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KTM RC8 Workshop manual 2009 .pdf



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REPAIR MANUAL 2009
1190 RC8 R EU/UK
1190 RC8 R AUS
1190 RC8 R FR
1190 RC8 R JP
Article no. 3206077en

INTRODUCTION

1

Read this repair manual carefully and thoroughly before beginning work.
INTRODUCTION

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 of
technical advancement without at the same time updating this manual.
We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop will not be specified
here. It is assumed that the repair work will be performed by a fully trained mechanic.
All specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifications, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt
these to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery
options, deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain special equipment that does not form part of the regular scope of delivery.

© 2009 by KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
Reproduction, even in part, is permitted only with the express written permission of the copyright owner.

ISO 9001(12 100 6061)
According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead
to the maximum possible quality of the products.
Issued by: TÜV Management Service
KTM-Sportmotorcycle AG
5230 Mattighofen, Austria

CONTENTS
CONTENTS

MEANS OF REPRESENTATION ............................................ 6
IMPORTANT NOTES ............................................................ 7
LOCATION OF SERIAL NUMBERS ........................................ 8
Vehicle identification number/type label ............................ 8
Key number ....................................................................
8
Engine number................................................................
8
Fork part number.............................................................
8
Shock absorber part number ............................................. 8
Steering damper part number ........................................... 9
MOTORCYCLE...................................................................
10
Jacking up motorcycle front ............................................ 10
Taking front of motorcycle off work stand......................... 10
Jacking up the motorcycle in the middle (screw-in type).... 10
Removing the motorcycle from the work stand (screw-in
type) ............................................................................
11
Jacking up the motorcycle in the middle (insertable
type) ............................................................................
12
Removing the motorcycle from the work stand (insertable
type) ............................................................................
12
Jacking up motorcycle at the rear.................................... 13
Taking the rear from the workstand ................................. 13
Starting ........................................................................
13
01/FORK, TRIPLE CLAMP.................................................. 15
Adjusting the compression damping of the fork ................ 15
Adjusting the rebound damping of the fork....................... 15
Adjusting the spring preload of the fork ........................... 16
Bleeding fork legs..........................................................
16
Vehicle level .................................................................
17
Adjusting front vehicle level............................................ 17
Removing the fork .........................................................
18
Installing the fork ..........................................................
19
performing a fork service ................................................ 21
Disassembling the fork legs ............................................ 21
Disassembling the outer tubes ........................................ 24
Checking the fork legs.................................................... 25
changing the lower DU bush ........................................... 26
Assembling the outer tubes ............................................ 27
Assembling the fork legs ................................................ 27
02/HANDLEBAR, CONTROLS AND INSTRUMENTS..............32
Adjusting basic position of clutch lever............................ 32
Adjusting the steering damper ........................................ 32
Adjusting the handlebar height ....................................... 32
Adjusting the play in the throttle cable ............................ 33
Throttle grip ..................................................................
34
Changing the throttle grip...............................................
34
Adjusting the throttle cable at the throttle valve................ 37
03/FRAME ........................................................................
40
Side stand switch ..........................................................
40
Footrest position............................................................
40
Adjusting footrest position .............................................. 40
Rear frame position .......................................................
41
Adjusting the rear frame position .................................... 41
04/SHOCK ABSORBER, SWINGARM................................... 44
Adjusting the low-speed compression damping of the
shock absorber .............................................................. 44
Adjusting the high-speed compression damping of the
shock absorber .............................................................. 44
Adjusting the rebound damping of the shock absorber.......45
Adjusting the spring preload of the shock absorber ........... 45
Adjusting the vehicle level at the rear .............................. 46
Removing the shock absorber ......................................... 46
Installing the shock absorber .......................................... 47

2
Servicing the shock absorber .......................................... 48
Removing the spring ...................................................... 48
Disassembling the damper ............................................. 49
Disassembling the piston rod .......................................... 50
Checking the damper ..................................................... 51
Assembling the piston rod .............................................. 52
Assembling the damper.................................................. 53
Bleeding and filling the damper ...................................... 55
Filling the damper with nitrogen ..................................... 58
Installing the spring .......................................................
59
Removing the heim joint ................................................ 59
Installing the heim joint .................................................
60
05/EXHAUST ....................................................................
62
Lambda sensor .............................................................. 62
Lambda sensor heater .................................................... 62
Removing the exhaust cover completely ........................... 63
Installing the exhaust cover completely............................ 63
Removing the exhaust system ......................................... 63
Installing the exhaust system.......................................... 65
06/AIR FILTER..................................................................
67
Removing the air filter ...................................................
67
Installing the air filter ....................................................
67
Removing the filter box bottom ....................................... 67
Installing the filter box bottom ........................................ 68
07/FUEL TANK, SEAT, TRIM.............................................. 70
Removing the seat ......................................................... 70
Fitting the seat..............................................................
70
Removing the passenger seat.......................................... 70
Mounting the passenger seat .......................................... 70
Dismounting the fuel tank .............................................. 70
Installing the fuel tank ...................................................
71
Removing the fuel tank guard ......................................... 72
Installing the fuel tank guard .......................................... 73
Checking the fuel pressure ............................................. 73
Checking the fuel pressure during the actuator test........... 74
08/MASK, FENDER, DECAL ............................................... 75
Removing the side covers ............................................... 75
Installing the side covers ................................................ 75
Removing the inside cover .............................................. 75
Installing the inside cover ..............................................
76
09/FRONT WHEEL ............................................................ 77
Removing the front wheel ............................................... 77
Installing the front wheel................................................
77
Checking the tire condition.............................................
78
Checking the tire pressure .............................................. 79
Checking the front brake discs ........................................ 80
10/REAR WHEEL ..............................................................
81
Removing the rear wheel ................................................ 81
Installing the rear wheel ................................................. 81
Installing the rear wheel - when installing the engine ........ 82
Checking the rear brake disc........................................... 83
Checking for chain dirt...................................................
83
Cleaning the chain.........................................................
84
Checking the chain tension ............................................ 84
Adjusting the chain tension ............................................ 85
Checking rear sprocket / engine sprocket for wear .............85
Checking chain wear ...................................................... 86
Checking chain sliding guard .......................................... 86
Checking rear hub cush drive.......................................... 86
11/WIRING HARNESS, BATTERY ....................................... 88
Electric starter lock control unit ...................................... 88

CONTENTS
Fuel pump relay ............................................................
88
Removing the battery ..................................................... 88
Installing the battery......................................................
89
Recharging the battery ................................................... 90
Changing the main fuse ................................................. 91
Changing the fuses of individual power consumers............ 91
13/BRAKE SYSTEM...........................................................
93
Brake linings.................................................................
93
Checking the front brake linings...................................... 93
Changing the front brake linings ..................................... 93
Checking the front brake fluid level ................................. 95
Adding front brake fluid .................................................
95
Adjusting the basic position of the hand brake lever.......... 96
Checking the rear brake linings ....................................... 96
Changing the rear brake linings....................................... 97
Checking the rear brake fluid level .................................. 99
Adding rear brake fluid ..................................................
99
Adjusting the foot brake pedal stub ............................... 100
Adjusting the foot brake pedal ...................................... 100
Removing the rear brake system.................................... 101
Installing the rear brake system .................................... 101
14/LIGHT SYSTEM, INSTRUMENTS ................................. 102
Immobilizer control unit ...............................................
102
Activating/deactivating ignition key ............................... 102
Activating the ICU .......................................................
104
Combination instrument - Activation of the
BOOTLOADER mode.................................................... 105
Updating the combination instrument software............... 105
Setting ROAD or RACE mode ........................................ 106
Setting the clock with SET CLOCK ................................ 106
Adjusting shift speed RPM1/2 ...................................... 106
Setting the blank time of the LAP button
LAP BLANK T .............................................................
107
Setting the number of laps SET NUM LAPS ................... 107
Setting the fuel reserve display TRIPF RESET ................108
Setting the kilometers/miles SET KM/MILES .................. 108
Setting the temperature unit SET °C/°F ......................... 109
Switching the external temperature display on/off ........... 109
Resetting service display .............................................. 110
Checking the headlight setting...................................... 110
Adjust the headlight range............................................ 111
Changing the parking light bulb .................................... 111
Changing the low beam bulb......................................... 112
Changing the high beam bulb ....................................... 113
30/ENGINE.....................................................................
115
Removing the engine ................................................... 115
Preparing the engine for installation .............................. 117
Installing the engine ....................................................
117
Setting the engine to ignition top dead center of the
rear cylinder................................................................
120
Setting the engine to ignition top dead center of the
front cylinder ..............................................................
121
30/DISASSEMBLING THE ENGINE................................... 122
Clamping the engine into the engine work stand ............. 122
Removing the engine bracket........................................ 122
Draining the engine oil ................................................. 122
Removing the front valve cover ..................................... 123
Removing the rear valve cover....................................... 123
Setting the engine to ignition top dead center of the
rear cylinder................................................................
123
Removing the starter motor .......................................... 124
Removing the oil filler tube .......................................... 124

3
Removing the heat exchanger ....................................... 124
Removing the rear timing chain tensioner ...................... 124
Removing the rear camshaft ......................................... 125
Removing the rear cylinder head ................................... 125
Removing the rear piston.............................................. 125
Setting the engine to ignition top dead center of the
front cylinder ..............................................................
126
Removing the front timing chain tensioner ..................... 126
Removing the front camshafts ...................................... 126
Removing the front cylinder head .................................. 126
Removing the front piston ............................................ 127
Removing the generator cover ....................................... 127
Removing the ignition pulse generator ........................... 127
Removing the torque limiter and idler............................ 128
Removing the rotor ...................................................... 128
Removing the idler and timing chain on the left ............. 128
Removing the oil filter..................................................
129
Removing the balancer shaft ........................................ 129
Removing the drive wheel of the balancer shaft .............. 129
Removing the gear position sensor ................................ 130
Removing the left suction pump ................................... 130
Removing the water pump wheel................................... 131
Removing the clutch cover ........................................... 131
Removing the idler and timing chain on the right............ 132
Removing the clutch facing .......................................... 132
Removing the outer clutch hub ..................................... 132
Removing the primary gear ........................................... 133
Removing the force pump ............................................ 133
Removing the shift shaft .............................................. 134
Removing the shift drum locating.................................. 134
Removing the locking lever ........................................... 135
Removing the left engine case ...................................... 135
Removing the crankshaft .............................................. 135
Removing the middle suction pump .............................. 136
Removing the transmission shaft................................... 136
Removing the oil spray tube ......................................... 137
Removing the timing chain rails of the right engine case
section .......................................................................
137
Removing the timing chain rails of the left engine case
section .......................................................................
137
30/ENGINE - WORK ON INDIVIDUAL PARTS..................... 138
Work on the right section of the engine case .................. 138
Removing the main bearing of the right engine case
section .......................................................................
139
Selecting the main bearing shells.................................. 140
Installing the right main bearing ................................... 140
Work on the left section of the engine case .................... 141
Removing the left main bearing .................................... 143
Installing the left main bearing ..................................... 143
Changing the conrod bearing ........................................ 144
Work on the clutch cover .............................................. 145
Changing the step bearing of the crankshaft................... 146
Checking the radial clearance of the bottom connecting
rod bearing .................................................................
147
Checking/measuring the cylinder................................... 147
Checking/measuring the piston ..................................... 148
Checking the piston ring end gap .................................. 149
Checking the piston/cylinder mounting clearance............ 149
Work on the cylinder head ............................................ 149
Checking the cylinder head .......................................... 152
Work on the right idler ................................................. 153
Checking the timing assembly ...................................... 154

CONTENTS
Preparing the timing chain tensioner for installation .......
Checking the oil pressure regulator valve........................
Checking the oil pumps................................................
Checking the clutch .....................................................
Checking the shift mechanism ......................................
Preassembling the shift shaft........................................
Dismantling the main shaft ..........................................
Dismantling the countershaft ........................................
Checking the transmission............................................
Assembling the main shaft ...........................................
Assembling the countershaft.........................................
30/ASSEMBLING THE ENGINE ........................................
Installing the timing chain rails of the left engine case
section .......................................................................
Installing the timing chain rails of the right engine case
section .......................................................................
Installing the oil spray tube ..........................................
Installing the transmission shaft ...................................
Installing the middle suction pump ...............................
Installing the crankshaft...............................................
Installing the left engine case .......................................
Installing the locking lever............................................
Installing the shift drum locating ..................................
Installing the shift shaft ...............................................
Installing the force pump .............................................
Installing the left suction pump ....................................
Setting the engine to ignition top dead center of the
rear cylinder................................................................
Installing the primary gear ............................................
Installing the outer clutch hub ......................................
Installing the clutch facing ...........................................
Installing the idler and timing chain on the right ............
Installing the clutch cover ............................................
Installing the water pump wheel ...................................
Installing the gear position sensor .................................
Installing the drive wheel of the balancer shaft ...............
Installing the balancer shaft .........................................
Installing the idler and timing chain on the left ..............
Installing the oil filter ..................................................
Installing the rotor .......................................................
Installing the torque limiter and idler ............................
Installing the ignition pulse generator ............................
Installing the generator cover ........................................
Installing the oil drain plug...........................................
Installing the rear piston ..............................................
Installing the rear cylinder head ....................................
Installing the rear camshaft ..........................................
Installing the rear timing chain tensioner .......................
Setting the engine to ignition top dead center of the
front cylinder ..............................................................
Installing the front piston .............................................
Installing the front cylinder head...................................
Installing the front camshafts .......................................
Installing the front timing chain tensioner......................
Installing the heat exchanger ........................................
Installing the oil filler tube ...........................................
Installing the starter motor ...........................................
Checking the rear cylinder control time..........................
Adjusting the rear cylinder control time .........................
Checking the rear valve clearance .................................
Adjusting the rear valve clearance .................................
Checking the front cylinder control time ........................

4
154
155
155
156
157
158
158
159
160
161
161
163
163
163
164
164
165
165
166
167
167
167
168
169
169
170
170
171
172
172
173
173
173
174
174
175
175
176
176
176
176
177
178
179
179
180
180
182
182
183
183
184
184
184
184
185
186
186

Adjusting the front cylinder control time ........................ 186
Checking the front valve clearance ................................ 187
Adjusting the front valve clearance ................................ 188
Installing the front valve cover ...................................... 188
Installing the rear valve cover ....................................... 188
Mounting the engine bracket ........................................ 189
Dismounting the engine from the work stand .................. 189
31/SECONDARY AIR SYSTEM .......................................... 190
Exhaust air injection ....................................................
190
32/CLUTCH ....................................................................
191
Checking fluid level of hydraulic clutch ......................... 191
Correcting fluid level of hydraulic clutch ........................ 191
34/SHIFT MECHANISM ................................................... 192
Adjusting shift lever stub..............................................
192
Adjusting shift lever .....................................................
192
35/WATER PUMP, COOLING SYSTEM .............................. 194
Checking the coolant level ............................................ 194
Checking the antifreeze................................................ 194
Removing the radiator .................................................. 195
Installing the radiator...................................................
195
Adding coolant/bleeding the cooling system ................... 196
Filling the cooling system compensating tank ................. 197
36/CYLINDER HEAD........................................................ 198
Engine coolant temperature sensor cylinder 1 ................ 198
Engine coolant temperature sensor for cylinder 2............ 199
Checking the valve clearance ........................................ 200
Adjusting the rear valve clearance ................................. 201
Adjusting the front valve clearance ................................ 202
Checking the rear cylinder control time.......................... 202
Checking the front cylinder control time ........................ 202
Adjusting the rear cylinder control time ......................... 203
Adjusting the front cylinder control time ........................ 204
Removing the rear camshaft ......................................... 205
Installing the rear camshaft .......................................... 205
Removing the front camshafts ...................................... 206
Installing the front camshafts ....................................... 206
Installing the rear timing chain tensioner ....................... 207
Installing the front timing chain tensioner...................... 207
38/LUBRICATION SYSTEM .............................................. 208
Oil circuit ...................................................................
208
Checking the engine oil level ........................................ 209
Changing the engine oil and filter, cleaning the oil
screens.......................................................................
209
Draining engine oil, cleaning oil screens ........................ 209
Removing the oil filter..................................................
211
Installing the oil filter ..................................................
212
Filling up with engine oil ..............................................
212
Adding engine oil ........................................................
213
Checking the engine oil pressure................................... 213
Removing the oil jet for the clutch lubrication ................ 215
Checking / cleaning the oil jet for clutch lubrication........ 216
Installing the oil jet for the clutch lubrication ................. 216
39/IGNITION SYSTEM ..................................................... 218
Crankshaft position sensor............................................ 218
Ignition coil ................................................................
218
41/THROTTLE VALVE BODY............................................. 219
Throttle position sensor circuit A................................... 219
Throttle position sensor circuit A - checking in the
"zero" position .............................................................
219
Adjusting the position of the throttle position sensor in
circuit A .....................................................................
220
Removing the throttle valve body to adjust ..................... 221

CONTENTS
Reinstalling the throttle valve body when the
adjustments have been made........................................ 222
Throttle position sensor circuit B................................... 223
Manifold absolute pressure sensor................................. 223
Connecting the vacuum hand pump to the manifold
absolute pressure sensor .............................................. 224
Ambient air pressure sensor.......................................... 225
Injector ......................................................................
225
Rollover sensor ............................................................ 226
EFI control unit ...........................................................
227
Requesting the EFI control unit activation code.............. 227
Coding the EFI control unit........................................... 227
Flashing the EFI control unit ........................................ 228
IMMOBILIZER BLINK CODE............................................. 229
ENGINE CONTROL TROUBLE CODE .................................238
CONNECTOR OVERVIEW.................................................. 391
Motor drive circuit A connector AE ................................ 391
Connector AI ...............................................................
391
Crankshaft position sensor connector AL ........................ 391
Clutch switch, connector AL ......................................... 391
Throttle position sensor circuit A, connector AM ............. 391
Throttle position sensor circuit B, connector AM ............. 392
Gear position sensor, connector AM............................... 392
Fuel pump connector AM ............................................. 392
Wheel speed sensor, connector AM ............................... 392
Connector AO .............................................................. 392
Diagnostic connection plug AP...................................... 393
Rollover sensor connector AP........................................ 393
Throttle position sensor circuit A, connector AR.............. 393
Throttle position sensor circuit B, connector AR ............. 394
Fuel pump connector AR.............................................. 394
Side stand switch, connector AR ................................... 394
Ignition coil cylinder 1 connector AS ............................. 394
Ignition coil cylinder 2 connector AS ............................. 394
CAN bus terminating resistor connector AT .................... 395
Crankshaft position sensor, connector AT ....................... 395
Clutch switch connector AT .......................................... 395
Engine coolant temperature sensor cylinder 1 connector
AX..............................................................................
395
Throttle stepper motor circuit B, connector CA ............... 395
Lambda sensor cylinder 1, connector CA ....................... 396
Lambda sensor cylinder 2, connector CA ....................... 396
Lambda sensor cylinder 1, connector CE ....................... 396
Lambda sensor cylinder 2, connector CE ....................... 396
Secondary air valve connector CK.................................. 396
Connector CM .............................................................
397
Connector CO .............................................................. 397
Connector CP .............................................................. 398
Connector CQ .............................................................. 398
Connector CU..............................................................
398
Fuel evaporation valve connector DF.............................. 399
Secondary air valve connector DF .................................. 399
Electric starter lock control unit, connector DN .............. 399
Immobilizer control unit, connector DN ......................... 399
Electric starter lock control unit, connector DO............... 399
Immobilizer control unit, connector DO.......................... 400
Ambient air pressure sensor connector DP ..................... 400
Manifold absolute pressure sensor cylinder 1,
connector DP ..............................................................
400
Manifold absolute pressure sensor cylinder 2
connector DP ..............................................................
400
Injector cylinder 1 connector DQ................................... 400

5
Injector cylinder 2 connector DQ................................... 401
ICU antenna connector DV ........................................... 401
Fuel pump relay connector EB ...................................... 401
ICU antenna connector EL............................................ 401
Connector EQ .............................................................. 401
Connector ER .............................................................. 402
Connector ES ..............................................................
402
Connector ET ..............................................................
402
Combination instrument connector EV ........................... 403
Exhaust air injection valve, connector FE ....................... 403
Fuel pump relay ..........................................................
404
CAN bus terminating resistor ........................................ 404
TECHNICAL DATA - ENGINE ............................................ 405
Capacity - engine oil .................................................... 405
Capacity - coolant........................................................
406
TECHNICAL DATA - TOLERANCE, WEAR LIMITS OF
ENGINE .........................................................................
407
TECHNICAL DATA - ENGINE TIGHTENING TORQUES........
409
TECHNICAL DATA - CHASSIS .......................................... 411
Lighting equipment .....................................................
411
Capacity - fuel.............................................................
412
TECHNICAL DATA - FORK................................................ 413
TECHNICAL DATA - SHOCK ABSORBER ...........................414
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ......
415
CLEANING/CONSERVATION............................................. 417
Cleaning motorcycle .................................................... 417
Conservation for winter operation .................................. 417
STORAGE .......................................................................
419
Storage.......................................................................
419
Putting into operation after storage ............................... 419
SERVICE SCHEDULE....................................................... 420
Important service tasks to be carried out by an
authorized KTM-RC8 workshop. .................................... 420
Important service tasks to be carried out by an
authorized KTM-RC8 workshop. (as additional job) .........421
WIRING DIAGRAM .......................................................... 422
1 of 3.........................................................................
422
2 of 3.........................................................................
426
3 of 3.........................................................................
432
OPERATING SUBSTANCES .............................................. 436
AUXILIARY SUBSTANCES................................................ 438
SPECIAL TOOLS.............................................................. 440
STANDARDS ................................................................... 452
INDEX ............................................................................
453

MEANS OF REPRESENTATION
Symbols used
The meaning of specific symbols is described below.
Indicates an expected reaction (e.g. of a work step or a function).

Indicates an unexpected reaction (e.g. of a work step or a function).

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

Formats used
The 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.

6

IMPORTANT NOTES

7

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

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

Spare parts, accessories
Only use spare parts and accessories approved and/or recommended by KTM. KTM accepts no liability for other products and any
resulting damage.
You will find the current KTM PowerParts for your vehicle on the KTM website.
International KTM Website: http://www.ktm.com

Work rules
Special tools are necessary for some of the work. These are not included with the vehicle and can be ordered under the number in
parentheses. 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 be
replaced 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 its
usage.
Parts that you want to reuse following repairs and servicing should be cleaned and checked for damage and wear. Change damaged or
worn parts.
Following repairs or servicing, the vehicle must be checked for roadworthiness.

Notes/warnings
Pay close attention to the notes/warnings.

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

Grades of risks
Danger
Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures
are not taken.

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

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

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

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

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.


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