Kramer GP2-890R 2020 User manual

OWNER’S MANUAL
GP2-890R
(Model Years 2020 - 2024)

2
About This Manual
Use this manual as a guide for proper procedures
for this motorcycle’s basic operation, inspection, and
maintenance. This manual is intended for professional
service technicians and those knowledgeable about
appropriate safety training and safe shop practices.
All information, directions, photographs, and
specications included in this manual are based on the
most current information at the time of publication.
Krämer Motorcycles accepts no liability for delivery
options, deviations from illustrations and descriptions,
misprints, or other errors. Krämer Motorcycles reserves
the right to make changes at any time without notice or
obligation.
This motorcycle is to be raced on a closed course
only. Krämer Motorcycles & Krämer Motorcycles USA
are not liable for any injury to riders, mechanics, public,
and any damage to the vehicle or property.
This manual is for the following models:
2020-24 Krämer GP2-890R
Version: GP2-890R-2023-00
Introduction
Dear Krämer Customer,
We want to congratulate you on purchasing a Krämer GP2-890R series motorcycle.
The GP2-890R is the next level and the logical expansion of the Krämer Motorcycles
portfolio. Like the strong “EVO2-690” single, the two-cylinder model was developed
and built exclusively for use on the racetrack. With 130 hp and 100 Nm of torque
and a weight of only 309 lbs (140 kg), the GP2-890R stands for spectacular riding
dynamics without overwhelming the rider. Ideal for the most intense enjoyment on
the racetrack - and for hunting lap times!
This manual will serve as a guide to keeping your GP2-890R in race-ready shape.
If you have any questions concerning the operation or maintenance of your
motorcycle, please consult your Krämer dealer.
THIS VEHICLE IS SOLD AS IS, NO WARRANTY.
Enter the serial numbers of your vehicle:
Vehicle identication number
____________________________________
Engine number
____________________________________
Dealer’s Stamp
Krämer Motorcycles
Gewerbepark Lindach B5
84489 Burghausen
Germany
[email protected]
www.kraemer-motorcycles.com
© 2023 Krämer Motorcycles
All rights reserved.

3
General Information
Table of Contents
INTRODUCTION
ABOUT THIS MANUAL
USAGE AND SETUP
Identication / Serial Numbers ...........4
Reference Views of Vehicle..............4
Serial Numbers .....................4
Operating Components ...............4
Control Components ...................5
Start Up Procedure ....................5
Shut Down Procedure ..................5
Vehicle Break-in Procedure..............6
Pre-Ride Inspection....................6
Post-Race Service .....................6
Post-Crash Inspection ................6
Transporting / Loading .................7
Raising the Motorcycle on Lift Stands .....7
Storage .............................7
MAINTENANCE / SERVICE
Service Schedule......................8
Krämer Motorcycles Online Shop .........8
Checking the Engine Oil Level ...........8
Changing the Engine Oil & Filter,
and Cleaning the Oil Screens ..........8
Chain Cleaning / Lubrication.............9
Checking the Chain Tension .............9
Adjusting the Chain Tension / Rear Axle
Alignment .........................9
Fuel Filler Cap .......................10
Air Filter Servicing....................10
ENGINE
Repairs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Recommended Engine Maintenance......11
Throttle Response Modes ..............11
Engine Braking Modes.................11
Pit Limiter Button ....................11
COOLING SYSTEM
Checking the Coolant Level.............12
Draining the Coolant ..................12
Filling/Bleeding the Cooling System ......12
CHASSIS
Handlebar Adjustment.................13
Steering Damper Setup ................13
Seat/Tank Height Adjustment ...........13
Bodywork Removal ...................14
Bodywork Installation .................14
Fuel Tank Draining Procedure ...........15
Fuel Tank Removal/Installation..........15
Clutch Lever Free Play and Reach
Distance .........................16
Front Brake Lever Response and Travel
Distance .........................16
Rearset Setup ....................... 17
Adjusting the Foot Pegs................ 17
Rear Brake Lever Adjustment ........... 17
Shift Lever Height Adjustment........... 17
BRAKE SYSTEM
Brake Inspection .....................18
Brake Bleeding ......................18
Changing the Brake Pads ..............19
SUSPENSION
Suspension Inspection.................20
Checking the Steering Head Bearing Play..20
Adjusting the Steering Head Bearing Play..20
Changing the Fork Offset...............21
Fork Suspension Settings ..............22
Adjusting Spring Preload...............22
Adjusting Compression Damping.........22
Adjusting Rebound Damping ............22
Fork Specications ...................22
Rear Shock Suspension Settings.........23
Adjusting the Spring Preload ...........23
Adjusting Compression Damping.........23
Adjusting Rebound Damping ............23
Shock Absorber Specications ..........23
WHEELS
Front Wheel Removal .................24
Front Wheel Installation ...............24
Rear Wheel Removal ..................25
Rear Wheel Installation ................25
ELECTRICAL
Tail light Operation....................25
Charging the Tail light .................25
Fuses ..............................26
Battery.............................26
Powered Accessory Leads..............26
Service Schedule.....................27
TECHNICAL DATA
GP2 890-R Specications ..............28
Fluid Capacities ......................28
Engine Specications .................28
Electrical System.....................28
Engine Torque Chart ..................29
Chassis Torque Chart..................30
Safety Wire .........................30
AIM Compact MXS 1.2 Dash Logger......31
Dash Logger Indicators Overview ........31
Dash Logger Menu Conguration Settings . 32
Set Date and Time..................32
Set Backlight......................32
Set Video Input ....................32
Lap Time Setup....................33
Counters Management ..............33
GPS & Tracks .....................33
Wi-Fi Management .................34
System Info .......................34
GPS Search.......................34
Sampled Data Recall................35
Pit Limiter Indicator ................35

4Usage and Setup
Usage and Setup
Right Side View
Left Side View
A
C
EF
G
D
Identification / Serial Numbers
Serial Numbers
AChassis S/N — R.H. side
steering head.
BEngine S/N — L.H. side of the
engine above the sprocket.
CFork S/N — inside the axle
clamp.
DShock S/N — top section of
shock.
Operating
Components
EFuel Fill
FRecommended Fuel Fill
Amount for Racing (9.5 L or
2.5 US gal). On translucent
tanks the fuel will show at
this level.
GIntake Cover/Air Filter Box
HOil Level Check
B
H
Reference Views of Vehicle NOTE: Instructions, such as right-hand (R.H.) side and left-hand(L.H.) side
are from rider position.

5
Usage and Setup
Control Components
Hand Controls
ADashboard
BMain Switch
(behind fairing support)
CClutch Lever
DThrottle Response
EEngine Braking Effect
FPit Limiter
G Run/Stop Switch
HStart Button
IFront Brake Lever
JThrottle
Foot Controls
KShift Lever
LRear Brake Lever
Start Up Procedure
1. Toggle the ignition switch B, located on the back side of
dashboard/fairing support, to the ON position
(Wait 5 seconds for fuel pump to pressurize)
2. Press START button H
Shut Down Procedure
1. Press the Run/Stop Switch G
2. Toggle Main switch Bto OFF position
A
C
D
D
E
E
F
F
J
B
I
StartStart
STOP
G
Hand Controls
Rear Brake Lever Shift Lever
Start/Stop SwitchEngine Performance Controls
Ignition Switch
LK
G
B
H
H

6Usage and Setup
Pre-Ride Inspection
• Check safety critical screws for
correct torque [See pg. 30]
• Check engine oil level - Oil level to be
centered between the “maximum” and
“minimum” indicators. [See pg. 8]
• Check coolant level - Coolant should
be visible at the bottom of the radiator ll
tting when the radiator cap is removed.
[See pg. 12]
• Check tire pressure in warm condition
(with tire warmers on)
Set to 2.3 bar (33 PSI) in the front tire and
1.65 bar (24 PSI) in the rear (Pirelli Superbike
Slick SC1 Tires). Tire temperature should be
75-85°C (167-185°F) while checking. Tire
warmers should always be used.
• Check fuel level - Recommended race fuel
amount is approximately 7.0 L (1.85 US gal)
per 20 minutes of riding time. Maximum fuel
capacity is 16 L (4.2 US gal).
• Check the chain tension [See pg. 9]
• Inspect suspension components (forks,
rear shock, linkages) for leaks, excessive
wear, or any looseness. [See pg. 20]
• Let the engine run up to 176°F (80°C),
during which the throttle should not be
turned.
Vehicle Break-in Procedure
Following the rst outing
(15-20 minutes):
• Screws should be checked for the correct
torque [See pg. 30] and general
condition.
• Bleed the front brakes [See pg. 18].
For the rst 100 km (62 miles)
• Do not exceed 70% of full brake pressure.
For the rst 200 km (124 miles)
• Do not exceed 7500 rpm.
After 2 hours of run time
• Change engine oil and lters.
Post-Race Service
After each race weekend or 5 hours ride
time, whichever comes rst:
• Remove and clean the fairing (except front
fender) [See pg. 14]
• Thoroughly clean the motorcycle (frame,
tank, swingarm, fenders, and rims)
• Check the visual condition and torque of
each screw [See pg. 30]
• Replace engine oil and oil lters
[See pg. 8]
• Bleed the front brake, rear brake, and the
clutch [See pg. 18]
• Perform chain maintenance
[See pg. 9]
Post-Crash Inspection
1. Remove the entire fairing (including the Intake Cover/Air
Filter Box). [See pg. 14]
2. Disassemble the air lter box and check for any
blemishes/dirt within the air lter box and air lter. [See
pg. 10]
3. Thoroughly clean the fairing and all exposed areas of the
motorcycle while checking for damage.
4. Replace any damaged parts with new ones.
5. Inspect Suspension. [See pg. 20]
Loosen the front axle pinch bolts and bottom triple
clamp bolts. Compress the front forks several times, to
insure functionality, before re-tightening every bolt to the
appropriate torque specications.
6. Clean and lubricate the chain. [See pg. 9]
7. Check the coolant level [See pg. 12]
8. Check the engine oil level [See pg. 8]
After crash the oil level may appear low, start engine, run
for 15 seconds, stop engine, and check level.
Typical crash damage to inspect:
- Front forks
- Handlebars
- Crash pads
- Crash pad frame mounting plates
- Rearset
- Shift & brake linkages
- Debris trapped between the linkages
CAUTION!
Danger of scalding
During motorcycle operation, the coolant
gets very hot and is under pressure.
– Do not open the radiator or other
cooling system components if the engine
or the cooling system are at operating
temperature.
– Allow the cooling system to cool down
before inspecting or servicing.

7
Usage and Setup
Raising the Motorcycle on Lift Stands
NOTE: Park the motorcycle on a level,  rm
surface.
• Lifting the rear
1. The motorcycle is equipped with lifting spools
C. Insert the lift stand into the groove of the
lifting spools.
2. Press down on the rear handle of the stand
raising the rear of the motorcycle.
• Lifting the front (raise rear  rst)
1. The motorcycle is equipped to lift the front with
a pin-style stand.
2. Position the pin of the lift stand into the hole on
the lower triple clamp Dof the front forks.
3. Press down on the front handle of the stand,
raising the front of the motorcycle.
Storage
To store the motorcycle for an extended period,
take the following actions.
Before storing the motorcycle:
• Inspect all parts for function and wear.
• If repairs or replacements are necessary,
perform the service before storing.
Preparing for
Storage:
1. Drain fuel tank E
empty. See “Fuel Tank
Draining Procedure” on
page 15.
2. Clean the motorcycle.
3. Change the engine oil and the oil  lter. Clean the oil
screens.
4. Check the coolant level and service if necessary with
Motul MoCool coolant.
If the storage area will reach temperatures below 0°C
(32°F) drain the coolant completely.
5. Check the tire pressure.
6. Remove the battery from the motorcycle. Store in a
safe, warm area, 0°-30°C (32°-85°F), out of direct
sun. Keep connected to a lithium rated fl oat charger.
7. Store motorcycle in a dry location with a stable
temperature.
8. Raise the motorcycle on the front, and rear lifting
stands.
Removing from Storage
1. Fill coolant, if drained for freezing temperature
storage conditions.
2. Install a fully charged battery.
3. Perform pre-ride checks.
4. Lower the motorcycle from the lifting stands.
5. Take for a test ride.
Transporting / Loading
NOTE: Use wheel chock to stabilize front wheel.
Recommended Tie-Down Points
1. FRONT: Attach a soft-tie loop straps on the lower triple tree.
Lead the loop forward out the lower front fairing Aattaching
to the tie-down straps secured to a solid mounting point in the
transport vehicle.
• Use one on each side of the motorcycle.
• Tighten straps enough to tension the front forks partially, being
careful that the forks are not compressed completely.
2. REAR: Attach a tie-down strap around the rear wheel Band
tighten the strap rearward, preventing the motorcycle from rolling
forward.
CAUTION!
Don’t park the motorcycle in
direct sun.
The windshield can amplify the sun’s
radiant heat.
A
C
C
B
Fuel Tank Drain - R.H.
D
E

8Maintenance / Service
Service Schedule
For a detailed listing of service schedule see the chart on pg. 27.
Krämer Motorcycles Onlineshop
If any part of your GP2-890R needs to be replaced because of wear or damage, spare parts can be found
in the Krämer Motorcycles Onlineshop:
www.kmc-shop.com
Checking the Engine Oil Level
Check the engine oil level at normal engine
operating temperature.
1. Stand the motorcycle upright on a level surface.
2. Start engine and warm to normal operating
temperature. (Turn off the engine, wait one
minute before checking the level.)
3. Check the engine oil in the sight glass window
A.
The level must be between the lower and upper
markings beside the window.
4. If needed, add oil, at oil  ller B, to speci ed
level.
Oil Level Window (R.H. side of engine)
Upper Level
Lower Level
A
Changing the Engine Oil & Filter, and Cleaning the Oil Screens
Oil Draining
1. Raise the rear of the motorcycle on a rear lift
stand. [See pg. 7]
2. Remove the front fairing. [See pg. 14]
3. Start the engine and warm it to normal
operating temperature.
4. Remove the safety wire.
5. Place a drain container under the engine
6. Remove the oil  ller cap Bfrom the clutch
cover.
7. Remove the oil drain plugs Calong with the
magnets, the o-rings, and the oil screens.
8. Completely drain the engine oil.
9. Inspect the magnets, o-rings, and
the oil screens for any metal shavings,
and thoroughly clean the plugs, screens, and
magnets.
Oil Filter Changing
1. Remove the screws from the oil  lter cover E,
and remove cover with the o-ring.
2. Pull out the  lter. Allow the remaining engine
oil to drain.
3. Thoroughly clean the parts and sealing
surfaces.
4. Insert the new oil  lter.
5. Coat the o-ring with oil, position the oil  lter
cover, and reinstall the cover screws.
6. Torque the cover screws – 6 Nm (4.4 lb-ft).
Oil Changing
1. Drain the oil
2. Change the oil  lter
3. Install the oil drain plugs C, the magnets, the
o-rings, and the oil screens.
4. Tighten the oil screen plugs C–
15 Nm (11.1 lb-ft).
5. Fill up engine oil at  ller B– 2.8 L. (3 qt.) of
Motorex 15W/50 Racing Pro 4T oil.
6. Install and tighten the  ller plug B.
7. Let the engine run for approx. 30 seconds,
check thoroughly for leaks.
8. Check the engine oil level A.
9. Rewire the locking safety wire following the
instructions on pg. 30.
Oil Filter, Drain Plugs with Screens and Magnets – Left Side of Engine
Oil Filler Oil Filter Screws
C
Maintenance / Service
Safety wire oil drain plugs
C, oil  lter cover E, and
 ller plug B
B
E

9
Maintenance / Service
Right side of swingarm
Left side of swingarm
Chain tension measurement
Checking the Chain Tension
1. Raise the rear of the motorcycle on a lift stand. [See pg. 7]
2. Check that the shift lever is in neutral.
3. Measure at the chain mid-point between sprockets. The speci ed vertical chain tension Fis 30-35
mm (1.18-1.38 in.).
Adjusting the Chain Tension / Rear Axle Alignment
1. Raise the rear of the motorcycle on a lift stand.
[See pg. 7]
2. Check that the shift lever is in neutral.
3. Loosen the jam nuts Bon the adjuster
screws on both sides of the swingarm.
4. Loosen the axle nut C.
5. Turn the adjuster screw Duntil the vertical
chain tension Fis 30-35 mm (1.18-1.38 in.).
Measure at the chain mid-point.
6. On both sides, measure and compare the
distance Ebetween the swingarm’s rear edge
and the edge of the adjuster blocks. Fine-tune
the adjuster screws until the distance is equal
(+/- 1 mm) on both sides.
7. Tighten the adjuster screw jam nuts B.
8. Check that the adjuster blocks are fully seated
forward against the adjuster screws.
9. While applying forward pressure on the wheel,
tighten the axle nut to speci ed torque –
100 Nm (73.7 ft-lb).
B
D
C
E
E
F
Chain Cleaning / Lubrication
1. Raise the rear of the motorcycle on a lift stand
[See pg. 7].
2. Check that the shift lever is in neutral.
3. Spray chain cleaner on the chain while turning
the rear tire. Rotate the wheel until the entire
chain is sprayed with the cleaner.
4. Let the cleaner soak for approximately 5
minutes.
5. Remove excess cleaner – using a fabric rag
(not a paper towel), wipe the chain while
rotating the wheel several turns, making sure
that the entire chain has run through the rag
several times.
6. Let the chain dry to the touch before spraying
lubricant.
7. Apply chain lubricant – Carefully spray the
lubricant in the front of the chain tunnel in the
swingarm A, with the spray nozzle facing
downwards into the inside of the chain links.
Rotate the rear wheel until the entire chain is
lubricated. Also lubricate the top of the chain as
shown by B.
8. Clean the area surrounding the chain – when
completing the cleaning and lubrication
process, check and clean any residues of any
liquids on the rear rim, tire, brake disc, and
swingarm.
9. Check the chain tension [See pg. 9].
Wipe Cleaner Dry
Spray Chain Lubricant
Spray Chain Cleaner
A
CAUTION! Pinch Hazard
Be careful not to pinch  ngers
between chain and sprockets.
B

10 Maintenance / Service
Air Filter 1/4-Turn Fasteners
Reusable Foam Air Filter Air Filter Support Cage
A
B
C
FIRE HAZARD
Fuel is highly
fl ammable.
The fuel in the fuel tank
expands when warm and
can escape if over lled.
• Turn off the engine for
refueling
• Do not refuel the vehicle
near open  ames or lit
cigarettes
• Wipe spilled fuel
immediately
Fuel Filler Cap
Open the Fuel Filler Cap
1. Push down on the cap lever A.
2. Rotate it counter-clockwise 1/4-turn.
3. Lift out the cap.
Close the Fuel Filler Cap
1. Line up the cap retainer pins Bwith slots C in the  ller neck.
2. Rotate it clockwise, approximately 1/4-turn until it clicks.
Air Filter Servicing
Removal
1. Remove the Intake Cover/Air Filter Box from
the motorcycle [See pg. 14].
2. Open the 1/4-turn fasteners Aat the front
and rear of the air  lter.
3. Remove the air  lter and inspect.
4. Remove the foam air  lter from the  lter
support cage.
Installation
1. Install foam air  lter on  lter support cage.
2. Grease the air  lter rim.
(TwinAir BIO Air Filter Sealant)
3. Position the air  lter in the air  lter box and
lock the 1/4-turn fasteners Aat the front and
rear of the air  lter.
Cleaning the Air Filter.
1. Clean and oil the foam air  lter element
following directions of the reusable foam air
 lter service kit. (TwinAir BIO line of cleaner, oil
and sealant).
2. Clean the air  lter support cage.
3. Clean the air  lter box.
4. Clean the intake fl ange and inspect for
damage.
5. Reinstall the air  lter.
A
AA
FOAM AIR FILTER CLEANER
AND OIL (RECOMMENDED)
• TwinAir BIO line of cleaner, oil and sealant.
• NOTE: The foam air  lter is factory oiled
with TwinAir BIO biodegradable oil and
sealant which are not compatible with
petroleum based  lter products. To ensure
compatibility and engine protection continue
using the TwinAir BIO line on the air  lter.

11
Engine
Repairs
In case of damage or problems with the engine, please contact your local Krämer Motorcycles
dealer.
Recommended Engine Maintenance
• See Service Schedule on Pg. 27
Repack the Muffler
• Every 1.000 km or when it is burned out. The muffl er is burned out when the bike is signi cantly louder
than normal. Empty muffl er reduces engine performance and can lead to cracks in the exhaust.
• Part Number for the Exhaust Service in the KMC Onlineshop: 300501001S
Throttle Response Modes
• Sun Symbol – Extremely direct response
• Rain Symbol – Gentle response
1. Throttle response modes are changed with
button Bon L.H. handlebar.
2. Modes can be changed while riding when the
throttle grip is closed.
3. A pre-setting Ccan be set while riding. The
pre-setting will become active when the throttle
grip is closed. The active state is shown in
section D.
Engine Braking Modes
• Arrow Up – More engine braking
• Arrow Down – Less engine braking
1. Engine Braking modes are changed with button
Eon L.H. handlebar.
2. Modes can be changed while riding when the
throttle grip is closed.
3. A pre-setting Fcan be set while riding. The
pre-setting will become active when the throttle
grip is closed. The active state is shown in
section G.
Pit Limiter Button
• NOTE: The Pit Limit mode limits the speed of
the motorcycle.
1. Engage Pit Limit mode by pressing the button
Hon L.H. handlebar. Disengage Pit Limit
mode by pressing the button again.
2. When engaged, the dash logger will display a
“PIT LIMITER” message.
Engine
B
C
F
D
G
E
H
Engine Braking Modes
Pit Limiter Button
Throttle Response Modes

12 Cooling System
Cooling System
Checking the Coolant Level
1. With the engine cold, position the motorcycle
on a level surface.
2. Remove the front fairing. [See pg. 14]
3. Check coolant level of the radiator.
Remove radiator cap A.
Coolant should be visible at the bottom of the
radiator  ll  tting—35mm (1.38”) below the
upper edge of  ller neck B.
4. Reinstall the radiator cap.
Draining the Coolant
1. With the engine cold, position the motorcycle
on a level surface.
2. If still in place, remove the front fairing.
[See pg. 14]
3. Place a suitable container under the engine.
Remove the drain screw C.
4. Remove the radiator cap.
5. Completely drain the coolant.
6. Insert and tighten the drain screw Cwith a
new seal ring – 6 Nm (4.4 ft-lb).
7. Install the radiator cap.
Filling/Bleeding the Cooling System
1. With the engine cold, remove the radiator cap
A
.
2. Tilt the vehicle slightly to the right.
3. Completely  ll the radiator with coolant. Run
the engine until the coolant is no longer visible
from the  ller neck. Stop the engine and  ll in
coolant up to the limit again.
4. Repeat Step 3 for two to three times until the
coolant level reaches the lower edge of the
 ller neck.
5. Start and run the engine to operating
temperature. Turn off the engine.
6. When the engine is cool, check the coolant
level in the compensating tank (located behind
the dashboard) and the radiator. Add coolant if
necessary.
AB
C
Radiator Fluid Level
Coolant Drain Plug

13
Chassis
Chassis
Fuel Tank Mounting/Height Adjustment Screws
Steering Damper Adjusting Knob
Handlebar Height and Angle Adjustment
Handlebar Width Adjustment
Handlebar Adjustment
The position of the handlebars is adjustable in both height and
angle. Please note that the right and the left handlebar sides
mirror each other, and neither should be at a different angle
or height.
Height and Angle Adjustment
1. Loosen the clamping screws Cof the clip-ons on both sides.
2. Adjust the height of the handlebars by sliding up or down on the
fork tube. Adjust the angle by rotating around the fork tube. Use
the angle marks Dto ensure that both sides are equal.)
3. Swing handlebars from lock to lock, making sure nothing touches
or rubs.
4. Tighten the clamping screws C of the clip-ons alternately until
the appropriate torque is attained – 10 Nm (7.4 ft-lb).
Width Adjustment (2 positions)
1. Loosen the clamping screws Eof the clip-ons on both sides.
2. Adjust the width of the handlebars. Read the setting marks at the
edge of the window F. (Ensure that both sides are equal.)
• Check the steering for binding and kinked cables or lines.
3. Tighten the clamping screws E of the clip-ons alternately until
the appropriate torque is attained – 10 Nm (7.4 ft-lb).
Steering Damper Setup
Setting the steering damper’s  rmness
is dependent on riding style and track
characteristics. In high-speed corners, a
higher setting may help keep the motorcycle
more stable. However, too high of a setting in
tight and twisty sections may cost valuable
agility and precision.
Adjust Damper Firmness
1. Rotate the adjusting knob Gclockwise to
the last detectable click.
2. Adjust to the desired  rmness by turning the
adjusting knob counter-clockwise.
• The Adjustment Range is 1-24 clicks
The standard is 12 clicks.
G
C
E
D
F
Seat/Tank Height Adjustment
The seat height is adjusted by moving
the complete seat/tank unit. The height
is adjusted by turning the eccentric tank
mounts B.
1. Loosen the bottom mount screws Aon both
sides of the tank.
2. Using a 6 mm Allen wrench placed in the
triangular hole, turn the eccentric base Bto
the desired seat position.
3. Temporarily tighten the left mounting screw.
4. Remove the right mounting screw, apply
blue thread lock*, reinsert and tighten to the
appropriate torque – 30 Nm (22.1 ft-lb).
5. Remove the left mounting screw, apply blue
thread lock*, reinsert and tighten to the
appropriate torque – 30 Nm (22.1 ft-lb).
* Loctite®243™
A B

14 Chassis
Bodywork Installation
Install bodywork in the order of appearance.
Install Upper Fairing
1. Turn the handlebar all the way to the left.
2. Install the upper fairing carefully maneuvering
around the forks.
3. Install the two 1/4-turn fasteners Aunder
the windshield.
Install Front Fender
4. Spread the fender and install it from the front
sliding it rearward.
5. Install the two 1/4-turn fasteners F– one on
each side.
Install Lower Fairing
6. Carefully install the lower fairing.
7. Install the four 1/4-turn fasteners E– two
on each side.
8. Install the two 1/4-turn fasteners D– one on
each side.
Install Intake Cover/Air Filter Box
9. Position the Intake Cover/Air Filter Box.
10. Finger-tighten the two screws Bat the rear
of each side.
11. Install the two 1/4-turn fasteners Con each
side.
12. Install the two screws Iholding the steering
damper mount — 10 Nm (7.4 ft-lb).
13. Torque the two screws Bat the rear of each
side — 6-9 Nm (50-80 in-lb).
Install Tail Cap
14. Slide the tail cap in position.
15. Install the two screws Gunder the tail cap —
5 Nm (44 in-lb).
16. Install the two screws Hon top of the tail
cap — 5 Nm (44 in-lb).
* Loctite®243™
Bodywork Removal
Remove the bodywork pieces in the order of
appearance. Reinstall the bodywork pieces in
reverse order [See below].
Remove Intake Cover/Air Filter Box
1. Remove the two screws Iholding the
steering damper mount.
2. Remove the two screws Bat the rear of each
side.
3. Remove the two 1/4-turn fasteners Con
each side.
4. Carefully lift the intake cover/air  lter box
rearward and up.
Remove Front Fender
5. Remove the 1/4-turn fasteners Fon each
side.
6. Spread the fender and remove it forward.
Remove Lower Fairing
7. Remove the two 1/4-turn fasteners Don
each side.
8. Remove the four 1/4-turn fasteners Eon
each side.
9. Carefully remove the lower fairing.
Remove Upper Fairing
10. Remove the two 1/4-turn fasteners Aunder
the windshield.
11. NOTE: If the intake cover/air  lter box is
not removed, then remove the two 1/4-turn
fasteners Con each side.
12. Remove the upper fairing by pulling it forward,
carefully maneuvering it around the forks.
Remove Tail Cap
13. Remove the two screws Gunder the tail cap.
14. Remove the two screws Hon top of the tail
cap.
15. Slide the tail cap rearward and upward. B
C
E
E
H
G
D
D
FF
B
C
A
Front Upper Fairing Fastener
Locations
Upper and Lower Fairing Fastener Locations
Front Fender Fasteners - R.H. Front Fender Fasteners - L.H.
Tail Cap Fastener Locations
I
Steering Damper Screws
NOTE:
Regularly check the tightness of velocity
stacks.
USE BLUE THREAD LOCK* ON
ALL THREADED FASTENERS.
Apply to the thread inserts not
the screw threads.

15
Chassis
Fuel Tank Removal/Installation
Removal
1. Remove the air box cover [See pg. 14].
2. Remove the shock adjuster screws Aand let
the adjuster hang to the side.
3. Unplug the fuel pump electrical connector C.
4. Remove fuel hose from injection rail.
5. Remove the support bracket screws Eand
the tank mounting screws Fon both sides.
6. Remove the fuel tank by lifting it towards the
rear of the motorcycle.
Installation
7. Position the fuel tank in place.
8. Install and tighten the screws Eon both sides
— 10 Nm (7.4 ft-lb).
9. Install, apply blue thread lock*, and tighten the
screws Fon both sides — 25 Nm (18.4 ft-lb).
10. Plug in the fuel pump electrical connector C.
11. Install fuel hose on the injection rail.
12. Mount the shock preload adjuster, install and
tighten the shock preload adjuster screws A
— 10 Nm (7.4 ft-lb)
* Loctite®243™
Fuel Tank Draining Procedure
NOTE:Before starting the draining procedure,
have at the ready a fuel container large enough to
hold the amount of fuel remaining in the tank.
1. Remove the fuel cap to allow tank ventilation.
2. Remove the protective red cap Afrom the
fuel tank quick-couple drain port Bon the
fuel pump located on the lower right-hand side
of the fuel tank.
3. Using the dealer-provided drain hose C, slide
back the collar of the quick-couple  tting, and
place it on the drain port. Fuel will start gravity-
draining immediately.
4. When the tank is empty, replace fuel cap.
5. Remove drain hose C, clean, and store.
6. Replace the red protective cap A.
A
C
EF
Shock Preload Adjuster Screws
Attaching the Quick-Couple Drain Hose
Protective Cap on the Fuel Tank Drain Port
Fuel Pump Connector
Fuel Tank Mounting ScrewsFuel Tank Support Bracket Screws
A
B C
CAUTION! Fire Hazard
Drain the fuel in a well-ventilated
area without any open  ame or sparks.
Have a  re extinguisher nearby.
Drain and store fuel in an approved fuel
container.
NOTE:
Regularly check the tightness of velocity
stacks.

16 Chassis
Clutch Lever Free Play and Reach Distance
Checking Clutch Lever Free Play
1. Check the clutch lever for smooth operation
2. Position the handlebar to straight-ahead.
3. Move the lever until resistance is felt, determine
the amount of play. 3-5mm is the speci ed
amount of free play.
Adjusting Clutch Lever Free Play
1. Position the handlebar straight ahead.
2. Loosen lock nut A.
3. Turn the adjusting barrel Bto adjust the
clutch lever free play. 3-5mm is the speci ed
amount of free play.
4. Tighten the lock nut A.
Adjusting Clutch Lever Reach Distance.
1. Position the handlebar straight ahead.
2. Turn the adjustment knob Cto achieve the
proper lever distance from the handlebar for the
rider to reach the lever comfortably and ensure
proper clutch engagement.
Front Brake Lever Response and Travel Distance
Adjusting Front Braking Response
1. Use the adjustment knob Dto set desired
brake response behavior.
N = Soft, liner braking
S = Sporty braking
R = Hard, direct braking
Adjusting Front Brake Lever Braking Ratio
1. Remove the protection cap E.
2. Turn the setting screw to the desired braking
ratio.
18 = Longer brake lever travel, soft response,
and less lever force. Red indicator visible G.
20 = Less brake lever travel, hard response,
and more lever force. Black indicator visible
3. Replace the protection cap E.
Adjusting Front Brake Lever Reach Distance
1. Position the handlebar straight ahead.
2. Turn the adjustment knob Fto achieve the
proper lever distance from the handlebar for the
rider to reach the lever comfortably and ensure
proper brake engagement.
Front Braking Response and Lever Reach Distance Adjusting Knobs
Front Braking Lever Ratio Adjustment Screw
3-5 mm
Lever Reach
Distance
Lever Reach
Distance
B
C
F
E
G
D
A
NOTE: Proper free play is important to prevent
clutch damage.
• No free play could cause the clutch to slip.
• Too much free play could cause incomplete
clutch engagement.

17
Chassis
Rear Brake Lever Adjustment
Rear Brake Lever Adjustment
1. Loosen the brake rod jam nut G.
2. Adjust the length of the brake rod H by
screwing the rod end bearing in or out of the
brake rod until the brake lever is in the desired
position.
3. Tighten the jam nut G.
Adjusting the Foot Pegs
Right Side
1. Remove the exhaust muffl er retainer
springs A.
2. Loosen the nuts B.
3. Loosen the bottom screw Dof the foot peg
carrier.
4. Loosen and remove the top screw Cso that
the carrier can move freely.
5. Position the carrier to the desired location.
6. Apply blue thread lock* and tighten the top
screw Cto the appropriate torque – 25 Nm
(18.4 ft-lb).
7. Apply blue thread lock* and tighten the bottom
screw Dto the appropriate torque – 25 Nm
(18.4 ft-lb).
8. Tighten the nuts Bto the appropriate torque –
25 Nm (18.4 ft-lb).
9. Reinstall the exhaust muffl er retainer
springs A.
Left Side
1. Loosen the bottom screw Fof the foot peg
carrier.
2. Loosen and remove the top screw Eso that
the carrier can move freely.
3. Position the carrier to the desired location.
4. Install, apply blue thread lock* and tighten the
top screw Eto the appropriate torque – 25
Nm (18.4 ft-lb).
5. Install, apply blue thread lock* and tighten the
bottom screw Fto the appropriate torque –
25 Nm (18.4 ft-lb).
6. Adjust the position of the shift and brake levers
[See below].
* Loctite®243™
Rearset Setup
The adjustable rearset allows a personalized setting for each rider, with both foot pegs, the
shift lever, and the brake lever being adjustable.
Shift Lever Height Adjustment
Adjust the shift lever height by changing the shift
linkage length.
1. Hold the shift shaft linkage Jwith a wrench
and loosen the jam nuts Iand Kwith a
second wrench.
2. Adjust the length of the shift shaft linkage by
rotating the shaft.
3. Adjust until the shift lever is in the desired
position. Keep a minimum of 8mm of thread
inside the linkage rod ends.
4. Tighten the jam nuts Iand Kto the
appropriate torque – 10 Nm (7.4 ft-lb).
R.H. Side Rearset Adjustment
R.H. Side Rearset Adjustment Preparation
L.H. Side Rearset Adjustment
Brake Lever Adjustment – R.H. Side
CE
A
D
F
B
H
G
I
J
K

18 Brake System
Brake System
WARNING! Danger of accidents
Reduced braking ef ciency can be caused
by worn brake pads.
– Check the brake pads regularly.
– Change worn brake pads immediately.
NOTE: If the brake pads are
not changed in time, the steel
brake pads carriers grind on the
brake disc. The braking effect is greatly
reduced and the brake discs are rendered
unserviceable.
Brake Inspection
Brake Pads
1. Visually inspect the brake pads for wear,
cracking, and damage on all brake calipers A.
2. Ensure they have the minimum thickness.
Minimum thickness 1 mm
(≥ 0.04 in)
If the minimum thickness is less than
speci ed or damage is found, change the
brake pads.
Brake Discs
1. Check the thickness of the brake disc in several
places to see if it is within the speci ed wear
tolerance.
Wear Limit
Front ≥ 4.5 mm (≥ 0.18 in)
Rear ≥ 4 mm (≥ 0.16 in)
If the brake disc thickness is less than the
speci ed value, change the brake discs.
Brake Lines and Master Cylinders
1. Visually inspect the brake lines and master
cylinders for leaking and cracking. Replace
components if necessary.
Brake Fluid Level
Checking/Adding Front Brake Fluid Level
1. Remove the brake fl uid reservoir mounting
screw B.
2. Position the brake fl uid reservoir to a horizontal
position.
3. Check that the fl uid level is between the MIN
and MAX markings. Add Motorex Racing brake
fl uid to the MAX level.
4. Remount the brake fl uid reservoir.
Checking/Adding Rear Brake Fluid Level
1. Position the motorcycle on rear lift stand.
2. Check that the fl uid level is between the MIN
and MAX markings. Add Motorex Racing brake
fl uid to the MAX level.
A
A
Front Brake Calipers
Front Brake Disc
Front Fluid Reservoir
Rear Brake Calipers
Rear Brake Disc
Rear Fluid Reservoir
Rear Caliper Bleed ScrewFront Caliper Bleed Screw
Brake Lever Bleed Screw
USE ONLY Motorex Racing
Brake Fluid
from a new closed container
MAX
MIN
B
Brake Bleeding
Bleeding Front Brake Calipers
Use standard manual or vacuum bleeding
procedures to bleed the front brake calipers.
SPECIAL NOTES:
• Bleed each caliper individually using the
bleed screw C.
• Bleed brake lever at the bleed screw D
Bleeding Rear Brake Caliper
Use standard manual or vacuum bleeding
procedures to bleed the brake caliper.
SPECIAL NOTES:
• Remove the rear brake caliper and invert
with the bleed screw Efacing up.
• Raise the caliper to a position where the
bleed screw is higher than the master
cylinder.
• Place a 6 mm Allen wrench between brake
pads to simulate the brake disc.
• Bleed the caliper using standard procedure.
• Remove the Allen wrench and install the
caliper back on the motorcycle.
MAX
MIN
MIN
MIN
MIN
MIN
MAX
MAX
MAX
E
C
D

19
Brake System
Rear Brake Caliper
1. Position the motorcycle on a rear lift stand.
2. Remove the locking safety wire E.
3. Remove mounting bolts D.
4. Remove brake reservoir cap and membrane.
5. Manually press the brake caliper against the
brake disc to retract the caliper piston. Monitor
that the fl uid in the reservoir doesn’t overfl ow.
Remove some if necessary.
6. Remove the retaining clip H.
7. Remove pin G.
8. Remove brake pads Fand retaining springs.
9. Clean the brake caliper.
10. Install the new brake pads with retaining
springs.
11. Replace pin Gand retaining clip H.
12. Position the caliper, apply white grease**,
install mounting bolts D, and tighten to the
appropriate torque – 20 Nm (14.8 ft-lb)
13. Rewire the locking safety wire E.
14. Press the brake pedal until brake pads contact
the brake disc and there is  rm resistance on
the pedal.
15. If needed,  ll brake fl uid level to the MAX line.
* Loctite®243™ ** White lithium grease
Front Brake Calipers
1. Position the motorcycle on a rear lift stand.
2. Position the brake reservoir in a horizontal
position. Remove from the mount if needed.
Remove brake reservoir cap and membrane.
3. Manually press the brake caliper against the
brake disc to retract the caliper piston. Monitor
that the fl uid in the reservoir doesn’t overfl ow.
Remove some if necessary.
4. Remove the locking safety wire A.
5. Remove mounting bolts B.
6. Remove calipers and spacers from mounts.
7. Remove brake pads Cfrom calipers.
8. Clean the brake calipers.
9. Install the new brake pads. Check that the
springs is correctly seated.
10. Position calipers and spacers in place and
install mounting bolts B, but do not tighten
them yet.
11. Squeeze the brake lever until brake pads
contact the brake disc and there is  rm
resistance on the lever. Secure the lever in an
active position. Check that the brake caliper is
straight and aligned.
12. Apply white grease** and tighten the mounting
bolts Bto the appropriate torque – 45 Nm
(33.2 ft-lb)
13. Rewire the locking safety wire.
14. If needed,  ll the brake fl uid level to the MAX
line, secure the cap, and remount the brake
reservoir.
* Loctite®243™ ** White lithium grease
Rear Brake Reservoir
Front Brake Reservoir
Rear Brake Caliper
Front Brake Calipers
Changing the Brake Pads
E
B
A
H
F
G
D
C
MIN
MIN
MAX
MAX
MAX
MIN
MIN
MIN
MAX
USE ONLY Motorex Racing
Brake Fluid
from a new closed container
USE ONLY Motorex Racing
Brake Fluid
from a new closed container

20 Suspension
Suspension
Checking the Steering Head Bearing Play
1. Raise the motorcycle under the frame, lifting
the front wheel off the ground.
2. Remove the front fairing. [See pg. 14]
3. Unbolt steering damper from the top triple
clamp E.
4. Position the handlebars in the straight-ahead
position.
5. Grab the lower fork legs, and push and pull in a
forward and rearward direction.
6. If play is detected, adjust the steering head play
[See below]
7. Move the handlebar over the entire steering
range. If any roughness or notching is detected,
replace the headset bearings.
8. Install and torque the steering damper bolt to
the top triple clamp E- 20 Nm (14.8 ft-lb).
9. Reassemble the front fairing. [See pg. 14]
Adjusting the Steering Head Bearing Play
1. Position the motorcycle on a rear lift stand.
2. Remove the front fairing. [See pg. 14]
3. Unbolt steering damper from the top triple
clamp E.
4. Loosen the top clamp bolts A.
5. Remove the top yoke bolt B.
6. Loosen the counter screw Cand the
steering
stem adjusting nut
D.
7. Tighten the
steering stem adjusting nut
Dto a
torque spec of 15 Nm (11.1 lb-ft).
8. Use a plastic hammer to tap lightly on the
upper triple clamp.
9. Reinstall bolt Band torque to 15 Nm (11.1
ft-lb).
10. Tighten bolts Ato appropriate torque of 15
Nm (11.1 ft-lb).
11. Check for smooth bearing operation with no
free play.
12. Tighten the counter screw Cto appropriate
torque of 20 Nm (14.8 ft-lb).
13. Install and torque the steering damper bolt to
the top triple clamp E- 20 Nm (14.8 ft-lb).
14. Reassemble the front fairing. [See pg. 14]
E
D
CAA
B
Suspension Inspection
Front Forks
1. Check the full action of the forks by applying the
front brake, pushing down on the handlebars, and
compressing the forks several times.
2. Inspect the entire fork assembly for leaks, damage, or
loose parts and fasteners.
3. Replace or repair any damaged components.
4. Tighten nuts and bolts to proper torque spec. [See
“Chassis Torque Chart” on page 30]
Rear Suspension
1. Check the full action of the shock absorber by
compressing it several times.
2. Inspect the shock absorber assembly for leaks,
damage, or loose parts and fasteners.
3. Replace or repair any damaged components.
4. Tighten nuts and bolts to proper torque spec.
[See pg. 30]
Swingarm
1. Raise the rear wheel off the ground and support the
motorcycle securely.
2. Check for worn swingarm bearings by grabbing the
swingarm and attempting to move it side to side.
3. Replace the bearings if any looseness is detected.