThe ignition is off.Connector CP is disconnected. ( p. 398)

400651-10

Motor drive circuit B phase B - check the resistance– Measure the resistance between the specified points.



Phase B at: 20 °C (68 °F) 5.85… 7.15 Ω






– Disconnect connector CA ( p. 395) from motor drive circuit B. Check thecable from connector CP pin 2.3 to pin 2.7 for a mutual short circuit.



– Check the next possible cause:Motor drive circuit B phase A - the signal wire has an open ( p. 338)

PartS

hark

.com

877-

999-

5686


Motor drive circuit B phase A - the signal wire has an openConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Connector CP is connected. ( p. 398)

600850-12

Motor drive circuit B phase A - check the signal wire for opens– Measure the resistance between the specified points.



Phase A at: 20 °C (68 °F) 5.85… 7.15 Ω






– Disconnect connector CQ ( p. 398) from motor drive circuit B. Check thecable from EFI control unit connector CO ( p. 392) pin 21 to pin 22 for amutual short circuit.


– Check the next possible cause:Motor drive circuit B phase B - the signal wire has an open ( p. 338)

Motor drive circuit B phase B - the signal wire has an openConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Connector CP is connected. ( p. 398)

600850-12

Motor drive circuit B phase B - check the signal wire for opens– Measure the resistance between the specified points.



Phase B at: 20 °C (68 °F) 5.85… 7.15 Ω






– Disconnect connector CQ ( p. 398) from motor drive circuit B. Check thecable from EFI control unit connector CO ( p. 392) pin 4 to pin 12 for amutual short circuit.


– Check the next possible cause:Motor drive circuit B phase A - the signal wire has a short circuit to ground (ter-minal 31) ( p. 339)

PartS

hark

.com

877-

999-

5686


Motor drive circuit B phase A - the signal wire has a short circuit to ground (terminal 31)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.

600850-12 400658-10

Motor drive circuit B phase A - check the signal wire for a short circuit to ground (terminal 31)– Measure the resistance between the specified points.


Resistance ∞ Ω



– Check connector CP ( p. 398) pin 2.11 to connector CA ( p. 395) pin 3 for a short circuit to ground (terminal 31).




– Check the next possible cause:Motor drive circuit B phase B - the signal wire has a short circuit to ground (terminal 31) ( p. 339)

Motor drive circuit B phase B - the signal wire has a short circuit to ground (terminal 31)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.

600850-12 400658-10

Motor drive circuit B phase B - check the signal wire for a short circuit to ground (terminal 31)– Measure the resistance between the specified points.


Resistance ∞ Ω






PartS

hark

.com

877-

999-

5686



– Check the next possible cause:Motor drive circuit B phase A - the signal wire has a short circuit to sensor ground ( p. 340)

Motor drive circuit B phase A - the signal wire has a short circuit to sensor groundConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.

600850-12 600850-11

Motor drive circuit B phase A - check the signal wire for a short circuit to sensor ground– Measure the resistance between the specified points.


Resistance ∞ Ω



– Check connector CP ( p. 398) pin 2.11 to connector CA ( p. 395) pin 3 for a short circuit to sensor ground.




– Check the next possible cause:Motor drive circuit B phase B - the signal wire has a short circuit to sensor ground ( p. 340)

Motor drive circuit B phase B - the signal wire has a short circuit to sensor groundConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.

600850-12 600850-11

Motor drive circuit B phase B - check the signal wire for a short circuit to sensor ground– Measure the resistance between the specified points.


Resistance ∞ Ω




PartS

hark

.com

877-

999-

5686





– Check the next possible cause:Motor drive circuit B phase A - the signal wire has a short circuit to plus (terminal 30) ( p. 341)

Motor drive circuit B phase A - the signal wire has a short circuit to plus (terminal 30)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.

600850-12 400658-10

Motor drive circuit B phase A - check the signal wire for a short circuit to plus (terminal 30)– Measure the voltage between the specified points.


Voltage < 0.1 V



– Check connector CP ( p. 398) pin 2.11 to connector CA ( p. 395) pin 3 for a short circuit to plus (terminal 30).




– Check the next possible cause:Motor drive circuit B phase B - the signal wire has a short circuit to plus (terminal 30) ( p. 341)

Motor drive circuit B phase B - the signal wire has a short circuit to plus (terminal 30)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.

600850-12 400658-10

Motor drive circuit B phase B - check the signal wire for a short circuit to plus (terminal 30)– Measure the voltage between the specified points.


Voltage < 0.1 V


PartS

hark

.com

877-

999-

5686







– Check the next possible cause:Motor drive circuit B phase A - the signal wire has a short circuit to ignition plus (terminal 15) ( p. 342)

Motor drive circuit B phase A - the signal wire has a short circuit to ignition plus (terminal 15)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.

600850-12 600850-11

Motor drive circuit B phase A - check the signal wire for a short circuit to ignition plus (terminal 15)– Measure the resistance between the specified points.


Resistance ∞ Ω



– Check connector CP ( p. 398) pin 2.11 to connector CA ( p. 395) pin 3 for a short circuit to ignition plus (terminal 15).




– Check the next possible cause:Motor drive circuit B phase B - the signal wire has a short circuit to ignition plus (terminal 15) ( p. 342)

Motor drive circuit B phase B - the signal wire has a short circuit to ignition plus (terminal 15)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.

600850-12 600850-11

Motor drive circuit B phase B - check the signal wire for a short circuit to ignition plus (terminal 15)– Measure the resistance between the specified points.


Resistance ∞ Ω

PartS

hark

.com

877-

999-

5686









PartS

hark

.com

877-

999-

5686




Display on diagnostic tool P1105"Manifold absolute pressure sensor cylinder 1""Connection leaks"

Error level condition The ambient air pressure is greater than the pressure at the manifold absolute pressure sensorcylinder 1Time: ≥ 3 sSubstitute value: 700 mbar (10.15 psi)


Possible cause Manifold absolute pressure sensor cylinder 1 - the vacuum hose to the cylinder head is faulty( p. 345)

Manifold absolute pressure sensor cylinder 1 - the vacuum connection at the cylinder head isfaulty ( p. 345)




– Connect the vacuum hand pump to the manifold absolute pressure sensor. ( p. 224)

– Create a vacuum with the vacuum pump.










at: 350 mbar (5.08 psi) 1.62… 1.68 V

at: 400 mbar (5.8 psi) 1.77… 1.83 V

at: 450 mbar (6.53 psi) 1.92… 1.98 V

at: 800 mbar (11.6 psi) 2.97… 3.03 V

at: 850 mbar (12.33 psi) 3.12… 3.18 V

at: 900 mbar (13.05 psi) 3.27… 3.33 V

at: 950 mbar (13.78 psi) 3.42… 3.48 V

at: 1,000 mbar (14.5 psi) 3.57… 3.63 V

at: 1,050 mbar (15.23 psi) 3.72… 3.78 V






– Check the next possible cause:Manifold absolute pressure sensor cylinder 1 - the vacuum hose to the cylinder head is faulty ( p. 345)

PartS

hark

.com

877-

999-

5686


Manifold absolute pressure sensor cylinder 1 - the vacuum hose to the cylinder head is faulty– Manifold absolute pressure sensor cylinder 1 - check the vacuum hose to the cylinder head for leaks.

Vacuum hose Is OK.


– Change the vacuum hose to the cylinder head.


– Check the next possible cause:Manifold absolute pressure sensor cylinder 1 - the vacuum connection at the cylinder head is faulty ( p. 345)

Manifold absolute pressure sensor cylinder 1 - the vacuum connection at the cylinder head is faulty– Manifold absolute pressure sensor cylinder 1 - check the vacuum connection at the cylinder head.

Vacuum connection Is OK.


– Change the vacuum connection at the cylinder head.



PartS

hark

.com

877-

999-

5686




Display on diagnostic tool P1106"Manifold absolute pressure sensor cylinder 2""Connection leaks"

Error level condition The ambient air pressure is greater than the pressure at the manifold absolute pressure sensorcylinder 2Time: ≥ 3 sSubstitute value: 700 mbar (10.15 psi)


Possible cause Manifold absolute pressure sensor cylinder 2 - the vacuum hose to the cylinder head is faulty( p. 347)

Manifold absolute pressure sensor cylinder 2 - the vacuum connection at the cylinder head isfaulty ( p. 347)


– Change the manifold absolute pressure sensor cylinder 2.


– Connect the vacuum hand pump to the manifold absolute pressure sensor. ( p. 224)

– Create a vacuum with the vacuum pump.










at: 350 mbar (5.08 psi) 1.62… 1.68 V

at: 400 mbar (5.8 psi) 1.77… 1.83 V

at: 450 mbar (6.53 psi) 1.92… 1.98 V

at: 800 mbar (11.6 psi) 2.97… 3.03 V

at: 850 mbar (12.33 psi) 3.12… 3.18 V

at: 900 mbar (13.05 psi) 3.27… 3.33 V

at: 950 mbar (13.78 psi) 3.42… 3.48 V

at: 1,000 mbar (14.5 psi) 3.57… 3.63 V

at: 1,050 mbar (15.23 psi) 3.72… 3.78 V






– Check the next possible cause:Manifold absolute pressure sensor cylinder 2 - the vacuum hose to the cylinder head is faulty ( p. 347)

PartS

hark

.com

877-

999-

5686


Manifold absolute pressure sensor cylinder 2 - the vacuum hose to the cylinder head is faulty– Manifold absolute pressure sensor cylinder 2 - check the vacuum hose to the cylinder head for leaks.

Vacuum hose Is OK.


– Change the vacuum hose to the cylinder head.


– Check the next possible cause:Manifold absolute pressure sensor cylinder 2 - the vacuum connection at the cylinder head is faulty ( p. 347)

Manifold absolute pressure sensor cylinder 2 - the vacuum connection at the cylinder head is faulty– Manifold absolute pressure sensor cylinder 2 - check the vacuum connection at the cylinder head.

Vacuum connection Is OK.


– Change the vacuum connection at the cylinder head.



PartS

hark

.com

877-

999-

5686




Display on diagnostic tool P1107"Ambient air pressure sensor ""Input signal too low"

Error level condition Ambient air pressure sensor voltage "PAAD": ≤ 0.508 VTime: ≥ 3 sSubstitute value: 970 mbar (14.07 psi)

Function check Ambient air pressure sensor - checking the voltage ( p. 348)

Possible cause Ambient air pressure sensor - the signal wire has a short circuit to sensor ground ( p. 348)

Ambient air pressure sensor - the signal wire has a short circuit to ground (terminal 31)( p. 349)

Ambient air pressure sensor - the power supply is interrupted ( p. 349)



Ambient air pressure sensor - checking the voltageConditionThe ignition is on.The diagnostic tool is connected and running.The engine is switched off.








– Highlight "Ambient air pressure sensor voltage (PAAD)" and deselect the other parameters with "Select live data".


at: 800 mbar (11.6 psi) 2.97… 3.03 V

at: 850 mbar (12.33 psi) 3.12… 3.18 V

at: 900 mbar (13.05 psi) 3.27… 3.33 V

at: 950 mbar (13.78 psi) 3.42… 3.48 V

at: 1,000 mbar (14.5 psi) 3.57… 3.63 V

at: 1,050 mbar (15.23 psi) 3.72… 3.78 V






– Check the next possible cause:Ambient air pressure sensor - the signal wire has a short circuit to sensor ground ( p. 348)

Ambient air pressure sensor - the signal wire has a short circuit to sensor groundConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The ambient air pressure sensor is disconnected. ( p. 225)

PartS

hark

.com

877-

999-

5686


400590-10

Ambient air pressure sensor - check the signal wire for a short circuit to sensor ground– Measure the resistance between the specified points.

Ambient air pressure sensor connector DP pin 2 – Ambient air pressure sen-sor connector DP pin 3

Resistance ∞ Ω




– Check the next possible cause:Ambient air pressure sensor - the signal wire has a short circuit to ground (ter-minal 31) ( p. 349)

Ambient air pressure sensor - the signal wire has a short circuit to ground (terminal 31)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The ambient air pressure sensor is disconnected. ( p. 225)

400590-10 400658-10

Ambient air pressure sensor - check the signal wire for a short circuit to ground (terminal 31)– Measure the resistance between the specified points.

Ambient air pressure sensor connector DP pin 3 – Measuring point Ground (−)

Resistance ∞ Ω




– Check the next possible cause:Ambient air pressure sensor - the power supply is interrupted ( p. 349)

Ambient air pressure sensor - the power supply is interruptedConditionThe ignition is on.EFI control unit is connected. ( p. 227)The ambient air pressure sensor is disconnected. ( p. 225)

400590-10 400658-10

Ambient air pressure sensor - check the power supply– Measure the voltage between the specified points.

Ambient air pressure sensor connector DP pin 1 – Measuring point Ground (−)


PartS

hark

.com

877-

999-

5686







PartS

hark

.com

877-

999-

5686




Display on diagnostic tool P1108"Ambient air pressure sensor ""Input signal too high"

Error level condition Ambient air pressure sensor voltage "PAAD": ≥ 4.961 VTime: ≥ 3 sSubstitute value: 970 mbar (14.07 psi)

Function check Ambient air pressure sensor - checking the voltage ( p. 351)

Possible cause Ambient air pressure sensor - the signal wire has an open ( p. 352)

Ambient air pressure sensor - the ground wire has an open ( p. 352)

Ambient air pressure sensor - the signal wire has a short circuit to plus (terminal 30) ( p. 353)

Ambient air pressure sensor - the signal wire has a short circuit to ignition plus (terminal 15)( p. 353)

Ambient air pressure sensor - the signal wire has a short circuit to the sensor power supply( p. 353)



Ambient air pressure sensor - checking the voltageConditionThe ignition is on.The diagnostic tool is connected and running.The engine is switched off.








– Highlight "Ambient air pressure sensor voltage (PAAD)" and deselect the other parameters with "Select live data".


at: 800 mbar (11.6 psi) 2.97… 3.03 V

at: 850 mbar (12.33 psi) 3.12… 3.18 V

at: 900 mbar (13.05 psi) 3.27… 3.33 V

at: 950 mbar (13.78 psi) 3.42… 3.48 V

at: 1,000 mbar (14.5 psi) 3.57… 3.63 V

at: 1,050 mbar (15.23 psi) 3.72… 3.78 V






– Check the next possible cause:Ambient air pressure sensor - the signal wire has an open ( p. 352)

PartS

hark

.com

877-

999-

5686


Ambient air pressure sensor - the signal wire has an openConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.The ambient air pressure sensor is disconnected. ( p. 225)

600850-11 400590-10

Ambient air pressure sensor - check the signal wire for opens– Measure the resistance between the specified points.

Break Out Box AO pin 23 – Ambient air pressure sensor connector DP pin 3






– Check the next possible cause:Ambient air pressure sensor - the ground wire has an open ( p. 352)

Ambient air pressure sensor - the ground wire has an openConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.The ambient air pressure sensor is disconnected. ( p. 225)

600850-11 400590-10

Ambient air pressure sensor - check the ground wire for opens– Measure the resistance between the specified points.

Break Out Box AO pin 7 – Ambient air pressure sensor connector DP pin 2






– Check the next possible cause:Ambient air pressure sensor - the signal wire has a short circuit to plus (terminal 30) ( p. 353)

PartS

hark

.com

877-

999-

5686


Ambient air pressure sensor - the signal wire has a short circuit to plus (terminal 30)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.The ambient air pressure sensor is disconnected. ( p. 225)

600850-11 400658-10

Ambient air pressure sensor - check the signal wire for a short circuit to plus (terminal 30)– Measure the voltage between the specified points.


Voltage < 0.1 V




– Check the next possible cause:Ambient air pressure sensor - the signal wire has a short circuit to ignition plus (terminal 15) ( p. 353)

Ambient air pressure sensor - the signal wire has a short circuit to ignition plus (terminal 15)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.The ambient air pressure sensor is disconnected. ( p. 225)

600850-11

Ambient air pressure sensor - check the signal wire for a short circuit to ignition plus(terminal 15)– Measure the resistance between the specified points.


Resistance ∞ Ω




– Check the next possible cause:Ambient air pressure sensor - the signal wire has a short circuit to the sensorpower supply ( p. 353)

Ambient air pressure sensor - the signal wire has a short circuit to the sensor power supplyConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Manifold absolute pressure sensor cylinder 1 is disconnected. ( p. 223)

PartS

hark

.com

877-

999-

5686


600850-11

Ambient air pressure sensor - check the signal wire for a short circuit to the sensor powersupply– Measure the resistance between the specified points.


Resistance ∞ Ω





PartS

hark

.com

877-

999-

5686




Display on diagnostic tool P1231"Fuel pump relay""Short circuit to ground or open circuit"

Error level condition Circuit fault.The engine is switched off: ≥ 3 s

Function check Checking the fuel pump relay ( p. 355)

Possible cause Fuel pump relay - value not plausible ( p. 355)

Fuel pump relay - the control wire has an open ( p. 356)

Fuel pump relay - there is an open in the power supply ( p. 356)

Fuel pump relay - the control wire has a short circuit to ground (terminal 31) ( p. 357)

Fuel pump relay - the control wire has a short circuit to sensor ground ( p. 357)



Checking the fuel pump relayConditionThe ignition is on.The diagnostic tool is connected and running.








– Select "Fuel pump relay function test".



Fuel pump Operating noise






– Check the next possible cause:Fuel pump relay - value not plausible ( p. 355)

Fuel pump relay - value not plausibleConditionThe ignition is off.The fuel pump relay is disconnected. ( p. 404)

600852-10

Fuel pump relay - check the resistance– Measure the resistance between the specified points.

Fuel pump relay pin 1 – Fuel pump relay pin 2

Fuel pump relay



– Replace the fuel pump relay.


PartS

hark

.com

877-

999-

5686


– Check the next possible cause:Fuel pump relay - the control wire has an open ( p. 356)

Fuel pump relay - the control wire has an openConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.The fuel pump relay is disconnected. ( p. 404)

600850-12 400653-10

Fuel pump relay - check the control wire for opens– Measure the resistance between the specified points.

Break out box CO pin 2 – Fuel pump relay connector EB pin 2



– Check EFI control unit connector CO ( p. 397) pin 2 and connector ES ( p. 402) pin 15.

– Check the cable from EFI control unit connector CO ( p. 397) pin 2 to connector ES ( p. 402) pin 15 for opens.

– Check connector ET ( p. 402) pin 15 and connector EB ( p. 401) pin 2.

– Check the cable from connector ET ( p. 402) pin 15 to connector EB ( p. 401) pin 2 for opens.


– Check the next possible cause:Fuel pump relay - there is an open in the power supply ( p. 356)

Fuel pump relay - there is an open in the power supplyConditionThe ignition is on.EFI control unit is connected. ( p. 227)The fuel pump relay is disconnected. ( p. 404)

400653-10 400658-10

Fuel pump relay - check the power supply– Measure the voltage between the specified points.

Fuel pump relay connector EB pin 1 – Measuring point Ground (−)

InfoEstablish a protected connection from battery ground to break out box EB pin 1.For measurement the measuring points must be subjected to a 12V/21W bulb load.



– Check connector EB pin 1.

PartS

hark

.com

877-

999-

5686


– Check the cable from connector EB pin 1 to the next node in the wiring harness for opens.


– Check the next possible cause:Fuel pump relay - the control wire has a short circuit to ground (terminal 31) ( p. 357)

Fuel pump relay - the control wire has a short circuit to ground (terminal 31)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.The fuel pump relay is disconnected. ( p. 404)

600850-12 400658-10

Fuel pump relay - check the control wire for a short circuit to ground (terminal 31)– Measure the resistance between the specified points.


Resistance ∞ Ω


– Check the cable from EFI control unit connector CO ( p. 397) pin 2 to connector ES ( p. 402) pin 15 for a short circuit toground (terminal 31).

– Check the cable from connector ET ( p. 402) pin 15 to connector EB ( p. 401) pin 2 for a short circuit to ground (termi-nal 31).


– Check the next possible cause:Fuel pump relay - the control wire has a short circuit to sensor ground ( p. 357)

Fuel pump relay - the control wire has a short circuit to sensor groundConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.The fuel pump relay is disconnected. ( p. 404)

600850-12 600850-11

Fuel pump relay - check the control wire for a short circuit to sensor ground.– Measure the resistance between the specified points.


Resistance ∞ Ω


– Check the cable from EFI control unit connector CO ( p. 397) pin 2 to connector ES ( p. 402) pin 15 for a short circuit tosensor ground.

PartS

hark

.com

877-

999-

5686


– Check the cable from connector ET ( p. 402) pin 15 to connector EB ( p. 401) pin 2 for a short circuit to sensor ground.



PartS

hark

.com

877-

999-

5686




Display on diagnostic tool P1232"Fuel pump relay""Short circuit to plus"

Error level condition Circuit fault.The engine is switched off: ≥ 3 s

Function check Checking the fuel pump relay ( p. 359)

Possible cause Fuel pump relay - value not plausible ( p. 359)

Fuel pump relay - the control wire has a short circuit to plus (terminal 30) ( p. 360)

Fuel pump relay - the signal wire has a short circuit to ignition plus (terminal 15) ( p. 360)



Checking the fuel pump relayConditionThe ignition is on.The diagnostic tool is connected and running.








– Select "Fuel pump relay function test".



Fuel pump Operating noise






– Check the next possible cause:Fuel pump relay - value not plausible ( p. 359)

Fuel pump relay - value not plausibleConditionThe ignition is off.The fuel pump relay is disconnected. ( p. 404)

600852-10

Fuel pump relay - check the resistance– Measure the resistance between the specified points.

Fuel pump relay pin 1 – Fuel pump relay pin 2

Fuel pump relay



– Replace the fuel pump relay.


– Check the next possible cause:Fuel pump relay - the control wire has a short circuit to plus (terminal 30)( p. 360)

PartS

hark

.com

877-

999-

5686


Fuel pump relay - the control wire has a short circuit to plus (terminal 30)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.The fuel pump relay is disconnected. ( p. 404)

600850-12 400658-10

Fuel pump relay - check the control wire for a short circuit to plus (terminal 30)– Measure the voltage between the specified points.


Voltage ≤ 0.1 V


– Check the cable from EFI control unit connector CO ( p. 397) pin 2 to connector ES ( p. 402) pin 15 for a short circuit toplus (terminal 30).

– Check the cable from connector ET ( p. 402) pin 15 to connector EB ( p. 401) pin 2 for a short circuit to plus(terminal 30).


– Check the next possible cause:Fuel pump relay - the signal wire has a short circuit to ignition plus (terminal 15) ( p. 360)

Fuel pump relay - the signal wire has a short circuit to ignition plus (terminal 15)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.The fuel pump relay is disconnected. ( p. 404)

600850-12 600850-11

Fuel pump relay - check the signal wire for a short circuit to ignition plus (terminal 15)– Measure the resistance between the specified points.


Resistance ∞ Ω


– Check the cable from EFI control unit connector CO ( p. 397) pin 2 to connector ES ( p. 402) pin 15 for a short circuit toignition plus (terminal 15).

– Check the cable from connector ET ( p. 402) pin 15 to connector EB ( p. 401) pin 2 for a short circuit to ignition plus (ter-minal 15).



PartS

hark

.com

877-

999-

5686




Display on diagnostic tool P1590"Side stand switch (A/D type)""Circuit fault"

Error level condition Fault present: ≥ 3.2 sSide stand switch voltage: ≤ 0.996 V

Function check Checking the side stand switch ( p. 361)

Possible cause Side stand switch - the signal wire has a short circuit to sensor ground ( p. 361)

Side stand switch - the signal wire has a short circuit to ground (terminal 31) ( p. 362)



Checking the side stand switchConditionThe ignition is on.The diagnostic tool is connected and running.








– Highlight "Side stand switch (SSTAND AD)" and deselect the other parameters with "Select live data".

Side stand voltage "Side stand AD"

Retracted 1.5… 3.2 V

Extended 4.0… 5.0 V






– Check the next possible cause:Side stand switch - the signal wire has a short circuit to sensor ground ( p. 361)

Side stand switch - the signal wire has a short circuit to sensor groundConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.The electric starter lock control unit connector is disconnected. ( p. 88)The side stand switch is disconnected. ( p. 40)

400584-10

Side stand switch - check the signal wire for a short circuit to sensor ground– Measure the resistance between the specified points.

Side stand switch, connector AR pin 2 – Side stand switch, connector ARpin 3

Resistance ∞ Ω


– Check the cable from EFI control unit connector AO ( p. 392) pin 26 to con-nector AR pin 3 for a short circuit to sensor ground.


PartS

hark

.com

877-

999-

5686


– Check the next possible cause:Side stand switch - the signal wire has a short circuit to ground (terminal 31)( p. 362)

Side stand switch - the signal wire has a short circuit to ground (terminal 31)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.The electric starter lock control unit connector is disconnected. ( p. 88)The side stand switch is disconnected. ( p. 40)

400584-10 400658-10

Side stand switch - check the signal wire for a short circuit to ground (terminal 31)– Measure the resistance between the specified points.

Side stand switch, connector AR pin 3 – Measuring point Ground (−)

Resistance ∞ Ω


– Check the cable from EFI control unit connector AO ( p. 392) pin 26 to connector AR pin 3 for a short circuit to ground (ter-minal 31).



PartS

hark

.com

877-

999-

5686




Display on diagnostic tool P1631"Rollover sensor (A/D type)""Input signal too low"

Error level condition Signal voltage "rollover sensor (A/D type)": ≤ 0.352 VTime: ≥ 3 s

Function check Checking the rollover sensor ( p. 363)

Possible cause Rollover sensor - there is an open in the power supply ( p. 363)

Rollover sensor - the signal wire has a short circuit to ground (terminal 31) ( p. 364)

Rollover sensor - the signal wire has a short circuit to sensor ground ( p. 364)



Checking the rollover sensorConditionThe ignition is on.The diagnostic tool is connected and running.








– Highlight "Rollover sensor (A/D type)" and deselect the other parameters with "Select live data".

Rollover sensor

Voltage (Rollover AD) "no fall detected" 0.4… 1.4 V

Voltage (Rollover AD) "fall detected" 3.7… 4.1 V






– Check the next possible cause:Rollover sensor - there is an open in the power supply ( p. 363)

Rollover sensor - there is an open in the power supplyConditionThe ignition is on.The diagnostics tool is connected and active.EFI control unit is connected. ( p. 227)The rollover sensor is disconnected. ( p. 226)

PartS

hark

.com

877-

999-

5686


400583-10 400658-10

Rollover sensor - check if there is an open in the power supply– Measure the voltage between the specified points.

Rollover sensor connector AP pin 6 – Measuring point Ground (−)



– Check connector AP pin 6.

– Check the cable from connector AP pin 6 to the next node in the wiring harness for opens.


– Check the next possible cause:Rollover sensor - the signal wire has a short circuit to ground (terminal 31) ( p. 364)

Rollover sensor - the signal wire has a short circuit to ground (terminal 31)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.The rollover sensor is disconnected. ( p. 226)

600850-11 400658-10

Rollover sensor - check the signal wire for a short circuit to ground (terminal 31)– Measure the resistance between the specified points.


Resistance ∞ Ω


– Check the cable from EFI control unit connector AO ( p. 392) pin 4 to connector AP ( p. 393) pin 5 for a short circuit toground (terminal 31).


– Check the next possible cause:Rollover sensor - the signal wire has a short circuit to sensor ground ( p. 364)

Rollover sensor - the signal wire has a short circuit to sensor groundConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.The rollover sensor is disconnected. ( p. 226)

PartS

hark

.com

877-

999-

5686


600850-11

Rollover sensor - check the signal wire for a short circuit to sensor ground– Measure the resistance between the specified points.


Resistance ∞ Ω


– Check the cable from EFI control unit connector AO ( p. 392) pin 4 to con-nector AP ( p. 393) pin 5 for a short circuit to sensor ground.



PartS

hark

.com

877-

999-

5686




Display on diagnostic tool P1632"Rollover sensor (A/D type)""Input signal too high"

Error level condition Signal voltage "rollover sensor (A/D type)": 1.992… 3.008 VTime: ≥ 25.5 sSignal voltage "rollover sensor (A/D type)": ≥ 4.805 VTime: ≥ 25.5 s

Function check Checking the rollover sensor ( p. 366)

Possible cause Rollover sensor - the signal wire has a short circuit to plus (terminal 30) ( p. 366)

Rollover sensor - the signal wire has a short circuit to ignition plus (terminal 15) ( p. 367)

Rollover sensor - the signal wire has a short circuit to the sensor power supply ( p. 367)

Rollover sensor - the signal wire has an open ( p. 368)

Rollover sensor - the ground wire has an open ( p. 368)



Checking the rollover sensorConditionThe ignition is on.The diagnostic tool is connected and running.








– Highlight "Rollover sensor (A/D type)" and deselect the other parameters with "Select live data".

Rollover sensor

Voltage (Rollover AD) "no fall detected" 0.4… 1.4 V

Voltage (Rollover AD) "fall detected" 3.7… 4.1 V






– Check the next possible cause:Rollover sensor - the signal wire has a short circuit to plus (terminal 30) ( p. 366)

Rollover sensor - the signal wire has a short circuit to plus (terminal 30)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.The rollover sensor is disconnected. ( p. 226)

PartS

hark

.com

877-

999-

5686


600850-11 400658-10

Rollover sensor - check the signal wire for a short circuit to plus (terminal 30)– Measure the voltage between the specified points.


Voltage < 0.1 V


– Check the cable from EFI control unit connector AO ( p. 392) pin 4 to connector AP ( p. 393) pin 5 for a short circuit toplus (terminal 30).


– Check the next possible cause:Rollover sensor - the signal wire has a short circuit to ignition plus (terminal 15) ( p. 367)

Rollover sensor - the signal wire has a short circuit to ignition plus (terminal 15)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.The rollover sensor is disconnected. ( p. 226)

600850-11

Rollover sensor - check the signal wire for a short circuit to ignition plus (terminal 15)– Measure the resistance between the specified points.


Resistance ∞ Ω


– Check the cable from EFI control unit connector AO ( p. 392) pin 4 to con-nector AP ( p. 393) pin 5 for a short circuit to ignition plus (terminal 15).


– Check the next possible cause:Rollover sensor - the signal wire has a short circuit to the sensor power supply( p. 367)

Rollover sensor - the signal wire has a short circuit to the sensor power supplyConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.The rollover sensor is disconnected. ( p. 226)

600850-11

Rollover sensor - check the signal wire for a short circuit to the sensor power supply– Measure the resistance between the specified points.


Resistance ∞ Ω


– Check the cable from EFI control unit connector AO ( p. 392) pin 4 to con-nector AP ( p. 393) pin 5 for a short circuit to the sensor power supply.


– Check the next possible cause:Rollover sensor - the signal wire has an open ( p. 368)

PartS

hark

.com

877-

999-

5686


Rollover sensor - the signal wire has an openConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.The rollover sensor is disconnected. ( p. 226)

600850-11 400583-10

Rollover sensor - check the signal wire for opens– Measure the resistance between the specified points.

Break Out Box AO pin 4 – Rollover sensor connector AP pin 5



– Check EFI control unit connector AO ( p. 392) pin 4 and connector AP pin 5.

– Check the cable from EFI control unit connector AO ( p. 392) pin 4 to connector AP pin 5 for opens.


– Check the next possible cause:Rollover sensor - the ground wire has an open ( p. 368)

Rollover sensor - the ground wire has an openConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.The rollover sensor is disconnected. ( p. 226)

600850-11 400583-10

Rollover sensor - check the ground wire for opens– Measure the resistance between the specified points.

Break Out Box AO pin 7 – Rollover sensor connector AP pin 4



– Check EFI control unit connector AO ( p. 392) pin 7 and connector AP pin 4.

– Check the cable from EFI control unit connector AO ( p. 392) pin 7 to connector AP pin 4 for opens.



PartS

hark

.com

877-

999-

5686




Display on diagnostic tool P1650"Immobilizer control unit""Circuit fault"

Possible cause The ICU is faulty ( p. 369)


– Correct the immobilizer fault.

The ICU is faultyConditionThe ignition is on.

– Read out the blink code at the immobilizer indicator lamp .

Immobilizer indicator lamp flashes




– Correct the immobilizer fault.

PartS

hark

.com

877-

999-

5686




Display on diagnostic tool P1687"Manifold absolute pressure sensor cylinder 2""Input signal too low"

Error level condition Manifold absolute pressure sensor cylinder 2, voltage "PM2AD": ≤ 0.508 VTime: ≥ 1 sSubstitute value: 700 mbar (10.15 psi)


Possible cause Manifold absolute pressure sensor cylinder 2 - the signal wire has a short circuit to sensor ground( p. 371)

Manifold absolute pressure sensor cylinder 2 - the signal wire has a short circuit to ground (termi-nal 31) ( p. 371)

Manifold absolute pressure sensor cylinder 2 - the power supply is interrupted ( p. 371)













at: 350 mbar (5.08 psi) 1.62… 1.68 V

at: 400 mbar (5.8 psi) 1.77… 1.83 V

at: 450 mbar (6.53 psi) 1.92… 1.98 V

at: 800 mbar (11.6 psi) 2.97… 3.03 V

at: 850 mbar (12.33 psi) 3.12… 3.18 V

at: 900 mbar (13.05 psi) 3.27… 3.33 V

at: 950 mbar (13.78 psi) 3.42… 3.48 V

at: 1,000 mbar (14.5 psi) 3.57… 3.63 V

at: 1,050 mbar (15.23 psi) 3.72… 3.78 V






– Check the next possible cause:Manifold absolute pressure sensor cylinder 2 - the signal wire has a short circuit to sensor ground ( p. 371)

PartS

hark

.com

877-

999-

5686


Manifold absolute pressure sensor cylinder 2 - the signal wire has a short circuit to sensor groundConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)Manifold absolute pressure sensor cylinder 2 is disconnected. ( p. 223)

400590-10

Manifold absolute pressure sensor cylinder 2 - check the signal wire for a short circuit tosensor ground– Measure the resistance between the specified points.

Manifold absolute pressure sensor cylinder 2 connector DP pin 2 – Manifoldabsolute pressure sensor cylinder 2 connector DP pin 3

Resistance ∞ Ω




– Check the next possible cause:Manifold absolute pressure sensor cylinder 2 - the signal wire has a short cir-cuit to ground (terminal 31) ( p. 371)

Manifold absolute pressure sensor cylinder 2 - the signal wire has a short circuit to ground (terminal 31)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)Manifold absolute pressure sensor cylinder 2 is disconnected. ( p. 223)

400590-10 400658-10

Manifold absolute pressure sensor cylinder 2 - check the signal wire for a short circuit to ground (terminal 31)– Measure the resistance between the specified points.

Manifold absolute pressure sensor cylinder 2 connector DP pin 3 – Measuring point Ground (−)

Resistance ∞ Ω




– Check the next possible cause:Manifold absolute pressure sensor cylinder 2 - the power supply is interrupted ( p. 371)

Manifold absolute pressure sensor cylinder 2 - the power supply is interruptedConditionThe ignition is on.EFI control unit is connected. ( p. 227)Manifold absolute pressure sensor cylinder 2 is disconnected. ( p. 223)

PartS

hark

.com

877-

999-

5686


400590-10 400658-10

Manifold absolute pressure sensor cylinder 2 - checking the power supply– Measure the voltage between the specified points.

Manifold absolute pressure sensor cylinder 2 connector DP pin 1 – Measuring point Ground (−)







PartS

hark

.com

877-

999-

5686




Display on diagnostic tool P1688"Manifold absolute pressure sensor cylinder 2""Input signal too high"

Error level condition Manifold absolute pressure sensor cylinder 2, voltage "PM2AD": ≥ 4.922 VTime: ≥ 1 sSubstitute value: 700 mbar (10.15 psi)


Possible cause Manifold absolute pressure sensor cylinder 2 - the signal wire has an open ( p. 374)

Manifold absolute pressure sensor cylinder 2 - the ground wire has an open ( p. 374)

Manifold absolute pressure sensor cylinder 2 - the signal wire has a short circuit to plus (termi-nal 30) ( p. 375)

Manifold absolute pressure sensor cylinder 2 - the signal wire has a short circuit to ignition plus(terminal 15) ( p. 375)

Manifold absolute pressure sensor cylinder 2 - the signal wire has a short circuit to the sensorpower supply ( p. 375)













at: 350 mbar (5.08 psi) 1.62… 1.68 V

at: 400 mbar (5.8 psi) 1.77… 1.83 V

at: 450 mbar (6.53 psi) 1.92… 1.98 V

at: 800 mbar (11.6 psi) 2.97… 3.03 V

at: 850 mbar (12.33 psi) 3.12… 3.18 V

at: 900 mbar (13.05 psi) 3.27… 3.33 V

at: 950 mbar (13.78 psi) 3.42… 3.48 V

at: 1,000 mbar (14.5 psi) 3.57… 3.63 V

at: 1,050 mbar (15.23 psi) 3.72… 3.78 V






– Check the next possible cause:Manifold absolute pressure sensor cylinder 2 - the signal wire has an open ( p. 374)

PartS

hark

.com

877-

999-

5686


Manifold absolute pressure sensor cylinder 2 - the signal wire has an openConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Manifold absolute pressure sensor cylinder 2 is disconnected. ( p. 223)

600850-11 400590-10

Manifold absolute pressure sensor cylinder 2 - check the signal wire for opens– Measure the resistance between the specified points.

Break Out Box AO pin 24 – Manifold absolute pressure sensor cylinder 2 connector DP pin 3






– Check the next possible cause:Manifold absolute pressure sensor cylinder 2 - the ground wire has an open ( p. 374)

Manifold absolute pressure sensor cylinder 2 - the ground wire has an openConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Manifold absolute pressure sensor cylinder 2 is disconnected. ( p. 223)

600850-11 400590-10

Manifold absolute pressure sensor cylinder 2 - check the ground wire for opens– Measure the resistance between the specified points.

Break Out Box AO pin 7 – Manifold absolute pressure sensor cylinder 2 connector DP pin 2






– Check the next possible cause:Manifold absolute pressure sensor cylinder 2 - the signal wire has a short circuit to plus (terminal 30) ( p. 375)

PartS

hark

.com

877-

999-

5686


Manifold absolute pressure sensor cylinder 2 - the signal wire has a short circuit to plus (terminal 30)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Manifold absolute pressure sensor cylinder 2 is disconnected. ( p. 223)

600850-11 400658-10

Manifold absolute pressure sensor cylinder 2 - check the signal wire for a short circuit to plus (terminal 30)– Measure the voltage between the specified points.


Voltage < 0.1 V




– Check the next possible cause:Manifold absolute pressure sensor cylinder 2 - the signal wire has a short circuit to ignition plus (terminal 15) ( p. 375)

Manifold absolute pressure sensor cylinder 2 - the signal wire has a short circuit to ignition plus (terminal 15)ConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Manifold absolute pressure sensor cylinder 2 is disconnected. ( p. 223)

600850-11

Manifold absolute pressure sensor cylinder 2 - check the signal wire for a short circuit toignition plus (terminal 15)– Measure the resistance between the specified points.


Resistance ∞ Ω




– Check the next possible cause:Manifold absolute pressure sensor cylinder 2 - the signal wire has a short cir-cuit to the sensor power supply ( p. 375)

Manifold absolute pressure sensor cylinder 2 - the signal wire has a short circuit to the sensor power supplyConditionThe ignition is off.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.Manifold absolute pressure sensor cylinder 2 is disconnected. ( p. 223)

PartS

hark

.com

877-

999-

5686


600850-11

Manifold absolute pressure sensor cylinder 2 - check the signal wire for a short circuit to thesensor power supply– Measure the resistance between the specified points.


Resistance ∞ Ω





PartS

hark

.com

877-

999-

5686




Display on diagnostic tool 1690"CAN bus communication error"


CAN communication: data format and CAN reply - incorrect data format: ≥ 10 s

Possible cause Combination instrument - the CAN-high wire has an open ( p. 377)

Combination instrument - the CAN-low wire has an open ( p. 378)

Combination instrument - the CAN-high wire has an open ( p. 378)

Immobilizer control unit - the CAN-low wire has an open ( p. 379)

CAN-high - the signal wire has a short circuit to ground (terminal 31) ( p. 379)

CAN-low - the signal wire has a short circuit to ground (terminal 31) ( p. 380)

CAN-high - the signal wire has a short circuit to sensor ground ( p. 381)

CAN-low - the signal wire has a short circuit to sensor ground ( p. 381)

CAN bus terminating resistor - the CAN-high wire has an open ( p. 382)

CAN bus terminating resistor - the CAN-low wire has an open ( p. 383)

Connector CU - the CAN-high wire has an open ( p. 383)

Connector CU - the CAN-low wire has an open ( p. 384)

Diagnostics connector - the CAN-high wire has an open ( p. 384)

Diagnostics connector - the CAN-low wire has an open ( p. 385)

CAN-high - the signal wire has a short circuit to plus (terminal 30) ( p. 385)

CAN-low - the signal wire has a short circuit to plus (terminal 30) ( p. 386)

CAN-high - the signal wire has a short circuit to ignition plus (terminal 15) ( p. 387)

CAN-low - the signal wire has a short circuit to ignition plus (terminal 15) ( p. 387)

CAN-high - the signal wire has a short circuit to the sensor power supply ( p. 388)

CAN-low - the signal wire has a short circuit to the sensor power supply ( p. 389)

CAN bus terminating resistor - value not plausible ( p. 389)



Combination instrument - the CAN-high wire has an openConditionThe ignition is off.The diagnostics tool is disconnected.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.The CAN bus terminating resistor is disconnected. ( p. 404)The immobilizer control unit is disconnected. ( p. 102)The instrument panel is disconnected.

600850-12 400645-10

Combination instrument - check the CAN-high wire for opens– Measure the resistance between the specified points.

Break out box CO pin 19 – Combination instrument connector EV pin 4


PartS

hark

.com

877-

999-

5686



– Check EFI control unit connector CO ( p. 397) pin 19 and connector EV pin 4.

– Check the cable from EFI control unit connector CO ( p. 397) pin 19 to connector EV pin 4 for opens.


– Check the next possible cause:Combination instrument - the CAN-low wire has an open ( p. 378)

Combination instrument - the CAN-low wire has an openConditionThe ignition is off.The diagnostics tool is disconnected.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.The CAN bus terminating resistor is disconnected. ( p. 404)The immobilizer control unit is disconnected. ( p. 102)The instrument panel is disconnected.

600850-12 400645-10

Combination instrument - check the CAN-low wire for opens– Measure the resistance between the specified points.

Break out box CO pin 20 – Combination instrument connector EV pin 5



– Check EFI control unit connector CO ( p. 397) pin 20 and connector EV pin 5.

– Check the cable from EFI control unit connector CO ( p. 397) pin 20 to connector EV pin 5 for opens.


– Check the next possible cause:Combination instrument - the CAN-high wire has an open ( p. 378)

Combination instrument - the CAN-high wire has an openConditionThe ignition is off.The diagnostics tool is disconnected.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.The CAN bus terminating resistor is disconnected. ( p. 404)The immobilizer control unit is disconnected. ( p. 102)The instrument panel is disconnected.

600850-12 400657-10

Immobilizer control unit - check the CAN-high wire for opens– Measure the resistance between the specified points.

Break out box CO pin 19 – Immobilizer control unit, connector DO pin 6


PartS

hark

.com

877-

999-

5686



– Check EFI control unit connector CO ( p. 397) pin 19 and connector DO pin 6.

– Check the cable from EFI control unit connector CO ( p. 397) pin 19 to connector DO pin 6 for opens.


– Check the next possible cause:Immobilizer control unit - the CAN-low wire has an open ( p. 379)

Immobilizer control unit - the CAN-low wire has an openConditionThe ignition is off.The diagnostics tool is disconnected.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.The CAN bus terminating resistor is disconnected. ( p. 404)The immobilizer control unit is disconnected. ( p. 102)The instrument panel is disconnected.

600850-12 400657-10

Immobilizer control unit - check the CAN-low wire for opens– Measure the resistance between the specified points.

Break out box CO pin 20 – Immobilizer control unit, connector DO pin 8



– Check EFI control unit connector CO ( p. 397) pin 20 and connector DO pin 8.

– Check the cable from EFI control unit connector CO ( p. 397) pin 20 to connector DO pin 8 for opens.


– Check the next possible cause:CAN-high - the signal wire has a short circuit to ground (terminal 31) ( p. 379)

CAN-high - the signal wire has a short circuit to ground (terminal 31)ConditionThe ignition is off.The diagnostics tool is disconnected.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.The CAN bus terminating resistor is disconnected. ( p. 404)The immobilizer control unit is disconnected. ( p. 102)The instrument panel is disconnected.

600850-12 400658-10

CAN-high - check the signal wire for a short circuit to ground (terminal 31)– Measure the resistance between the specified points.


Resistance ∞ Ω

PartS

hark

.com

877-

999-

5686



– Check the cable from connector EV ( p. 403) pin 4 to EFI control unit connector CO ( p. 397) pin 19 for a short circuit toground (terminal 31).

– Check the cable from connector DO ( p. 400) pin 6 to EFI control unit connector CO ( p. 397) pin 19 for a short circuit toground (terminal 31).

– Check the cable from connector AT ( p. 395) pin 2 to EFI control unit connector CO ( p. 397) pin 19 for a short circuit toground (terminal 31).

– Check the cable from connector AP ( p. 393) pin 2 to EFI control unit connector CO ( p. 397) pin 19 for a short circuit toground (terminal 31).

– Check the cable from connector CU ( p. 398) pin 3 to EFI control unit connector CO ( p. 397) pin 19 for a short circuit toground (terminal 31).


– Check the next possible cause:CAN-low - the signal wire has a short circuit to ground (terminal 31) ( p. 380)

CAN-low - the signal wire has a short circuit to ground (terminal 31)ConditionThe ignition is off.The diagnostics tool is disconnected.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.The CAN bus terminating resistor is disconnected. ( p. 404)The immobilizer control unit is disconnected. ( p. 102)The instrument panel is disconnected.

600850-12 400658-10

CAN-low - check the signal wire for a short circuit to ground (terminal 31)– Measure the resistance between the specified points.


Resistance ∞ Ω


– Check the cable from connector EV ( p. 403) pin 5 to EFI control unit connector CO ( p. 397) pin 20 for a short circuit toground (terminal 31).

– Check the cable from connector DO ( p. 400) pin 8 to EFI control unit connector CO ( p. 397) pin 20 for a short circuit toground (terminal 31).

– Check the cable from connector AT ( p. 395) pin 1 to EFI control unit connector CO ( p. 397) pin 20 for a short circuit toground (terminal 31).

– Check the cable from connector AP ( p. 393) pin 3 to EFI control unit connector CO ( p. 397) pin 20 for a short circuit toground (terminal 31).

– Check the cable from connector CU ( p. 398) pin 4 to EFI control unit connector CO ( p. 397) pin 20 for a short circuit toground (terminal 31).


– Check the next possible cause:CAN-high - the signal wire has a short circuit to sensor ground ( p. 381)

PartS

hark

.com

877-

999-

5686


CAN-high - the signal wire has a short circuit to sensor groundConditionThe ignition is off.The diagnostics tool is disconnected.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.The CAN bus terminating resistor is disconnected. ( p. 404)The immobilizer control unit is disconnected. ( p. 102)The instrument panel is disconnected.

600850-12 600850-11

CAN-high - check the signal wire for a short circuit to sensor ground– Measure the resistance between the specified points.


Resistance ∞ Ω


– Check the cable from connector EV ( p. 403) pin 4 to the EFI control unit connector CO ( p. 397) pin 19 for a short circuitto sensor ground.

– Check the cable from connector DO ( p. 400) pin 6 to the EFI control unit connector CO ( p. 397) pin 19 for a short circuitto sensor ground.

– Check the cable from connector AT ( p. 395) pin 2 to the EFI control unit connector CO ( p. 397) pin 19 for a short circuitto sensor ground.

– Check the cable from connector AP ( p. 393) pin 2 to the EFI control unit connector CO ( p. 397) pin 19 for a short circuitto sensor ground.

– Check the cable from connector CU ( p. 398) pin 3 to the EFI control unit connector CO ( p. 397) pin 19 for a short cir-cuit to sensor ground.


– Check the next possible cause:CAN-low - the signal wire has a short circuit to sensor ground ( p. 381)

CAN-low - the signal wire has a short circuit to sensor groundConditionThe ignition is off.The diagnostics tool is disconnected.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.The CAN bus terminating resistor is disconnected. ( p. 404)The immobilizer control unit is disconnected. ( p. 102)The instrument panel is disconnected.

PartS

hark

.com

877-

999-

5686


600850-12 600850-11

CAN-low - check the signal wire for a short circuit to sensor ground– Measure the resistance between the specified points.


Resistance ∞ Ω


– Check the cable from connector EV ( p. 403) pin 5 to the EFI control unit connector CO ( p. 397) pin 20 for a short circuitto sensor ground.

– Check the cable from connector DO ( p. 400) pin 8 to the EFI control unit connector CO ( p. 397) pin 20 for a short circuitto sensor ground.

– Check the cable from connector AT ( p. 395) pin 1 to the EFI control unit connector CO ( p. 397) pin 20 for a short circuitto sensor ground.

– Check the cable from connector AP ( p. 393) pin 3 to the EFI control unit connector CO ( p. 397) pin 20 for a short circuitto sensor ground.

– Check the cable from connector CU ( p. 398) pin 4 to the EFI control unit connector CO ( p. 397) pin 20 for a short cir-cuit to sensor ground.


– Check the next possible cause:CAN bus terminating resistor - the CAN-high wire has an open ( p. 382)

CAN bus terminating resistor - the CAN-high wire has an openConditionThe ignition is off.The diagnostics tool is disconnected.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.The CAN bus terminating resistor is disconnected. ( p. 404)The immobilizer control unit is disconnected. ( p. 102)The instrument panel is disconnected.

600850-12 400585-10

CAN bus terminating resistor - check the CAN-high wire for opens– Measure the resistance between the specified points.

Break out box CO pin 19 – CAN bus terminating resistor connector AT pin 2



– Check EFI control unit connector CO ( p. 397) pin 19 and connector AT pin 2.

– Check the cable from EFI control unit connector CO ( p. 397) pin 19 to connector AT pin 2 for opens.


– Check the next possible cause:CAN bus terminating resistor - the CAN-low wire has an open ( p. 383)

PartS

hark

.com

877-

999-

5686


CAN bus terminating resistor - the CAN-low wire has an openConditionThe ignition is off.The diagnostics tool is disconnected.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.The CAN bus terminating resistor is disconnected. ( p. 404)The immobilizer control unit is disconnected. ( p. 102)The instrument panel is disconnected.

600850-12 400585-10

CAN bus terminating resistor - check the CAN-low wire for opens– Measure the resistance between the specified points.

Break out box CO pin 20 – CAN bus terminating resistor connector AT pin 1



– Check EFI control unit connector CO ( p. 397) pin 20 and connector AT pin 1.

– Check the cable from EFI control unit connector CO ( p. 397) pin 20 to connector AT pin 1 for opens.


– Check the next possible cause:Connector CU - the CAN-high wire has an open ( p. 383)

Connector CU - the CAN-high wire has an openConditionThe ignition is off.The diagnostics tool is disconnected.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.The CAN bus terminating resistor is disconnected. ( p. 404)The immobilizer control unit is disconnected. ( p. 102)The instrument panel is disconnected.

600850-12 400588-10

Connector CU - check the CAN-high wire for opens– Measure the resistance between the specified points.

Break out box CO pin 19 – Connector CU pin 3



– Check EFI control unit connector CO ( p. 397) pin 19 and connector CU pin 3.

– Check the cable from EFI control unit connector CO ( p. 397) pin 19 to connector CU pin 3 for opens.


PartS

hark

.com

877-

999-

5686


– Check the next possible cause:Connector CU - the CAN-low wire has an open ( p. 384)

Connector CU - the CAN-low wire has an openConditionThe ignition is off.The diagnostics tool is disconnected.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.The CAN bus terminating resistor is disconnected. ( p. 404)The immobilizer control unit is disconnected. ( p. 102)The instrument panel is disconnected.

600850-12 400588-10

Connector CU - check the CAN-low wire for opens– Measure the resistance between the specified points.

Break out box CO pin 20 – Connector CU pin 4



– Check EFI control unit connector CO ( p. 397) pin 20 and connector CU pin 4.

– Check the cable from EFI control unit connector CO ( p. 397) pin 20 to connector CU pin 4 for opens.


– Check the next possible cause:Diagnostics connector - the CAN-high wire has an open ( p. 384)

Diagnostics connector - the CAN-high wire has an openConditionThe ignition is off.The diagnostics tool is disconnected.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.The CAN bus terminating resistor is disconnected. ( p. 404)The immobilizer control unit is disconnected. ( p. 102)The instrument panel is disconnected.

600850-12 400583-10

Diagnostics connector - check the CAN-high wire for opens– Measure the resistance between the specified points.

Break out box CO pin 19 – Diagnostic connection plug AP pin 2



– Check EFI control unit connector CO ( p. 397) pin 19 and connector AP pin 2.

PartS

hark

.com

877-

999-

5686


– Check the cable from EFI control unit connector CO ( p. 397) pin 19 to connector AP pin 2 for opens.


– Check the next possible cause:Diagnostics connector - the CAN-low wire has an open ( p. 385)

Diagnostics connector - the CAN-low wire has an openConditionThe ignition is off.The diagnostics tool is disconnected.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.The CAN bus terminating resistor is disconnected. ( p. 404)The immobilizer control unit is disconnected. ( p. 102)The instrument panel is disconnected.

600850-12 400583-10

Diagnostics connector - check the CAN-low wire for opens– Measure the resistance between the specified points.

Break out box CO pin 20 – Diagnostic connection plug AP pin 3



– Check EFI control unit connector CO ( p. 397) pin 20 and connector AP pin 3.

– Check the cable from EFI control unit connector CO ( p. 397) pin 20 to connector AP pin 3 for opens.


– Check the next possible cause:CAN-high - the signal wire has a short circuit to plus (terminal 30) ( p. 385)

CAN-high - the signal wire has a short circuit to plus (terminal 30)ConditionThe ignition is off.The diagnostics tool is disconnected.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.The CAN bus terminating resistor is disconnected. ( p. 404)The immobilizer control unit is disconnected. ( p. 102)The instrument panel is disconnected.

600850-12 400658-10

CAN-high - check the signal wire for a short circuit to plus (terminal 30)– Measure the voltage between the specified points.


Voltage ≤ 0.1 V

PartS

hark

.com

877-

999-

5686



– Check the cable from connector EV ( p. 403) pin 4 to the EFI control unit connector CO ( p. 397) pin 19 for a short circuitto plus (terminal 30).

– Check the cable from connector DO ( p. 400) pin 6 to the EFI control unit connector CO ( p. 397) pin 19 for a short circuitto plus (terminal 30).

– Check the cable from connector AT ( p. 395) pin 2 to the EFI control unit connector CO ( p. 397) pin 19 for a short circuitto plus (terminal 30).

– Check the cable from connector AP ( p. 393) pin 2 to the EFI control unit connector CO ( p. 397) pin 19 for a short circuitto plus (terminal 30).

– Check the cable from connector CU ( p. 398) pin 3 to the EFI control unit connector CO ( p. 397) pin 19 for a short cir-cuit to plus (terminal 30).


– Check the next possible cause:CAN-low - the signal wire has a short circuit to plus (terminal 30) ( p. 386)

CAN-low - the signal wire has a short circuit to plus (terminal 30)ConditionThe ignition is off.The diagnostics tool is disconnected.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.The CAN bus terminating resistor is disconnected. ( p. 404)The immobilizer control unit is disconnected. ( p. 102)The instrument panel is disconnected.

600850-12 400658-10

CAN-low - check the signal wire for a short circuit to plus (terminal 30)– Measure the voltage between the specified points.


Voltage ≤ 0.1 V








– Check the next possible cause:CAN-high - the signal wire has a short circuit to ignition plus (terminal 15) ( p. 387)

PartS

hark

.com

877-

999-

5686


CAN-high - the signal wire has a short circuit to ignition plus (terminal 15)ConditionThe ignition is off.The diagnostics tool is disconnected.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.The CAN bus terminating resistor is disconnected. ( p. 404)The immobilizer control unit is disconnected. ( p. 102)The instrument panel is disconnected.

600850-12 600850-11

CAN-high - check the signal wire for a short circuit to ignition plus (terminal 15)– Measure the resistance between the specified points.


Resistance ∞ Ω








– Check the next possible cause:CAN-low - the signal wire has a short circuit to ignition plus (terminal 15) ( p. 387)

CAN-low - the signal wire has a short circuit to ignition plus (terminal 15)ConditionThe ignition is off.The diagnostics tool is disconnected.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.The CAN bus terminating resistor is disconnected. ( p. 404)The immobilizer control unit is disconnected. ( p. 102)The instrument panel is disconnected.

PartS

hark

.com

877-

999-

5686


600850-12 600850-11

CAN-low - check the signal wire for a short circuit to ignition plus (terminal 15)– Measure the resistance between the specified points.


Resistance ∞ Ω








– Check the next possible cause:CAN-high - the signal wire has a short circuit to the sensor power supply ( p. 388)

CAN-high - the signal wire has a short circuit to the sensor power supplyConditionThe ignition is off.The diagnostics tool is disconnected.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.The CAN bus terminating resistor is disconnected. ( p. 404)The immobilizer control unit is disconnected. ( p. 102)The instrument panel is disconnected.

600850-12 600850-11

CAN-high - check the signal wire for a short circuit to the sensor power supply– Measure the resistance between the specified points.


Resistance ∞ Ω




PartS

hark

.com

877-

999-

5686






– Check the next possible cause:CAN-low - the signal wire has a short circuit to the sensor power supply ( p. 389)

CAN-low - the signal wire has a short circuit to the sensor power supplyConditionThe ignition is off.The diagnostics tool is disconnected.The EFI control unit is disconnected. ( p. 227)The break out box is connected to the wiring harness.The CAN bus terminating resistor is disconnected. ( p. 404)The immobilizer control unit is disconnected. ( p. 102)The instrument panel is disconnected.

600850-12 600850-11

CAN-low - check the signal wire for a short circuit to the sensor power supply– Measure the resistance between the specified points.


Resistance ∞ Ω








– Check the next possible cause:CAN bus terminating resistor - value not plausible ( p. 389)

CAN bus terminating resistor - value not plausibleConditionThe ignition is off.The CAN bus terminating resistor is disconnected. ( p. 404)

PartS

hark

.com

877-

999-

5686


600857-10

CAN bus terminating resistor - check the resistor.– Measure the resistance between the specified points.

CAN bus terminating resistor pin 1 – CAN bus terminating resistor pin 2

CAN bus terminating resistor



– Change the CAN bus terminating resistor.



PartS

hark

.com

877-

999-

5686

CONNECTOR OVERVIEW 391

32.1Motor drive circuit A connector AE

400682-10

Pin overview

1 Motor drive circuit A phase BP, control wire

2 Motor drive circuit A phase AN, control wire

3 Motor drive circuit A phase AP, control wire

4 Motor drive circuit A phase BN, control wire

32.2Connector AI

400681-10

Pin overview

1 Power supply, main relay, fuel pump input

2 Power supply, main relay, fuel pump output

32.3Crankshaft position sensor connector AL

400581-10

Pin overview

1 Signal wire

2 Signal wire

32.4Clutch switch, connector AL

400581-10

Pin overview

1 Ground

2 Signal wire

32.5Throttle position sensor circuit A, connector AM

400582-10

Pin overview

1 System voltage

2 Signal wire

3 Sensor ground

PartS

hark

.com

877-

999-

5686


32.6Throttle position sensor circuit B, connector AM

400582-10

Pin overview

1 Signal wire

2 Power supply

3 Sensor ground

32.7Gear position sensor, connector AM

400582-10

Pin overview

1 Signal wire 3rd gear

2 Signal wire 2nd gear

3 Signal wire, idle

32.8Fuel pump connector AM

400582-10

Pin overview

1 Power supply

2 Not assigned

3 Ground

32.9Wheel speed sensor, connector AM

400582-10

Pin overview

1 Signal wire

2 System voltage

3 Ground

32.10Connector AO

400642-10

Pin overview

1 Sensor voltage supply

2 Throttle position sensor circuit B, signal wire

3 Manifold absolute pressure sensor cylinder 1, signal wire

4 Rollover sensor, signal wire

5 Not assigned

6 Ground (terminal 31)

7 Sensor ground

8 Input status, electric starter lock control unit

9 Engine coolant temperature sensor cylinder 1, signal wire

PartS

hark

.com

877-

999-

5686


10 Throttle position sensor circuit A, signal wire

11 Lambda sensor cylinder 1, signal wire

12 Lambda sensor cylinder 2, signal wire

13 Crankshaft position sensor, signal wire

14 Crankshaft position sensor, signal wire

15 3rd gear, signal wire

16 Not assigned

17 K bus wire to KTM diagnostics tool

18 2nd gear, signal wire

19 Neutral switch, signal wire

20 EFI control unit voltage supply (terminal 15)

21 Octane selector

22 Intake air temperature sensor, signal wire

23 Ambient air pressure sensor, signal wire

24 Manifold absolute pressure sensor cylinder 2, signal wire

25 Clutch switch, signal wire

26 Side stand switch, signal wire

32.11Diagnostic connection plug AP

400583-10

Pin overview

1 System voltage

2 CAN high

3 CAN low

4 K bus signal wire to KTM diagnostics tool

5 Not assigned

6 Ground

32.12Rollover sensor connector AP

400583-10

Pin overview

1 Not assigned

2 Not assigned

3 Not assigned

4 Sensor ground

5 Signal wire

6 System voltage

32.13Throttle position sensor circuit A, connector AR

400584-10

Pin overview

1 Power supply

2 Signal wire

3 Sensor ground

PartS

hark

.com

877-

999-

5686


32.14Throttle position sensor circuit B, connector AR

400584-10

Pin overview

1 Signal wire

2 System voltage

3 Sensor ground

32.15Fuel pump connector AR

400584-10

Pin overview

1 Power supply

2 Not assigned

3 Ground

32.16Side stand switch, connector AR

400584-10

Pin overview

1 System voltage

2 Sensor ground

3 Signal wire

32.17Ignition coil cylinder 1 connector AS

400644-10

Pin overview

1 Control wire

2 System voltage

32.18Ignition coil cylinder 2 connector AS

400644-10

Pin overview

1 Control wire

2 System voltage

PartS

hark

.com

877-

999-

5686


32.19CAN bus terminating resistor connector AT

400585-10

Pin overview

1 CAN low

2 CAN high

32.20Crankshaft position sensor, connector AT

400585-10

Pin overview

1 Signal wire

2 Signal wire

32.21Clutch switch connector AT

400585-10

Pin overview

1 Signal wire

2 Ground

32.22Engine coolant temperature sensor cylinder 1 connector AX

400586-10

Pin overview

1 Sensor ground

2 Signal wire

32.23Throttle stepper motor circuit B, connector CA

400646-10

Pin overview

1 Motor drive circuit B phase AP, control wire

2 Motor drive circuit B phase BP, control wire

3 Motor drive circuit B phase AN, control wire

4 Motor drive circuit B phase BN, control wire

PartS

hark

.com

877-

999-

5686


32.24Lambda sensor cylinder 1, connector CA

400646-10

Pin overview

1 Power supply, lambda sensor heater

2 Lambda sensor heater, control wire

3 Sensor ground

4 Signal wire

32.25Lambda sensor cylinder 2, connector CA

400646-10

Pin overview



3 Sensor ground

4 Signal wire

32.26Lambda sensor cylinder 1, connector CE

400647-10

Pin overview



3 Sensor ground

4 Signal wire

32.27Lambda sensor cylinder 2, connector CE

400647-10

Pin overview



3 Sensor ground

4 Signal wire

32.28Secondary air valve connector CK

400648-10

Pin overview

1 Power supply

2 Control wire

PartS

hark

.com

877-

999-

5686


32.29Connector CM

400650-10

Pin overview

1 Sensor ground

2 Signal wire

32.30Connector CO

400643-10

Pin overview

1 Not assigned

2 Fuel pump relay, control wire



5 Injector cylinder 1, control wire





10 Not assigned



13 Exhaust air injection valve, control wire

14 Tachometer signal wire

15 Lambda sensor heater cylinder 2, control wire

16 EFI warning lamp (MIL)

17 Not assigned

18 Not assigned

19 CAN high

20 CAN low




24 Not assigned

25 Not assigned

26 Ignition coil cylinder 2, control wire

27 Not assigned

28 Not assigned

29 Ignition coil cylinder 1, control wire

30 Not assigned

31 Fuel evaporation valve, control wire

32 Control wire status, electric starter lock control unit

33 Lambda sensor heater cylinder 1, control wire

34 K bus wire, combination instrument

PartS

hark

.com

877-

999-

5686


32.31Connector CP

400651-10

Pin overview

2.1 Not assigned

2.2 Sensor ground

2.3 Motor drive circuit B phase BN, control wire

2.4 Motor drive circuit A phase BN, control wire

2.5 Injector cylinder 1, control wire

2.6 Throttle position sensor circuit A, signal wire

2.7 Motor drive circuit B phase BP, control wire

2.8 Motor drive circuit A phase BP, control wire

2.9 Injector cylinder 2, control wire

2.10 Throttle position sensor circuit B, signal wire

2.11 Motor drive circuit B phase AN, control wire

2.12 Motor drive circuit A phase AN, control wire

2.13 Intake air temperature sensor, signal wire

2.14 Sensor power supply

2.15 Motor drive circuit B phase AP, control wire

2.16 Motor drive circuit A phase AP, control wire

32.32Connector CQ

400652-10

Pin overview

1 Not assigned

2 Sensor ground




6 Throttle position sensor circuit A, signal wire




10 Throttle position sensor circuit B, signal wire



13 Intake air temperature sensor, signal wire

14 Sensor power supply



32.33Connector CU

400588-10

Pin overview

1 Not in use

2 Ground

3 CAN high

4 CAN low

PartS

hark

.com

877-

999-

5686


32.34Fuel evaporation valve connector DF

400589-10

Pin overview

1 Power supply

2 Control wire

32.35Secondary air valve connector DF

400589-10

Pin overview

1 Power supply

2 Control wire

32.36Electric starter lock control unit, connector DN

600859-10

Pin overview

1 Power supply


3 Starter auxiliary relay


5 Ground

6 Signal wire status, electric starter lock control unit

7 Signal wire status, electric starter lock control unit


32.37Immobilizer control unit, connector DN

600859-10

Pin overview

1 Coil antenna

2 Coil antenna

3 System voltage

4 System voltage

5 LED

6 CAN high

7 Ground

8 CAN low

32.38Electric starter lock control unit, connector DO

400657-10

Pin overview

1 System voltage




5 Ground

6 Control wire status, electric starter lock control unit

7 EFI control unit, control wire status


PartS

hark

.com

877-

999-

5686


32.39Immobilizer control unit, connector DO

400657-10

Pin overview

1 Coil antenna

2 Coil antenna

3 Power supply

4 Power supply

5 LED

6 CAN high

7 Ground

8 CAN low

32.40Ambient air pressure sensor connector DP

400590-10

Pin overview

1 System voltage

2 Sensor ground

3 Signal wire

32.41Manifold absolute pressure sensor cylinder 1, connector DP

400590-10

Pin overview

1 System voltage

2 Sensor ground

3 Signal wire

32.42Manifold absolute pressure sensor cylinder 2 connector DP

400590-10

Pin overview

1 System voltage

2 Sensor ground

3 Signal wire

32.43Injector cylinder 1 connector DQ

400591-10

Pin overview

1 Power supply

2 Control wire

PartS

hark

.com

877-

999-

5686


32.44Injector cylinder 2 connector DQ

400591-10

Pin overview

1 Power supply

2 Control wire

32.45ICU antenna connector DV

400593-10

Pin overview

1 Coil antenna

2 Coil antenna

32.46Fuel pump relay connector EB

400653-10

Pin overview

1 Control circuit, power supply

2 Control wire

3 Component power supply


32.47ICU antenna connector EL

400685-10

Pin overview

1 Coil antenna

2 Coil antenna

32.48Connector EQ

400683-10

Pin overview

1 Not assigned

2 LED alarm system (optional), signal wire


4 Power supply (terminal 15)

5 CAN high

6 Not assigned




PartS

hark

.com

877-

999-

5686


10 CAN low

32.49Connector ER

400684-10

Pin overview

1 Not assigned




5 CAN high

6 Not assigned




10 CAN low

32.50Connector ES

400654-10

Pin overview

1 Power supply (terminal 15) fuse 3




5 Brake light switch, control wire


7 Right turn signal, control wire

8 Left turn signal, control wire

9 Not assigned

10 Not assigned

11 Not assigned

12 Not assigned




16 Power supply, main relay, fuel pump


18 Power supply, start auxiliary relay, working circuit

32.51Connector ET

400655-10

Pin overview





5 Brake light switch, control wire


7 Right turn signal, control wire

8 Left turn signal, control wire

9 Not assigned

10 Not assigned

11 Not assigned

12 Not assigned



PartS

hark

.com

877-

999-

5686



16 Power supply, main relay, fuel pump


18 Power supply, start auxiliary relay, working circuit

32.52Combination instrument connector EV

400645-10

Pin overview

1 Power supply

2 Power supply

3 Ground

4 CAN high

5 CAN low



8 Fuel level indicator, signal wire

9 Wheel speed sensor, signal wire

10 Tachometer, signal wire

11 Sensor power supply

12 Ambient air temperature sensor, signal wire

13 Not assigned

14 Ground

15 Oil pressure sensor, signal wire

16 High beam indicator light


18 Ground


20 EFI warning lamp (MIL)

21 LAP button, signal wire

22 MODE button, signal wire

23 Turn signal, signal wire

24 Not assigned

25 Not assigned

26 Not assigned

32.53Exhaust air injection valve, connector FE

600854-10

Pin overview

1 System voltage

2 Control wire

PartS

hark

.com

877-

999-

5686


32.54Fuel pump relay

600852-10

Pin overview

1 Control circuit power supply

2 Control wire

3 Fuel pump power supply


32.55CAN bus terminating resistor

600857-10

Pin overview

1 CAN low

2 CAN high

PartS

hark

.com

877-

999-

5686

TECHNICAL DATA - ENGINE 405

Design 2-cylinder 4-stroke Otto motor, 75° V arrangement, water-cooled

Displacement 1,195 cm³ (72.92 cu in)

Stroke 69 mm (2.72 in)

Bore 105 mm (4.13 in)

Compression ratio 13.5:1

Control DOHC, 4 valves per cylinder, chain-driven


Intake 42 mm (1.65 in)

Exhaust 34 mm (1.34 in)

Valve clearance

Exhaust at: 20 °C (68 °F) 0.25… 0.30 mm (0.0098… 0.0118 in)

Intake at: 20 °C (68 °F) 0.10… 0.15 mm (0.0039… 0.0059 in)

Crankshaft bearing Sleeve bearing

Conrod bearing Sleeve bearing

Piston pin bearing No bearing bushes - DLC-coated piston pins

Piston Forged light alloy

Piston ring 1 Upper compression (rectangular) ring, 1 lower compressionring, 1 oil scraper ring

Engine lubrication Dry sump lubrication system with three rotor pumps

Primary transmission 40:76

Clutch Multi-disc clutch in oilbath / hydraulically operated

Transmission 6-speed claw gears

Transmission ratio

1st gear 14:36

2nd gear 16:30

3rd gear 20:30

4th gear 21:27

5th gear 23:26

6th gear 25:26

Mixture preparation Electronically controlled fuel injection

Ignition system Contactless controlled fully electronic ignition with digital igni-tion adjustment

Generator 12 V, 390 W

Spark plug NGK LKAR9BI9

Electrode gap, spark plug 0.8… 0.9 mm (0.031… 0.035 in)

Cooling Water cooling, permanent circulation of coolant by water pump

Cold start device Electric starter

33.1Capacity - engine oil

Engine oil 3.60 l (3.8 qt.) External temperature: ≥ 0 °C(≥ 32 °F)

Engine oil (SAE 10W/50)( p. 436)

External temperature: < 0 °C(< 32 °F)

Engine oil (SAE 5W/40)( p. 436)

PartS

hark

.com

877-

999-

5686

TECHNICAL DATA - ENGINE 406

33.2Capacity - coolant

Coolant 2.60 l (2.75 qt.) Coolant ( p. 436)

Coolant (mixed ready to use) ( p. 436)

PartS

hark

.com

877-

999-

5686

TECHNICAL DATA - TOLERANCE, WEAR LIMITS OF ENGINE 407

Camshaft - cam height

Intake 39.34… 39.44 mm (1.5488… 1.5528 in)

Exhaust 38.59… 38.69 mm (1.5193… 1.5232 in)

Camshaft - bearing pin 23.960… 23.980 mm (0.94331… 0.94409 in)

Camshaft bearing - radial clearance



Valve guide - diameter



Valve - sealing seat width

Intake: New condition 1.0 mm (0.039 in)

Intake: Wear limit 1.7 mm (0.067 in)

Exhaust: New condition 1.0 mm (0.039 in)

Exhaust: Wear limit 2.0 mm (0.079 in)

Valve - run-out

On the valve stem ≤ 0.05 mm (≤ 0.002 in)

On the valve plate: New condition ≤ 0.016 mm (≤ 0.00063 in)

On the valve plate: Wear limit ≤ 0.030 mm (≤ 0.00118 in)


Exhaust 5.893… 5.970 mm (0.23201… 0.23504 in)

Intake 5.965… 5.980 mm (0.23484… 0.23543 in)

Valve spring - length

New condition 42.0 mm (1.654 in)


Cylinder head - bearing hole of camshaft 24.000… 24.021 mm (0.94488… 0.94571 in)

Cylinder/cylinder head - sealing area distortion ≤ 0.05 mm (≤ 0.002 in)

Cylinder - bore diameter

Size I 105.000… 105.012 mm (4.13385… 4.13432 in)

Size II 105.012… 105.025 mm (4.13432… 4.13483 in)

Piston - diameter

Size I 104.955… 104.985 mm (4.13208… 4.13326 in)

Size II 104.965… 104.995 mm (4.13247… 4.13365 in)

Piston/cylinder - mounting clearance



Piston - piston pin hole diameter 20.010… 20.020 mm (0.78779… 0.78819 in)

Piston ring

Width, first ring (rectangular ring) 1.170… 1.200 mm (0.04606… 0.04724 in)

Width, second ring (lower compression ring) 1.170… 1.200 mm (0.04606… 0.04724 in)

Width, oil scraper ring 1.970… 2.000 mm (0.07756… 0.07874 in)

Piston ring - groove clearance

First ring (rectangular ring) ≤ 0.105 mm (≤ 0.00413 in)

Second ring (lower compression ring) ≤ 0.150 mm (≤ 0.00591 in)

Oil scraper ring ≤ 0.180 mm (≤ 0.00709 in)

Piston ring end gap ≤ 0.5 mm (≤ 0.02 in)

Piston pin - diameter 19.995… 20.004 mm (0.7872… 0.78756 in)

Connecting rod - diameter of upper conrod eye 20.000… 20.013 mm (0.7874… 0.78791 in)

Connecting rod - axial clearance of lower conrod bearing



Connecting rod - radial clearance of lower conrod bearing

PartS

hark

.com

877-

999-

5686

TECHNICAL DATA - TOLERANCE, WEAR LIMITS OF ENGINE 408



Connecting rod - large end width 20.950… 21.000 mm (0.8248… 0.82677 in)

Crankshaft - axial clearance



Crankshaft - crank pin width 42.100… 42.150 mm (1.65748… 1.65945 in)

Crankshaft - crank pin diameter

Yellow 41.978… 41.989 mm (1.65267… 1.65311 in)

Blue 41.990… 42.000 mm (1.65315… 1.65354 in)

Red 42.001… 42.011 mm (1.65358… 1.65397 in)

Crankshaft - main bearing diameter

Yellow 53.965… 53.975 mm (2.1246… 2.125 in)

Blue 53.976… 53.985 mm (2.12504… 2.12539 in)

Red 53.986… 53.995 mm (2.12543… 2.12578 in)

Crankshaft - radial clearance of main bearing



Crankshaft - step bearing diameter 27.985… 28.000 mm (1.10177… 1.10236 in)

Crankshaft - radial clearance of step bearing



Clutch facing disc - thickness



Intermediate disk - thickness



Clutch discs - thickness of total package



Clutch spring - length 33.00… 34.00 mm (1.2992… 1.3386 in)

Outer clutch hub - contact surface of clutch facing discs


Oil pressure regulator valve - minimum spring length 40.5 mm (1.594 in)

Oil pumps

Clearance between external rotor and engine case 0.20… 0.40 mm (0.0079… 0.0157 in)

Clearance between external rotor and internal rotor 0.10… 0.25 mm (0.0039… 0.0098 in)

Axial clearance 0.04… 0.25 mm (0.0016… 0.0098 in)

Engine oil pressure

Coolant temperature: ≥ 70 °C (≥ 158 °F)Engine speed: 1,500 rpm

1.3… 2.3 bar (19… 33 psi)

Coolant temperature: ≥ 70 °C (≥ 158 °F)Engine speed: 5,000 rpm

3.0… 4.0 bar (44… 58 psi)

Oil consumption ≤ 0.6 l/1.000 km (≤ 0.6 qt./600 mi)

Shift fork

Thickness at leaf 4.85… 4.95 mm (0.1909… 0.1949 in)

Clearance in the sliding gear groove: New condition 0.35… 0.55 mm (0.0138… 0.0217 in)

Clearance in the sliding gear groove: Wear limit 0.70 mm (0.0276 in)

Shift shaft - play in sliding plate/shift quadrant 0.40… 0.80 mm (0.0157… 0.0315 in)

Sliding gear - width of shift fork groove 5.30… 5.40 mm (0.2087… 0.2126 in)

Transmission shaft - axial clearance 0.05… 0.15 mm (0.002… 0.0059 in)

PartS

hark

.com

877-

999-

5686

TECHNICAL DATA - ENGINE TIGHTENING TORQUES 409

Hose clip, intake flange M4 1.5 Nm (1.11 lbf ft) –

Remaining engine screws M5 6 Nm (4.4 lbf ft) –

Screw, bearing retainer M5 6 Nm (4.4 lbf ft) Loctite® 243™

Screw, gear sensor M5 3 Nm (2.2 lbf ft) Loctite® 243™

Screw, pulse generator M5 10 Nm (7.4 lbf ft) Loctite® 243™

Camshaft drive sprocket bolt M6 13 Nm (9.6 lbf ft) –

Freewheel ring bolt M6 15 Nm (11.1 lbf ft) Loctite® 648™

Nut, cylinder head M6 10 Nm (7.4 lbf ft) –

Plug, vacuum connection M6 5 Nm (3.7 lbf ft) Loctite® 243™

Remaining engine screws M6 10 Nm (7.4 lbf ft) –

Screw, camshaft bearing support M6 10 Nm (7.4 lbf ft) –

Screw, clutch cover M6 10 Nm (7.4 lbf ft) –

Screw, clutch spring M6 12 Nm (8.9 lbf ft) Loctite® 243™

Screw, coolant connection on cylinderhead

M6 10 Nm (7.4 lbf ft) –

Screw, engine case M6x60 10 Nm (7.4 lbf ft) –



Screw, freewheel holder M6 10 Nm (7.4 lbf ft) Loctite® 243™

Screw, generator cover M6 10 Nm (7.4 lbf ft) –

Screw, locking lever M6 10 Nm (7.4 lbf ft) Loctite® 243™

Screw, oil pump cover M6 10 Nm (7.4 lbf ft) Loctite® 243™

Screw, shift drum locating M6 10 Nm (7.4 lbf ft) Loctite® 243™

Screw, shift lever M6 10 Nm (7.4 lbf ft) Loctite® 243™

Screw, starter motor M6 10 Nm (7.4 lbf ft) –

Screw, stator clamp M6 10 Nm (7.4 lbf ft) Loctite® 243™

Screw, valve cover M6 10 Nm (7.4 lbf ft) –

Screw, water pump cover M6 10 Nm (7.4 lbf ft) –

Screw, water pump wheel M6 10 Nm (7.4 lbf ft) Loctite® 243™

Stud, chain shaft M6 8 Nm (5.9 lbf ft) –

Vacuum connection M6 5 Nm (3.7 lbf ft) Loctite® 243™

Jet 140 M6x0.75 4 Nm (3 lbf ft) Loctite® 243™

Oil jet M6x0.75 4 Nm (3 lbf ft) Loctite® 243™

Oil jet for clutch lubrication M6x0.75 4 Nm (3 lbf ft) –

Plug, crankshaft retainer M8 15 Nm (11.1 lbf ft) –

Screw, camshaft bearing support M8 Step 110 Nm (7.4 lbf ft)Step 218 Nm (13.3 lbf ft)

–

Screw, camshaft bearing support M8 Step 18.5 Nm (6.27 lbf ft)Step 214.5 Nm (10.7 lbf ft)

Only applies when using:Hex key bit(61229025000)( p. 446)

Screw, engine case M8 18 Nm (13.3 lbf ft) –

Screw, engine console M8 20 Nm (14.8 lbf ft) Loctite® 243™

Screw, heat exchanger M8 15 Nm (11.1 lbf ft) –

Screw, timing chain guide rail M8 15 Nm (11.1 lbf ft) Loctite® 243™

Screw, timing chain tensioning rail M8 15 Nm (11.1 lbf ft) Loctite® 243™

Stud, exhaust flange M8 10 Nm (7.4 lbf ft) –

Oil pressure sensor M10x1 10 Nm (7.4 lbf ft) –

Plug, cam lever axis M10x1 15 Nm (11.1 lbf ft) –

Plug, clutch lubrication M10x1 15 Nm (11.1 lbf ft) –

PartS

hark

.com

877-

999-

5686

TECHNICAL DATA - ENGINE TIGHTENING TORQUES 410

Screw, conrod bearing M10x1 Step 125 Nm (18.4 lbf ft)Step 230 Nm (22.1 lbf ft)Step 390°

–

Screw, timing chain tensioner release M10x1 10 Nm (7.4 lbf ft) –

Cylinder head screw M11x1.5 Tightening sequence:Using a crisscross patternStep 115 Nm (11.1 lbf ft)Step 230 Nm (22.1 lbf ft)Step 390°Step 490°

lubricated with engine oil

Coolant temperature sensor M12x1.5 12 Nm (8.9 lbf ft) –

Rotor screw M12x1.5 90 Nm (66.4 lbf ft) –

Spark plug M12x1.5 17 Nm (12.5 lbf ft) –

Nut of engine sprocket M20x1.5 100 Nm (73.8 lbf ft) Loctite® 243™

Oil drain plug M20x1.5 20 Nm (14.8 lbf ft) –

Nut, inner clutch hub M22x1.5 130 Nm (95.9 lbf ft) Loctite® 243™

Plug, timing-chain tensioner M24x1.5 25 Nm (18.4 lbf ft) –

Screw in generator cover M24x1.5 8 Nm (5.9 lbf ft) –

Nut, primary gear M33LHx1.5 130 Nm (95.9 lbf ft) Loctite® 243™

PartS

hark

.com

877-

999-

5686

TECHNICAL DATA - CHASSIS 411

Frame Lattice frame made of chromium molybdenum steel tubing,powder-coated

Fork WP Suspension Up Side Down 4354

Shock absorber WP Suspension 4014 VP

Suspension travel

Front 120 mm (4.72 in)

Rear 120 mm (4.72 in)

Brake system

Front Twin floating disc with radial mount, 4-piston calipers

Rear Single non-floating disc with 2 piston brake caliper

Brake discs - diameter

Front 320 mm (12.6 in)

Rear 220 mm (8.66 in)

Brake discs - wear limit

Front 4.5 mm (0.177 in)

Brake disc - wear limit

Rear 4.5 mm (0.177 in)

Tire air pressure, Solo



Tire air pressure with passenger / full payload



Secondary drive 17:37

Chain 5/8 x 5/16” X‑ring

Steering head angle 66.7°

Wheelbase 1,425 mm (56.1 in)

Seat height, unloaded

Lower frame rear position 805 mm (31.69 in)

Upper frame rear position 825 mm (32.48 in)

Ground clearance, unloaded 110 mm (4.33 in)

Weight without fuel approx. 184 kg (406 lb.)

Maximum permissible front axle load 150 kg (331 lb.)

Maximum permissible rear axle load 240 kg (529 lb.)

Maximum permissible total weight 380 kg (838 lb.)

Battery YTZ14S Battery voltage: 12 VNominal capacity: 11.2 Ahmaintenance-free

Fuse 58011109130 30 A

Fuse 75011088015 15 A

Fuse 75011088010 10 A

36.1Lighting equipment

Low beam / high beam H7 / base PX26d 12 V55 W

Parking light W5W/ base W2.1x9.5d 12 V5 W

Instrument lights and control lamps LED

Turn signal LED

Brake/tail light LED

License plate lamp W5W/ base W2.1x9.5d 12 V5 W

PartS

hark

.com

877-

999-

5686

TECHNICAL DATA - CHASSIS 412

Front tire Rear tire

120/70 ZR 17 M/C 58W TLPirelli Dragon Supercorsa Pro

190/55 ZR 17 M/C 75W TLPirelli Dragon Supercorsa Pro

Additional information is available in the Service section under:http://www.ktm.com

36.2Capacity - fuel

Total fuel tank capacity,approx.

16.5 l (4.36 US gal) Super unleaded (ROZ 98 / RON 98 / PON 94) ( p. 437)

Fuel reserve, approx. 3.5 l (3.7 qt.)

PartS

hark

.com

877-

999-

5686

TECHNICAL DATA - FORK 413

Fork part number 05.18.7E.10

Fork WP Suspension Up Side Down 4354

Compression damping

Comfort 15 clicks

Standard 10 clicks

Sport 5 clicks


Rebound damping

Comfort 15 clicks

Standard 10 clicks

Sport 5 clicks



Comfort 5 turns

Standard 5 turns

Sport 3 turns


Spring length with preload spacer(s) 405 mm (15.94 in)

Spring rate

Medium (standard) 9.5 N/mm (54.2 lb/in)

Air chamber length 80+20−10 mm (3.15+0.79

−0.39 in)

Fork length 735 mm (28.94 in)

Fork oil per fork leg 520 ml (17.58 fl. oz.) Fork oil (SAE 5) ( p. 437)

PartS

hark

.com

877-

999-

5686

TECHNICAL DATA - SHOCK ABSORBER 414

Shock absorber part number 17.18.7E.10

Shock absorber WP Suspension 4014 VP


Comfort 2 turns

Standard 1.5 turns

Sport 1 turn

Full payload 1 turn


Comfort 20 clicks

Standard 15 clicks

Sport 10 clicks


Rebound damping

Comfort 15 clicks

Standard 10 clicks

Sport 5 clicks


Spring preload





Spring rate

Medium (standard) 95 N/mm (542 lb/in)

Spring length 160 mm (6.3 in)


Static sag 10… 15 mm (0.39… 0.59 in)

Riding sag 30… 35 mm (1.18… 1.38 in)

Inbuilt length 290 mm (11.42 in)

PartS

hark

.com

877-

999-

5686

TECHNICAL DATA - CHASSIS TIGHTENING TORQUES 415

Screw, side stand switch M4 2 Nm (1.5 lbf ft) Loctite® 243™

Remaining frame bolts M5 5 Nm (3.7 lbf ft) –

Screw, brake fluid reservoir of rearbrake

M5 5 Nm (3.7 lbf ft) Loctite® 243™

Screw, brake line holder M5 5 Nm (3.7 lbf ft) –

Screw, chain guard M5 5 Nm (3.7 lbf ft) –

Screw, chain sliding piece M5 5 Nm (3.7 lbf ft) –

Screw, fuel level indicator M5 3 Nm (2.2 lbf ft) –

Screw, fuel tank guard M5x17 3 Nm (2.2 lbf ft) –

Screw, steering damper fixing bracket M5 5 Nm (3.7 lbf ft) Loctite® 243™

Bolt, foot brake pedal stub M6 10 Nm (7.4 lbf ft) Loctite® 243™

Remaining chassis nuts M6 15 Nm (11.1 lbf ft) –

Remaining chassis screws M6 10 Nm (7.4 lbf ft) –

Screw for wheel speed sensor bracket M6 3 Nm (2.2 lbf ft) Loctite® 243™

Screw, exhaust clamp M6 8 Nm (5.9 lbf ft) –

Screw, exhaust heat shield M6 15 Nm (11.1 lbf ft) –

Screw, foot brake cylinder M6 10 Nm (7.4 lbf ft) Loctite® 243™

Screw, foot brake pedal M6 15 Nm (11.1 lbf ft) Loctite® 243™

Screw, fuel pump M6 6 Nm (4.4 lbf ft) –

Screw, shift lever stub M6 10 Nm (7.4 lbf ft) Loctite® 243™

Screw, shift rod M6 12 Nm (8.9 lbf ft) Loctite® 243™

Screw, shift shaft deflector on chainsecuring guide


Screw, shift shaft deflector on shiftshaft


Fork end pinch bolts M8 15 Nm (11.1 lbf ft) –

Nut, forked bracket on foot brake pedal M8 30 Nm (22.1 lbf ft) Loctite® 243™



Screw of rear brake caliper M8 22 Nm (16.2 lbf ft) Loctite® 243™

Screw, bottom triple clamp M8 15 Nm (11.1 lbf ft) –

Screw, front brake disc M8 30 Nm (22.1 lbf ft) Loctite® 243™

Screw, front footrest bracket M8 25 Nm (18.4 lbf ft) Loctite® 243™

Screw, handlebar stub M8 20 Nm (14.8 lbf ft) –

Screw, ignition lock (ratchet screw) M8 Loctite® 243™

Screw, rear brake disc M8 30 Nm (22.1 lbf ft) Loctite® 243™

Screw, rear footrest bracket M8 25 Nm (18.4 lbf ft) –

Screw, shift lever M8 25 Nm (18.4 lbf ft) Loctite® 243™

Screw, side stand bracket M8 25 Nm (18.4 lbf ft) Loctite® 243™

Screw, spring holder on side standbracket


Screw, steering damper clamp on con-sole


Screw, steering damper fixing bracketon triple clamp


Screw, steering stem M8 20 Nm (14.8 lbf ft) –

Screw, subframe M8 20 Nm (14.8 lbf ft) Loctite® 243™

Screw, top triple clamp M8 17 Nm (12.5 lbf ft) –

Screw, work stand adapter M8 25 Nm (18.4 lbf ft) Loctite® 243™



Screw, connecting lever, shockabsorber deflector


PartS

hark

.com

877-

999-

5686

TECHNICAL DATA - CHASSIS TIGHTENING TORQUES 416

Screw, engine bearer M10 45 Nm (33.2 lbf ft) –

Screw, shock absorber M10 45 Nm (33.2 lbf ft) Loctite® 243™

Screw, side stand M10 35 Nm (25.8 lbf ft) Loctite® 243™

Rear sprocket bolt M10x1.25 50 Nm (36.9 lbf ft) Loctite® 243™

Screw, front brake caliper M10x1.25 45 Nm (33.2 lbf ft) Loctite® 243™

Nut of bell crank on frame M14x1.5 100 Nm (73.8 lbf ft) –

Lambda sensor M18x1.5 45 Nm (33.2 lbf ft) –

Nut, swingarm pivot M19x1.5 130 Nm (95.9 lbf ft) Thread greased

Screw, seat lock M22x1.5 8 Nm (5.9 lbf ft) –

Bolt, front axle M25x1.5 45 Nm (33.2 lbf ft) –

Nut, rear wheel spindle M25x1.5 90 Nm (66.4 lbf ft) Thread greased

Screw, steering head M25x1.5 18 Nm (13.3 lbf ft) –

PartS

hark

.com

877-

999-

5686

CLEANING/CONSERVATION 417

40.1Cleaning motorcycle

NoteMaterial damage Damage and destruction of components by high-pressure cleaning equipment.

– Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electri-cal components, socket connects, throttle cables, and bearings, etc., and can damage or destroy these parts.



InfoTo maintain the value and appearance of the motorcycle over a long period, clean it regularly.Avoid direct sunshine when cleaning the motorcycle.

– Before cleaning, seal the exhaust system to prevent water from entering.

– Remove loose dirt first with a soft jet of water.

– Spray very dirty parts with a normal commercial engine cleaner and then brush off with a soft brush.

Motorcycle cleaner ( p. 439)

InfoUse warm water mixed with a normal commercial engine cleaner and a soft sponge.If the vehicle has been used on salted roads, clean it with cold water. Warm water intensifies the effects of salt.

– After cleaning the motorcycle thoroughly with a soft jet of water, dry it with compressed air and a cloth.

WarningDanger of accidents Reduced braking efficiency due to wet or dirty brakes.

– Clean or dry dirty or wet brakes by riding and braking gently.

– After cleaning, ride a short distance until operating temperature is reached, and apply the brakes.

InfoThe heat causes water to evaporate from inaccessible parts of the engine and brakes.

– After the engine has cooled down, lubricate or grease all moving parts and bearings.


– Treat bare metal (except for brake discs and the exhaust system) with an anticorrosive.

Cleaning and polishing materials for metal, rubber and plastic ( p. 438)

– Treat all painted parts with a mild lacquer care spray.

Paint cleaner and polish for high-gloss and matte finishes, bare metal and plastic surfaces ( p. 439)

– Oil the ignition/steering lock, tank lock, and seat lock.

Universal oil spray ( p. 439)

40.2Conservation for winter operation

InfoIf you use the motorcycle in the winter, you have to expect salt on the roads. You therefore have to take precautions against theaggressive road salt.If the vehicle has been used on salted roads, clean it with cold water. Warm water intensifies the effects of salt.

– Clean the motorcycle. ( p. 417)

– Treat the engine, swingarm and all other bare or galvanized parts (except the brake discs) with a wax-based anticorrosive.

InfoAvoid getting anticorrosive on the brake discs: this would badly affect the braking.After riding on salted roads, thoroughly wash the motorcycle with cold water and dry it well.

PartS

hark

.com

877-

999-

5686

CLEANING/CONSERVATION 418


PartS

hark

.com

877-

999-

5686

STORAGE 419

41.1Storage

InfoIf you want to garage the motorcycle for a longer period, take the following actions.Before storing the motorcycle, check all parts for function and wear. If service, repairs or replacements are necessary, youshould do this during the storage period (less workshop overload). In this way, you can avoid long workshop waiting times at thestart of the new season.

– Make sure the tank is as empty as possible so that you can fill up with fresh fuel when you put the motorcycle back into operation.

– Clean the motorcycle. ( p. 417)

– Change the engine oil and filter, clean the oil screens. ( p. 209)


– Check the antifreeze. ( p. 194)

– Check the tire pressure. ( p. 79)

– Remove the battery. ( p. 88)

– Recharge the battery. ( p. 90)

Guideline

Storage temperature of battery without direct sunshine. 0… 35 °C (32… 95 °F)

– The storage place should be dry and not subject to large temperature differences.

InfoKTM recommends jacking up the motorcycle.

– Jack up the motorcycle at the rear. ( p. 13)

– Jack up the motorcycle at the front. ( p. 10)

– Cover the motorcycle with a porous sheet or blanket.

InfoDo not use non-porous materials since they prevent humidity from escaping, thus causing corrosion.Avoid running the engine for a short time only. Since the engine cannot warm up properly, the water vapor produced duringcombustion condenses and causes valves and exhaust system to rust.

41.2Putting into operation after storage– Take the front of the motorcycle off the work stand. ( p. 10)


– Recharge the battery. ( p. 90)

– Install the battery. ( p. 89)


– Fill up with fuel.

– Make checks before putting into operation.

– Take a test ride.PartS

hark

.com

877-

999-

5686

SERVICE SCHEDULE 420

42.1Important service tasks to be carried out by an authorized KTM-RC8 workshop.

K10N K75A K150A J1A J2A

Engine Change the engine oil and filter, clean the oil screens. ( p. 209) • • • • •

Check the valve clearance. ( p. 200) •

Replace the spark plugs. •

Check the engine attachment bolts and other engine bolts accessi-ble from outside to ensure that they are tight.

• • •

Check the clutch. •

Check / clean the oil jet for clutch lubrication. ( p. 216) •

Fuel injection Read out the status request and fault memory with the KTM diag-nostics tool.

• • •

Check bellows for tears and leaks, and check the linkage of thethrottle valve spigot for freedom of movement.

•

Check the wiring harness of the throttle valve body for damage andcorrect routing.

•

Check hoses of vacuum sensors, SLS hoses and vent hoses fordamage, correct routing and leaks.

• • • • •

Check the fuel hose for damage, correct routing and leaks. • • • • •

Check the fuel pressure. ( p. 73) • •

Attachments Check the cooling system for leaks. • • • • •

Check the water pump for leaks (visual check). • • •

Check the coolant level. ( p. 194) • • • • •

Check the antifreeze. ( p. 194) • • • • •

Check radiator fan operation. • • •

Check the exhaust system for leaks and correct fitting and checkthat the exhaust brackets are tight.

• • •

Check the control cables for damage, smooth operation, kink-freerouting and adjustment.

• • • • •

Check the fluid level of the hydraulic clutch. ( p. 191) • • • •

Check the air filter and change if necessary. Clean the air filterbox.

•

Drain the drainage hose of the air filter box. • • • • •

Check cables for damage and kink-free routing. • • •

Check the headlight setting. ( p. 110) • • • • •

Check that the electrical equipment is functioning properly. • • • • •

Check the fairing parts for damage and breakage. • • •

Check the fasteners for tightness. • • •

Brakes Check the front brake linings. ( p. 93) • • •

Check the rear brake linings. ( p. 96) • • •

Check the front brake discs. ( p. 80) • • •

Check the rear brake disc. ( p. 83) • • •

Check the front brake fluid level. ( p. 95) • • • • •

Check the rear brake fluid level. ( p. 99) • • • • •

Change brake fluid. • •

Check that brake lines are undamaged and free of leaks. • • • • •

Check the braking. • • • • •

Check the bolts and guide pins of the brake system for tightness. • • •

Chassis Check the operation of the forks and the rear shock absorber, alsocheck for leaks.

• • • • •

Bleed fork legs. ( p. 16) • • • • •

Check the steering head bearings and adjust if necessary. • • •

Check the swingarm bearings. • • •

Check deflector. • •

Check the eccentric shaft adjustment. • •

PartS

hark

.com

877-

999-

5686

SERVICE SCHEDULE 421

K10N K75A K150A J1A J2A

Chassis Check all bolts to make sure they are tight. • • •

Wheels Check the tire condition. ( p. 78) • • •

Check the tire pressure. ( p. 79) • • • • •

Check the chain wear. ( p. 86) • • •

Check the rear sprocket / engine sprocket / chain sliding guard toensure that they are tight.

• • •

Check the rear sprocket / engine sprocket for wear. ( p. 85) • • •

Check the chain tension. ( p. 84) • • •

Clean the chain. ( p. 84) • • • • •

Check chain sliding guard. ( p. 86) • • • • •

Check wheel bearings for play. • • •

Check the rear hub cush drive. ( p. 86) • • • • •

K10N: after 1,000 km (621.4 mi)K75A: every 7,500 km (4,660 mi)K150A: every 15,000 km (9,320 mi) / after every sporting useJ1A: annuallyJ2A: every 2 years

42.2Important service tasks to be carried out by an authorized KTM-RC8 workshop. (as additional job)

K150N K150A K300A J1A J2N J2A J4A

Perform a fork service. ( p. 21) • • • •

Perform a shock absorber service. ( p. 48) • •

Clean and grease the steering head bearing and sealing elements. • • • •

Clean the battery terminals and treat with contact grease. • • •

Change the coolant. • •

K150N: after 15,000 km (9,320 mi)K150A: every 15,000 km (9,320 mi) / after every sporting useK300A: every 30,000 km (18,640 mi)J1A: annuallyJ2N: after 2 yearsJ2A: every 2 yearsJ4A: every 4 years

PartS

hark

.com

877-

999-

5686

WIRING DIAGRAM 422

43.11 of 3

E D C BF A

E D C BF A

87

65

43

21

87

65

43

21

P.

Page: 13

/2.B5STR-A3

/3.D6

flaL-X200

/3.D6

flaR-X200

/3.A7lig-X3

/2.C1

K4-X8

/3.D1

-X1

EF/14

-A11

23

45

67

89

1011

1213

14

/2.E5fuel-A4

/3.E1tlig-H1

/3.B2B+

/3.B6ACC1

EB/4

-K2

12

34

15A

12

-F2

10A

12

-F8

10A

12

-F5

BS/2

BV/2

-S3

12

EB/4

-K4

12

34

10A

12

-F6

10A

12

-F1

BK/4

BR/4

-S2

12

34

EB/4

-K3

12

34

EB/4

-K5

12

34

G3

-G2

EN/3

EM/3

-G1

A 30

AF/4

-K1

43

21

M

-M1

U

AU/2BI/2

-N1

1 22 1

/2.C2

GND#1

AI/2

-V1

12

/2.B3B+

/2.B1GND#1

-X5

-X4

-X1-X2

-X3

BP/4

DG

/4

-X150

12

34

EL/2

DV/2

12

/2.B3#Ant-1

/2.B3#Ant-2

-S1

12

AU/2

BI/2

/3.D6

GND#1

/2.B3#702

M

AM/3

AR/3

-M2

12

3

3131415161718

248

1234

2-X40148

3-X403131415161718

1 -X405

234

gn

11

90

RC

8 (R

) 20

09

ER

/10E

Q/10

ES/18

ET/18

EU/4

AF/4

11

121920

1926

24

27

1431

301

82,177

25

28

38

36,37

38910

68

86175

176177

24,25

33

34

46

4,5,6

1

23

13

7,8,9,10,14

39

716668

68717069

11,12,13

1615

21

21353126321537

20

29

23

23

36

35

5758

6160

65

64606163

62

34

33,62

152

147

63 65 64939598

29

32

86 85 84 83 82 81 74

74 81 83

27,28,30,39,46,66

69

178

178

144,153,169,182

84

1

175,176,144,153,169,18295

98,152,147

146145

54,55

600859-01

PartS

hark

.com

877-

999-

5686

WIRING DIAGRAM 423

Components

A1 Plug-in connector for alarm system (optional) F1‑2

G1 Battery A7

G2 Generator B‑C8

K1 Starter relay with main fuse A6

K2 Fuel pump relay F4

K3 Light relay F5‑6

K4 Power relay F6

K5 Start auxiliary relay F7

M1 Starter motor A‑B6

M2 Fuel pump F5

N1 Voltage regulator/rectifier B8

S1 Ignition/steering lock, ICU antenna A1‑2

S2 Emergency OFF switch, electric starter button A2‑3

S3 Seat monitoring switch (optional) F3‑4

V1 Diode A4

X150 Resistance F3

Cable colors

gn Green

1 Green

2 Green

3 Green

4 Green

5 Green

6 Green

7 White-red

8 White-red

9 White-red

10 White-red

11 White-red

12 White-red

13 White-red

14 White-red

15 White-red

16 Yellow

19 Black-yellow

20 Black-green

21 Yellow-red

23 Black-blue

24 White-orange

25 White-orange

26 Blue-gray

27 Brown

28 Brown

29 Orange

30 Brown

31 Red

32 Yellow-orange

33 Brown

34 Red

35 Green-orange

36 Red-violet

PartS

hark

.com

877-

999-

5686

WIRING DIAGRAM 424

37 Red-violet

38 Blue-red

39 Brown

46 Brown

54 Brown

55 Brown

57 Black

58 Violet

60 White-black

61 Red-violet

62 Brown

63 White-red

64 Blue-red

65 Yellow-orange

66 Brown

68 White-red

69 White-red

70 Brown

71 Yellow

74 Yellow-red

81 Green-orange

82 Red

83 Blue-gray

84 Yellow-orange

85 White-red

86 Red-violet

93 Blue-red

95 Yellow-orange

98 White-red

144 Yellow-orange

145 Green

146 Black-green

147 White-red

152 White-red

153 Yellow-orange

169 Yellow-orange

175 Yellow-orange

176 Yellow-orange

177 Red

178 White-red

182 Yellow-orange

PartS

hark

.com

877-

999-

5686

WIRING DIAGRAM 425

PartS

hark

.com

877-

999-

5686

WIRING DIAGRAM 426

43.22 of 3

E D C BF A

E D C BF A

87

65

43

21

87

65

43

21

P.

Page: 23

/3.B2Neu-P1

/3.B2GND-P1

/3.F1CLU-S6

/1.B4fuel-A4

/3.B2TAC-P1

/3.B2MIL-P1

/1.B4STR-A3

/1.E7K4-X8

/1.B6GND#1

AR/3

AM/3

-B1

13

2

AP/6

-B3

45

6D

P/3p

-B6

12

3A

L/2

AT/2

-L3

12

AP/6

-X501

23

45

6

12

34

56

78

910

1112

1314

1516

1718

1920

2122

2324

2526

12

34

56

78

910

1112

1314

1516

1718

1920

2122

2324

2526

2728

2930

3132

3334

43/

OC

62/

OA

-A4t°

L CA

/4

CE

/4

-B5

12

34

t°

L CA

/4

CE

/4

-B4

12

34

DO

/8

DN

/8

12

34

56

78

-A3

DP

/3p-B7

12

3D

P/3p

-B8

12

3

M

AE/4

-M4

21

43

M

CE

/4C

A/4

-M5

12

34

DQ

/2

-Y4

21

DQ

/2

-Y3

21

AM/3

AR/3

-B13

21

3AR

/3

AM/3

-B12

12

3

CP/16CQ/16-X300

12345678910111213141516

2.12.22.32.42.52.62.72.82.92.102.112.122.132.142.152.16

-L1

21

AS/2

-X101

-L2

21

AS/2

/3.D3

CAN-H

/3.D3

CAN-L

DF/2

-Y1

12

/1.D3

B+

/1.E7GND#1

-X6

-X7

-X8

-X303

-X302

-X301

-X15

-X17

-X16

-X13

-X12

-X11

-X14

/3.E1GND#2

-X9

AT/2

-X51

21 AL/2

-X10

/1.B2#Ant-1

/1.B2#Ant-2

/1.D3

#702/3.B2

#702-X26

2nd3th

N

AM/3

AR/3

-S4

12

3

DO

/8D

N/8

12

34

56

78

-A2

357910

3-X40157910

AX

/2

t°-B16

12

CM

/2

t°-B2

12

CK/2

-Y2

12FE

/2

11

90

RC

8 (R

) 20

09

EQ

/10E

R/10

244252

247251

258254

248256

257253

249238

243255

250

199200

190

198

202

203

196

184

187

207

88

201

128

104

204

103

206

208

210

212

214

215

107

194

219

221

121

97

126

83

209

211

213

216

157

163

220

192

222

209

210

216

211

220

224

219

208

203

215

200

212

225

221

41

94114

205

217218

81227226

228229202222230

121

120

192

191

197

196195194

193

128127126125

101

186

89

123

122

124

115

168189190188

161

163

157

239

256

240

251

250247248249

252253254255

241258

245

242257

246

44

29

49

50

40506743

46 48

4648

47

4542

109,118,129,167,171,181,213,214,22970

154

198

145146147148

149

151

94969710099

103

102

187

185

88

90

105

104

105

107

106

113

114

113

115,204,230

150

183184

223

41,404245

44,43

29

47

238,239

245,244246

241,243

228,206

96,149155,180,217

155,180

99,151

156,179,218

188,127,195,183

123,226,225,199185,90,102,189

193,125,205,120,191,106100,148,224

122

227

207

109,118,129,167,171,181,150

89,101,124,186,201,223,116

117

117116

260

93

261

600860-01

PartS

hark

.com

877-

999-

5686

WIRING DIAGRAM 427

Components

A2 Immobilizer control unit A3

A3 Control unit of electric starter lock A5

A4 EFI control unit F4‑7

B1 Side stand switch A4

B2 Intake air temperature sensor F1

B3 Roll angle sensor F1

B4 Lambda sensor (cylinder 2) F1‑2

B5 Lambda sensor (cylinder 1) F2

B6 Ambient air pressure sensor F2‑3

B7 Pressure sensor, induction manifold (cylinder 2) F3

B8 Pressure sensor, induction manifold (cylinder 1) F3

B12 Throttle position sensor circuit A A7

B13 Throttle position sensor circuit B A8

B16 Coolant temperature sensor (1st cylinder) F8

L1 Ignition coil (cylinder 2) F7

L2 Ignition coil (cylinder 1) F7

L3 Crankshaft position sensor F4

M4 Motor drive circuit A C‑D8

M5 Motor drive circuit B C‑D8

S4 Gear position sensor A4‑5

X50 Diagnostics connector A1

X51 CAN bus terminating resistor A2

Y1 Fuel evaporation valve (USA version only) A2

Y2 Secondary air valve F8

Y3 Injection valve (cylinder 2) C‑D7

Y4 Injection valve (cylinder 1) C‑D7

Cable colors

29 Orange

40 Black-blue

41 Black-blue

42 Black-blue

43 White-blue

44 White-blue

45 White-blue

46 Brown

47 Orange

48 Light blue

49 Orange

50 Black-orange

67 Orange

70 Brown

81 Green-orange

83 Blue-gray

88 Violet

89 Black

90 Blue

94 Light blue

96 Black-blue

97 Black-orange

99 White-blue

100 Orange

PartS

hark

.com

877-

999-

5686

WIRING DIAGRAM 428

101 Black

102 Blue

103 Green-gray

104 Yellow-blue

105 White-yellow

106 Orange

107 White-pink

109 Brown

113 Yellow-brown

114 Gray

115 Black-green

116 Black

117 Red-violet

118 Brown

120 Orange

121 White-violet

122 Pink

123 Blue

124 Black

125 Orange

126 White-orange

127 Black

128 Brown-red

129 Brown

145 Green

146 Black-green

147 White-red

148 Orange

149 Black-blue

150 Brown

151 White-blue

154 Brown-violet

155 Black-blue

156 White-blue

157 Black-brown

161 Black-green

163 White

167 Brown

168 Yellow

171 Brown

179 White-blue

180 Black-blue

181 Brown

183 Black

184 Red

185 Blue

186 Black

187 Black-blue

188 Black

189 Blue

190 Yellow-red

191 Orange

PartS

hark

.com

877-

999-

5686

WIRING DIAGRAM 429

192 White-brown

193 Orange

194 White-black

195 Black

196 Green-red

197 Brown

198 Brown-violet

199 Blue

200 Red-violet

201 Black

202 Blue-red

203 Black

204 Black-green

205 Orange

206 Yellow

207 Pink

208 Blue-orange

209 Blue-pink

210 Black-gray

211 Yellow-orange

212 White-red

213 Brown

214 Brown

215 Green

216 White-green

217 Black-blue

218 White-blue

219 Brown-gray

220 Yellow-green

221 Green-orange

222 Blue-brown

223 Black

224 Orange

225 Blue

226 Blue

227 Pink

228 Yellow

229 Brown

230 Black-green

238 Orange

239 Orange

240 Orange

241 Blue

242 Blue

243 Blue

244 Black

245 Black

246 Black

247 Black

248 Green

249 Gray

250 Violet

PartS

hark

.com

877-

999-

5686

WIRING DIAGRAM 430

251 Violet

252 Blue

253 Yellow

254 Red

255 Gray

256 Black-blue

257 Green-red

258 White

260 Blue-orange

PartS

hark

.com

877-

999-

5686

WIRING DIAGRAM 431

PartS

hark

.com

877-

999-

5686

WIRING DIAGRAM 432

43.33 of 3

E D C BF A

E D C BF A

87

65

43

21

87

65

43

21

P.

Page:33

/1.E3flaL-X200

/1.E3flaR-X200

/2.D7

TAC-P1

/2.D7

MIL-P1

/2.B6Neu-P1

/2.C3

GND-P1

/2.B7CLU-S6

/1.B3-X1

/1.B6tlig-H1

/1.D3

B+

BY/4CV/4

-X200

1234

2.12.22.32.4

AL/2

AT/2

-S6

1 2

BD

/12

HI

LOR

LP.light

AD

/12

-S7

13

24

56

78

9

M

AU/2

BI/2

-M3

12

12

-H7

DI/2

t

AV/2

-S9

12

AH/2AK/2

-S5

1 2

BJ/1AY/1

-X521 2.1

/2.C3

GND#2

/2.B6CAN-H

/2.D6

CAN-L

R

AT/2

AL/2

-B11

12

/1.A5lig-X3

10A

12

-F9

10A

12

-F3

10A

12

-F4

/1.B4ACC1

-H4

12

P

AH/2AK/2

-S10

12

PCR

/1

-S8

1

/1.E4GND#1

CW/2

CX/2

t°-B14

1 2

CU

/4-X500

12

34

-X19

-X18

-X201

-X25

EV/261 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

-P1G

AM/3

AR/3

-B10

1 2 3

-X20

AJ/3

BG/3

-H6

123

CW/2

CX/2

-H5

12

CW/2

CX/2

-H8

12

CW/2

CX/2

-H3

1 2

CW/2

CX/2

-H2

1 2EW/4

pos. low high-H1

1 2 3 4

DB

/4D

A/4

-S11

12

34

/2.B3#702

CR

/1-X24

1C

R/1

-X231

CR

/1-X21

1C

R/1

-X221

1245678

1-X403

245678

C_A

X/2t°

-B15

12

11

90

RC

8 (R

) 20

09

AN/4

ET/18

ES/18

5152,53

525556,5758,59

7787

132134

141140

108

108

109

55,54

54

80,13579,134

173

139,160172

110170,171

168

167

135133

139138

136

154

112

237234236235

235233

232237

236231

4,5,6

22

17

130

654

18

17182251535659

5758

71,136,137,172

80 79 78 76 75 73 72

169170165

164

111

110

72,17487

74

131

75

174

76,77

91

9192

152

153154

155156

92 119143

157158

140

159112

160161

162261

163164

165166

152

157161261163

73

259

118

119

130,131,138,159,162,129,150,133,132

137

71

109,118,129,167,171,181,150

142144143

144,153,169,182

166

155,180

156,179

182181180179

141,142,158

231

78

600861-01

PartS

hark

.com

877-

999-

5686

WIRING DIAGRAM 433

Components

B10 Wheel speed sensor D1

B11 Fuel level indicator A4

B14 Ambient air temperature sensor B1

B15 Engine coolant temperature sensor (2nd cylinder) F3

H1 Low beam, high beam, parking light D‑E1

H2 Front right flasher B1

H3 Front left flasher E1

H4 Horn F5‑6

H5 Rear right flasher C8

H6 Brake/tail light C‑D8

H7 License plate lamp D8

H8 Rear left flasher D‑E8

M3 Radiator fan A4‑5

P1 Combination instrument C‑D1

S5 Front brake light switch A1

S6 Clutch switch F1

S7 Horn switch, light switch, headlamp flasher button, flasher switch F3‑4

S8 Oil pressure sensor A4

S9 Thermoswitch A5

S10 Rear brake light switch B8

S11 MODE/LAP button F5

X21 Plug-in connector for supplementary equipment (terminal 30) A6



X24 Plug-in connector for supplementary equipment (terminal 31) A5‑6

X500 Plug-in connector not used A3

Cable colors

4 Green

5 Green

6 Green

17 Yellow-blue

18 White-black

22 Black-red

51 White-green

52 Yellow

53 Yellow

54 Brown

55 Brown

56 Black

57 Black

58 Violet

59 Violet

71 Yellow

72 Yellow-blue

74 Yellow-red

75 Black-red

76 White-green

77 White-green

78 Yellow

79 Black

80 Violet

PartS

hark

.com

877-

999-

5686

WIRING DIAGRAM 434

87 Yellow-blue

91 Yellow-green

92 Black-green

93 Blue-red

108 Black

109 Brown

110 Gray

111 Yellow-blue

112 Green-gray

118 Brown

119 Brown-red

129 Brown

130 Brown

131 Brown

132 Brown

133 Brown

134 Black

135 Violet

136 Yellow

137 Yellow

138 Brown

139 Blue

140 Gray

141 Yellow-green

142 Yellow-green

143 Black-orange

144 Yellow-orange

150 Brown

152 White-red

153 Yellow-orange

154 Brown-violet

155 Black-blue

156 White-blue

157 Black-brown

158 Yellow-green

159 Brown

160 Blue

161 Black-green

162 Brown

163 White

164 Red

165 Green

166 Blue-orange

167 Brown

168 Yellow

169 Yellow-orange

170 Brown

171 Brown

172 Yellow

173 Yellow

174 Yellow-blue

179 White-blue

PartS

hark

.com

877-

999-

5686

WIRING DIAGRAM 435

180 Black-blue

181 Brown

182 Yellow-orange

231 Brown

232 Brown

233 Brown

234 Brown

235 Violet

236 Black

237 White

PartS

hark

.com

877-

999-

5686

OPERATING SUBSTANCES 436

Brake fluid DOT 4 / DOT 5.1According to– DOT

Guideline– Use only brake fluid that complies with the specified standards (see specifications on the container) and that possesses the corre-

sponding properties. KTM recommends Castrol and Motorex® products.

SupplierCastrol– RESPONSE BRAKE FLUID SUPER DOT 4

Motorex®

– Brake Fluid DOT 5.1

CoolantGuideline– Use only suitable coolant (also in countries with high temperatures). Use of low-quality antifreeze can lead to corrosion and foam-

ing. KTM recommends Motorex® products.

Mixture ratio

Antifreeze protection: −25… −45 °C (−13…−49 °F)

50 % corrosion inhibitor/antifreeze50 % distilled water

Coolant (mixed ready to use)

Antifreeze −40 °C (−40 °F)

SupplierMotorex®

– Anti Freeze

Engine oil (SAE 10W/50)According to– JASO T903 MA ( p. 452)

– SAE ( p. 452) (SAE 10W/50)

Guideline– Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corre-

sponding properties. KTM recommends Motorex® products.

Fully synthetic engine oil

SupplierMotorex®

– Power Synt 4T

Engine oil (SAE 5W/40)According to– JASO T903 MA ( p. 452)

– SAE ( p. 452) (SAE 5W/40)

Guideline– Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corre-

sponding properties. KTM recommends Motorex® products.

Synthetic engine oil

SupplierMotorex®

– Power Synt 4T

PartS

hark

.com

877-

999-

5686

OPERATING SUBSTANCES 437

Fork oil (SAE 5)According to– SAE ( p. 452) (SAE 5)

Guideline– Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding

properties. KTM recommends Motorex® products.

SupplierMotorex®

– Racing Fork Oil

Hydraulic fluid (15)According to– ISO VG (15)

Guideline– Use only hydraulic fluid that complies with the specified standards (see specifications on the container) and that possesses the

corresponding properties. KTM recommends Motorex® products.

SupplierMotorex®

– Hydraulic Fluid 75

Shock absorber oil (SAE 2.5) (50180342S1)According to– SAE ( p. 452) (SAE 2.5)

Guideline– Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding

properties.

Super unleaded (ROZ 98 / RON 98 / PON 94)According to– DIN EN 228 (ROZ 98 / RON 98 / PON 94)

PartS

hark

.com

877-

999-

5686

AUXILIARY SUBSTANCES 438

Chain cleanerGuideline– KTM recommends Motorex® products.

SupplierMotorex®

– Chain Clean 611

Chain lube for road useGuideline– KTM recommends Motorex® products.

SupplierMotorex®

– Chain Lube 622 Strong

Cleaning and polishing materials for metal, rubber and plasticGuideline– KTM recommends Motorex® products.

SupplierMotorex®

– Protect & Shine 645

Long-life greaseGuideline– KTM recommends Motorex® products.

SupplierMotorex®

– Fett 2000

Lubricant (T511)Guideline– KTM recommends Lubcon® products.

SupplierLubcon®

– Turmsilon® GTI 300 P

Lubricant (T152)Guideline– KTM recommends Bel‑Ray® products.

SupplierBel‑Ray®

– Molylube® Anti‑Seize

Lubricant (T159)Guideline– KTM recommends Bel‑Ray® products.

SupplierBel‑Ray®

– MC‑11®

Lubricant (T158)Guideline– KTM recommends Lubcon® products.

SupplierLubcon®

– Turmogrease® PP 300

PartS

hark

.com

877-

999-

5686

AUXILIARY SUBSTANCES 439

Lubricant (T625)Guideline– KTM recommends Molykote® products.

SupplierMolykote®

– 33 Medium

Motorcycle cleanerGuideline– KTM recommends Motorex® products.

SupplierMotorex®

– Moto Clean 900

Paint cleaner and polish for high-gloss and matte finishes, bare metal and plastic surfacesGuideline– KTM recommends Motorex® products.

SupplierMotorex®

– Clean & Polish

Universal oil sprayGuideline– KTM recommends Motorex® products.

SupplierMotorex®

– Joker 440 Universal

PartS

hark

.com

877-

999-

5686

SPECIAL TOOLS 440

Bearing puller

400037-01

Art. no.: 15112017000

Circlip pliers reverse

400059-01

Art. no.: 51012011000

Extractor

400073-01

Art. no.: 58429009000

Valve spring mounter

400101-01

Art. no.: 59029019000

Limit plug gauge

400104-01

Art. no.: 59029026006

PartS

hark

.com

877-

999-

5686

SPECIAL TOOLS 441

Feeler gauge

25

20

30

15

1012

5

35

400110-01

Art. no.: 59029041100

Graduated disc

400120-01

Art. no.: 60029010000

Plastigauge measuring strips

400122-01

Art. no.: 60029012000

Piston ring mounting tool

400123-01

Art. no.: 60029015000

Insert for bearing puller

400038-01

Art. no.: 60029018000

Feature

23… 28 mm (0.91… 1.1 in)

PartS

hark

.com

877-

999-

5686

SPECIAL TOOLS 442

Step bearing tool

400136-01

Art. no.: 60029046028

Pliers for spring-loaded band-type clamp

400085-01

Art. no.: 60029057100

Multi-tooth wrench socket 10 mm; ½" drive

400145-01

Art. no.: 60029075000

Work stand rear

500077-01

Art. no.: 61029055100

Work stand adapter

700270-01

Art. no.: 61029055120

PartS

hark

.com

877-

999-

5686

SPECIAL TOOLS 443

Front work stand

500078-01

Art. no.: 61029055300

Pressure testing tool

400149-01

Art. no.: 61029094000

Engine work stand

200306-01

Art. no.: 61229001000

Engine holder

200307-01

Art. no.: 61229002000

Clutch holder

200308-01

Art. no.: 61229003000

PartS

hark

.com

877-

999-

5686

SPECIAL TOOLS 444

Mounting sleeve

200309-01

Art. no.: 61229005000

Pressure piece

200438-01

Art. no.: 61229008000

Extractor

200310-01

Art. no.: 61229010000

Press drift

200311-01

Art. no.: 61229013000

Engine blocking screw

200312-01

Art. no.: 61229015000

PartS

hark

.com

877-

999-

5686

SPECIAL TOOLS 445

Pressure bell

200313-01

Art. no.: 61229016000

Arms for extractor 78029033100

200314-01

Art. no.: 61229017000

Pressure piece

200315-01

Art. no.: 61229018000

Extractor

200316-01

Art. no.: 61229020000

Release device for timing chain tensioner

200317-01

Art. no.: 61229021000

PartS

hark

.com

877-

999-

5686

SPECIAL TOOLS 446

Hex key bit

200318-01

Art. no.: 61229025000

Press drift/press sleeve

200319-01

Art. no.: 61229044000

Press sleeve

200320-01

Art. no.: 61229045000

Frame support

400490-01

Art. no.: 61229050000

Centering pin

400491-01

Art. no.: 61229051000

PartS

hark

.com

877-

999-

5686

SPECIAL TOOLS 447

Floor jack attachment

400184-01

Art. no.: 61229055000

Work stand

400151-01

Art. no.: 62529055000

Adjustment gauge, control time, cylinder 2

301465-10

Art. no.: 69129030000

Adjustment gauge, control time, cylinder 1

301466-10

Art. no.: 69129130000

Piston pin lock ring insert

400160-01

Art. no.: 75029035000

PartS

hark

.com

877-

999-

5686

SPECIAL TOOLS 448

Oil pressure testing adapter

400169-01

Art. no.: 75029094000

Spark plug wrench

400170-01

Art. no.: 75029172000

Puller, 2-arm

500166-01

Art. no.: 78029033100

Valve spring mounting device

500165-01

Art. no.: 78029060000

Hook wrench

301085-01

Art. no.: T106S

PartS

hark

.com

877-

999-

5686

SPECIAL TOOLS 449

Depth micrometer

300577-10

Art. no.: T107S

Pressing tool

200583-10

Art. no.: T1206

Pressing tool

200585-01

Art. no.: T1207S

Pressing tool

200584-01

Art. no.: T129

Gripping tool

200639-10

Art. no.: T14026S1

PartS

hark

.com

877-

999-

5686

SPECIAL TOOLS 450

Open-end wrench

200640-10

Art. no.: T14032

Nitrogen filling tool

300574-10

Art. no.: T170S1

Mounting sleeve

300578-10

Art. no.: T313

Key

200641-10

Art. no.: T524

Clamping stand

200636-10

Art. no.: T526S

PartS

hark

.com

877-

999-

5686

SPECIAL TOOLS 451

Clamping stand

200638-10

Art. no.: T612S

PartS

hark

.com

877-

999-

5686

STANDARDS 452

JASO T903 MADifferent technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Ear-lier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specifi-cation. Whereas long service intervals are demanded for automobile engines, high performance at high engine speeds are in the fore-ground for motorcycle engines. With most motorcycles, the gearbox and the clutch are lubricated with the same oil as the engine. TheJASO MA Standard meets these special requirements.

SAEThe SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to their vis-cosity. The viscosity describes only one property of oil and says nothing about quality.

PartS

hark

.com

877-

999-

5686

INDEX 453

INDEX

A

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Air filterinstalling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Ambient air pressure sensor . . . . . . . . . . . . . . . . . . . . . . 225

Antifreezechecking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

Assembling the enginebalancer shaft, installing . . . . . . . . . . . . . . . . . . . . . 174clutch cover, installing . . . . . . . . . . . . . . . . . . . . . . 172clutch facing, installing . . . . . . . . . . . . . . . . . . . . . . 171crankshaft, installing . . . . . . . . . . . . . . . . . . . . . . . . 165drive wheel of the balancer shaft, installing . . . . . . . . 173engine bracket, mounting . . . . . . . . . . . . . . . . . . . . 189engine, dismounting from work stand . . . . . . . . . . . . 189force pump, installing . . . . . . . . . . . . . . . . . . . . . . . 168front camshafts, installing . . . . . . . . . . . . . . . . . . . . 182front cylinder control time, adjusting . . . . . . . . . . . . . 186front cylinder control time, checking . . . . . . . . . . . . . 186front cylinder head, installing . . . . . . . . . . . . . . . . . . 182front piston, installing . . . . . . . . . . . . . . . . . . . . . . . 180front timing chain tensioner, installing . . . . . . . . 183, 207front valve clearance, adjusting . . . . . . . . . . . . . . . . 188front valve clearance, checking . . . . . . . . . . . . . . . . . 187front valve cover, installing . . . . . . . . . . . . . . . . . . . 188gear position sensor, installing . . . . . . . . . . . . . . . . . 173generator cover, installing . . . . . . . . . . . . . . . . . . . . 176heat exchanger, installing . . . . . . . . . . . . . . . . . . . . 183idler and timing chain on the left, installing . . . . . . . . 174idler and timing chain on the right, installing . . . . . . . 172ignition pulse generator, installing . . . . . . . . . . . . . . 176ignition top dead center of the front cylinder, setting . . 180ignition top dead center of the rear cylinder, setting . . 169left engine case, installing . . . . . . . . . . . . . . . . . . . . 166left suction pump, installing . . . . . . . . . . . . . . . . . . 169locking lever, installing . . . . . . . . . . . . . . . . . . . . . . 167middle suction pump, installing . . . . . . . . . . . . . . . . 165oil drain plug, installing . . . . . . . . . . . . . . . . . . . . . . 176oil filler tube, installing . . . . . . . . . . . . . . . . . . . . . . 184oil filter, installing . . . . . . . . . . . . . . . . . . . . . . . . . 175oil spray tube, installing . . . . . . . . . . . . . . . . . . . . . 164outer clutch hub, installing . . . . . . . . . . . . . . . . . . . 170primary gear, installing . . . . . . . . . . . . . . . . . . . . . . 170rear camshaft, installing . . . . . . . . . . . . . . . . . . . . . 179rear cylinder control time, adjusting . . . . . . . . . . . . . 184rear cylinder control time, checking . . . . . . . . . . . . . . 184rear cylinder head, installing . . . . . . . . . . . . . . . . . . 178rear piston, installing . . . . . . . . . . . . . . . . . . . . . . . 177rear timing chain tensioner, installing . . . . . . . . 179, 207rear valve clearance, adjusting . . . . . . . . . . . . . . . . . 186rear valve clearance, checking . . . . . . . . . . . . . . . . . 185rear valve cover, installing . . . . . . . . . . . . . . . . . . . . 188rotor, installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175shift drum locating, installing . . . . . . . . . . . . . . . . . . 167shift shaft, installing . . . . . . . . . . . . . . . . . . . . . . . . 167starter motor, installing . . . . . . . . . . . . . . . . . . . . . . 184timing chain rails of the left engine case section, installing 163timing chain rails of the right engine case section,installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

torque limiter and idler, installing . . . . . . . . . . . . . . . 176transmission shaft, installing . . . . . . . . . . . . . . . . . . 164water pump wheel, installing . . . . . . . . . . . . . . . . . . 173

B

Batteryinstalling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89recharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Blank time of the LAP button LAP BLANK Tsetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Blink codeengine control . . . . . . . . . . . . . . . . . . . . . . . . . 238-390immobilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . 229-237

Brake disc of rear brakechecking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Brake discs, frontchecking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Brake fluidfront brake, adding . . . . . . . . . . . . . . . . . . . . . . . . . . 95rear brake, adding . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Brake fluid levelfront brake, checking . . . . . . . . . . . . . . . . . . . . . . . . 95rear brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . 99

Brake linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93front brake linings, changing . . . . . . . . . . . . . . . . . . . 93front brake, checking . . . . . . . . . . . . . . . . . . . . . . . . 93rear brake, changing . . . . . . . . . . . . . . . . . . . . . . . . . 97rear brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . 96

C

Camshaft, rearinstalling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

Camshafts, frontinstalling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

Chainchecking for dirt . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83checking for wear . . . . . . . . . . . . . . . . . . . . . . . . . . . 86cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Chain sliding guardchecking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Chain tensionadjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Clutchfluid level, checking . . . . . . . . . . . . . . . . . . . . . . . . 191fluid level, correcting . . . . . . . . . . . . . . . . . . . . . . . 191

Clutch leveradjusting basic position . . . . . . . . . . . . . . . . . . . . . . . 32

Combination instrumentactivating BOOTLOADER mode . . . . . . . . . . . . . . . . . . 105updating software . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Connector overview . . . . . . . . . . . . . . . . . . . . . . . . . 391-404Conservation for winter operation . . . . . . . . . . . . . . . . . . . 417Control unit of electric starter lock . . . . . . . . . . . . . . . . . . . 88

PartS

hark

.com

877-

999-

5686

INDEX 454

Coolantrefilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

Coolant levelchecking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

Cooling systembleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196filling compensating tank . . . . . . . . . . . . . . . . . . . . . 197

Crankshaft position sensor . . . . . . . . . . . . . . . . . . . . . . . 218

D

Disassembling the enginebalancer shaft, removing . . . . . . . . . . . . . . . . . . . . . 129clutch cover, removing . . . . . . . . . . . . . . . . . . . . . . 131clutch facing, removing . . . . . . . . . . . . . . . . . . . . . . 132crankshaft, removing . . . . . . . . . . . . . . . . . . . . . . . . 135engine bracket, removing . . . . . . . . . . . . . . . . . . . . . 122engine oil, draining . . . . . . . . . . . . . . . . . . . . . . . . . 122engine, clamping into engine work stand . . . . . . . . . . 122force pump, removing . . . . . . . . . . . . . . . . . . . . . . . 133front camshafts, removing . . . . . . . . . . . . . . . . . . . . 126front cylinder head, removing . . . . . . . . . . . . . . . . . . 126front piston, removing . . . . . . . . . . . . . . . . . . . . . . . 127front timing chain tensioner, removing . . . . . . . . . . . . 126front valve cover, removing . . . . . . . . . . . . . . . . . . . . 123gear position sensor, removing . . . . . . . . . . . . . . . . . 130generator cover, removing . . . . . . . . . . . . . . . . . . . . 127heat exchanger, removing . . . . . . . . . . . . . . . . . . . . 124idler and timing chain on the left, removing . . . . . . . . 128idler and timing chain on the right, removing . . . . . . . 132ignition pulse generator, removing . . . . . . . . . . . . . . . 127ignition top dead center of the front cylinder, setting . . 126ignition top dead center of the rear cylinder, setting . . 123left engine case, removing . . . . . . . . . . . . . . . . . . . . 135left suction pump, removing . . . . . . . . . . . . . . . . . . . 130locking lever, removing . . . . . . . . . . . . . . . . . . . . . . 135middle suction pump, removing . . . . . . . . . . . . . . . . 136oil filler tube, removing . . . . . . . . . . . . . . . . . . . . . . 124oil filter, removing . . . . . . . . . . . . . . . . . . . . . . . . . 129oil spray tube, removing . . . . . . . . . . . . . . . . . . . . . 137outer clutch hub, removing . . . . . . . . . . . . . . . . . . . 132rear camshaft, removing . . . . . . . . . . . . . . . . . . . . . 125rear cylinder head, removing . . . . . . . . . . . . . . . . . . 125rear piston, removing . . . . . . . . . . . . . . . . . . . . . . . 125rear timing chain tensioner, removing . . . . . . . . . . . . 124rear valve cover, removing . . . . . . . . . . . . . . . . . . . . 123rotor, removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128shift drum locating, removing . . . . . . . . . . . . . . . . . . 134shift shaft, removing . . . . . . . . . . . . . . . . . . . . . . . . 134starter motor, removing . . . . . . . . . . . . . . . . . . . . . . 124timing chain rails of the left engine case section, removing 137timing chain rails of the right engine case section, remov-ing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137transmission shaft, removing . . . . . . . . . . . . . . . . . . 136water pump wheel, removing . . . . . . . . . . . . . . . . . . 131

Dismantling the enginedrive wheel of the balancer shaft, removing . . . . . . . . 129primary gear, removing . . . . . . . . . . . . . . . . . . . . . . 133torque limiter and idler, removing . . . . . . . . . . . . . . . 128

E

EFI control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227activation code, requesting . . . . . . . . . . . . . . . . . . . 227coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227flashing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228, 335

Engineignition top dead center of the front cylinder, setting . . 121ignition top dead center of the rear cylinder, setting . . 120installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117preparing for installation . . . . . . . . . . . . . . . . . . . . . 117removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Engine - Work on individual partsclutch cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145clutch, checking . . . . . . . . . . . . . . . . . . . . . . . . . . . 156conrod bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144countershaft, assembling . . . . . . . . . . . . . . . . . . . . . 161countershaft, dismantling . . . . . . . . . . . . . . . . . . . . 159cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149cylinder head, checking . . . . . . . . . . . . . . . . . . . . . . 152cylinder, checking/measuring . . . . . . . . . . . . . . . . . . 147left engine case section . . . . . . . . . . . . . . . . . . . . . . 141left main bearing, installing . . . . . . . . . . . . . . . . . . . 143left main bearing, removing . . . . . . . . . . . . . . . . . . . 143main bearing of the right engine case section, removing 139main bearing shells, selecting . . . . . . . . . . . . . . . . . 140main shaft, assembling . . . . . . . . . . . . . . . . . . . . . . 161main shaft, dismantling . . . . . . . . . . . . . . . . . . . . . . 158oil pressure regulator valve, checking . . . . . . . . . . . . 155oil pumps, checking . . . . . . . . . . . . . . . . . . . . . . . . 155piston ring end gap, checking . . . . . . . . . . . . . . . . . . 149piston, checking/measuring . . . . . . . . . . . . . . . . . . . 148piston/cylinder mounting clearance, checking . . . . . . . 149radial clearance of the bottom connecting rod bearing,checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147right engine case section . . . . . . . . . . . . . . . . . . . . . 138right idler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153right main bearing, installing . . . . . . . . . . . . . . . . . . 140shift mechanism, checking . . . . . . . . . . . . . . . . . . . 157shift shaft, preassembling . . . . . . . . . . . . . . . . . . . . 158step bearing of the crankshaft, changing . . . . . . . . . . 146timing assembly, checking . . . . . . . . . . . . . . . . . . . . 154timing chain tensioner for installation, preparing . . . . . 154transmission, checking . . . . . . . . . . . . . . . . . . . . . . 160

Engine coolant temperature sensorcylinder 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198cylinder 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Engine oiladding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209refilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

Engine oil levelchecking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

Engine oil pressurechecking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213

Exhaust air injection valve . . . . . . . . . . . . . . . . . . . . . . . 190

Exhaust coverinstalling completely . . . . . . . . . . . . . . . . . . . . . . . . . 63

PartS

hark

.com

877-

999-

5686

INDEX 455

removing completely . . . . . . . . . . . . . . . . . . . . . . . . . 63

Exhaust systeminstalling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

External temperature displayswitching on/off . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

F

Filter box bottominstalling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Foot brake pedaladjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Foot brake pedal stubadjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Footrest position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Forkadjusting rebound . . . . . . . . . . . . . . . . . . . . . . . . . . . 15adjusting the spring preload . . . . . . . . . . . . . . . . . . . . 16compression damping, adjusting . . . . . . . . . . . . . . . . . 15fork legs, bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . 16installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Fork legsassembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25disassembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21fork service, performing . . . . . . . . . . . . . . . . . . . . . . . 21lower DU bush, changing . . . . . . . . . . . . . . . . . . . . . . 26outer tubes, assembling . . . . . . . . . . . . . . . . . . . . . . . 27outer tubes, disassembling . . . . . . . . . . . . . . . . . . . . . 24

Fork part number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Fork service, performing . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Front cylinder control timeadjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

Front wheelinstalling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Fuel pressurechecking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73checking during the actuator test . . . . . . . . . . . . . . . . 74

Fuel reserve display TRIP F RESETsetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Fuel tankinstalling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Fuel tank guardinstalling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Fuseindividual power consumers, changing . . . . . . . . . . . . . 91

H

Hand brake leverbasic position, adjusting . . . . . . . . . . . . . . . . . . . . . . 96

Handlebar heightadjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Headlight adjustmentadjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

High beam bulbchanging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

I

Ignition coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

Ignition keyactivating/deactivating . . . . . . . . . . . . . . . . . . . . . . . 102

Immobilizer control unit . . . . . . . . . . . . . . . . . . . . . . . . . 102activating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225

Inside coverinstalling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

K

Key number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Kilometers/miles SET KM/MILESsetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

L

Lambda sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62Lambda sensor heater . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Low beam bulbchanging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Lower DU bushfork legs, changing . . . . . . . . . . . . . . . . . . . . . . . . . . 26

M

Main fusechanging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Manifold absolute pressure sensor . . . . . . . . . . . . . . . . . . 223Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Motorcyclecleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417jacking up front . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10jacking up in the middle . . . . . . . . . . . . . . . . . . . 10, 12jacking up rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13taking front off work stand . . . . . . . . . . . . . . . . . . . . . 10taking rear from work stand . . . . . . . . . . . . . . . . . . . . 13work stand, removing from . . . . . . . . . . . . . . . . . . . 11-12

N

Number of laps SET NUM LAPSsetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

O

Oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208

Oil filterchanging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

Oil jet for clutch lubricationchecking / cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 216installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215

PartS

hark

.com

877-

999-

5686

INDEX 456

Oil screencleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

Oil screenscleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

Outer tubesfork legs, assembling . . . . . . . . . . . . . . . . . . . . . . . . 27fork legs, disassembling . . . . . . . . . . . . . . . . . . . . . . 24

P

Parking light bulbchanging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Passenger seatmounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Putting into operationafter storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419

R

RACE modesetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Radiatorinstalling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195

Rear brake systeminstalling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Rear cylinder control timeadjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

Rear frame position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Rear hub cush drivechecking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Rear sprocket / engine sprocketchecking for wear . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Rear wheelinstalling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81installing - when installing the engine . . . . . . . . . . . . . 82removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

ROAD modesetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Rollover sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226

S

Seatfitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Service interval SERVICE RESETresetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Service schedule . . . . . . . . . . . . . . . . . . . . . . . . . . 420-421Servicing the shock absorber . . . . . . . . . . . . . . . . . . . . . . 48

SET °C/°F temperature unitsetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

SET CLOCKsetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Shift leveradjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

Shift lever stubadjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

Shift speed RPM1/2adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Shock absorberadjusting the spring preload . . . . . . . . . . . . . . . . . . . . 45bleeding and filling . . . . . . . . . . . . . . . . . . . . . . . . . . 55compression damping, high-speed, adjusting . . . . . . . . 44compression damping, low-speed, adjusting . . . . . . . . . 44damper, assembling . . . . . . . . . . . . . . . . . . . . . . . . . 53damper, checking . . . . . . . . . . . . . . . . . . . . . . . . . . . 51damper, disassembling . . . . . . . . . . . . . . . . . . . . . . . 49heim joint, installing . . . . . . . . . . . . . . . . . . . . . . . . . 60heim joint, removing . . . . . . . . . . . . . . . . . . . . . . . . . 59installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47nitrogen, filling damper with . . . . . . . . . . . . . . . . . . . 58piston rod, assembling . . . . . . . . . . . . . . . . . . . . . . . 52piston rod, disassembling . . . . . . . . . . . . . . . . . . . . . 50rebound damping, adjusting . . . . . . . . . . . . . . . . . . . . 45removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48spring, installing . . . . . . . . . . . . . . . . . . . . . . . . . . . 59spring, removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Shock absorber part number . . . . . . . . . . . . . . . . . . . . . . . . 8

Side coversinstalling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Side stand switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Steering damperadjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Steering damper part number . . . . . . . . . . . . . . . . . . . . . . . . 9Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419

T

Technical datachassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411-412chassis tightening torques . . . . . . . . . . . . . . . . . 415-416engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405-406engine - tolerance, wear limits . . . . . . . . . . . . . . 407-408engine tightening torques . . . . . . . . . . . . . . . . . 409-410fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414

Throttle cable at throttle valveadjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Throttle cable playadjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Throttle grip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Throttle position sensor circuit A . . . . . . . . . . . . . . . . . . . 219adjusting the position . . . . . . . . . . . . . . . . . . . . . . . 220checking in the "zero" position . . . . . . . . . . . . . . . . . 219

Throttle position sensor circuit B . . . . . . . . . . . . . . . . . . . 223

Throttle valve bodyreinstalling when adjustments have been made . . . . . . 222removing to adjust . . . . . . . . . . . . . . . . . . . . . . . . . 221

Tire air pressurechecking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

PartS

hark

.com

877-

999-

5686

INDEX 457

Tire conditionchecking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Trouble codeengine control . . . . . . . . . . . . . . . . . . . . . . . . . 238-390

Type label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

V

Valve clearancechecking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

Valve clearance, frontadjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

Valve clearance, rearadjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

Vehicle identification number . . . . . . . . . . . . . . . . . . . . . . . 8

Vehicle level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17front, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17rear, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

W

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 422-435Work rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

PartS

hark

.com

877-

999-

5686

*3206077en*3206077en

KTM-Sportmotorcycle AG5230 Mattighofen/Austriahttp://www.ktm.com

04/2009

Photo: Mitterbauer

PartS

hark

.com

877-

999-

5686

ktm rc8 repair manual

Documents