KTM 690 SMC 2008 Operating instructions

REPAIR MANUAL 2008
690 SMC EU
690 SMC AUS/UK
690 SMC USA
Article no. 3206042en

INTRODUCTION 1
INTRODUCTION
Read this repair manual carefully and thoroughly before beginning work.
Only use ORIGINAL 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 are not 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 specifica-
tions, 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 spe-
cial equipment that does not belong to the regular scope of delivery.
© 2010 KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright
owner.
ISO 9001(12 100 6061)
According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead
to the maximum possible quality of the products.
Issued by: TÜV Management Service
KTM-Sportmotorcycle AG
5230 Mattighofen, Austria

CONTENTS 2
CONTENTS
MEANS OF REPRESENTATION ............................................ 5
IMPORTANT NOTES ............................................................ 6
LOCATION OF SERIAL NUMBERS ........................................ 7
Chassis number/type label (690 SMC EU,
690 SMC AUS/UK).......................................................... 7
Chassis number/type label (690 SMC USA)........................ 7
Key number .................................................................... 7
Engine number................................................................ 7
Fork part number............................................................. 8
Shock absorber part number............................................. 8
MOTORCYCLE..................................................................... 9
Raising the motorcycle with the rear wheel stand................ 9
Taking the motorcycle off of the rear wheel stand ............... 9
Raising the motorcycle with the front wheel stand .............. 9
Taking the motorcycle off of the front wheel stand .............. 9
Raising the motorcycle with the work stand...................... 10
Removing the motorcycle from the work stand.................. 10
Starting ........................................................................ 11
Starting the motorcycle to make checks........................... 11
01/FORK, TRIPLE CLAMP.................................................. 12
Adjusting compression damping of fork ........................... 12
Adjusting rebound damping of fork.................................. 12
Bleeding the fork legs .................................................... 12
Cleaning the dust boots of the fork legs ........................... 13
Removing the fork protector............................................ 13
Installing the fork protector ............................................ 13
Removing fork legs ........................................................ 14
Installing the fork legs ................................................... 15
Servicing the fork .......................................................... 16
Disassembling the fork legs ............................................ 17
Checking the fork legs.................................................... 20
Assembling the fork legs ................................................ 21
Checking the steering head bearing play .......................... 25
Adjusting the steering head bearing play.......................... 26
02/HANDLEBAR, INSTRUMENTS....................................... 27
Handlebar position ........................................................ 27
Adjusting handlebar position .......................................... 27
Checking the play in the throttle cable............................. 27
Adjusting the play in the throttle cable ............................ 28
04/SHOCK ABSORBER, SWINGARM................................... 29
Adjusting the high-speed compression damping of the
shock absorber .............................................................. 29
Adjusting the low-speed compression damping of the
shock absorber .............................................................. 29
Adjusting the rebound damping of the shock absorber....... 30
Measuring the unloaded rear wheel sag............................ 30
Checking the static sag of the shock absorber .................. 30
Checking the riding sag of the shock absorber .................. 31
Adjusting the spring preload of the shock absorber ........... 31
Adjusting the riding sag ................................................. 32
Removing the shock absorber ......................................... 32
Installing the shock absorber .......................................... 33
Servicing the shock absorber .......................................... 34
Removing the spring ...................................................... 35
Dismantling the damper ................................................. 35
Disassembling the piston rod .......................................... 36
Checking the damper ..................................................... 37
Removing the heim joint ................................................ 38
Installing the heim joint ................................................. 39
Assembling the piston rod .............................................. 40
Assembling the damper.................................................. 41
Bleeding and filling the damper ...................................... 43
Filling the damper with nitrogen ..................................... 45
Installing the spring....................................................... 45
05/EXHAUST .................................................................... 47
Removing the exhaust manifold ...................................... 47
Installing exhaust manifold............................................. 47
Removing the main silencer............................................ 48
Installing the main silencer ............................................ 49
06/AIR FILTER.................................................................. 51
Removing the air filter ................................................... 51
Installing the air filter .................................................... 51
Removing the air filter box ............................................. 51
Installing the air filter box .............................................. 52
07/FUEL TANK, SEAT, TRIM.............................................. 54
Opening filler cap.......................................................... 54
Closing filler cap ........................................................... 54
Removing the seat ......................................................... 54
Mounting the seat ......................................................... 54
Taking off the side cover ................................................ 54
Mounting the side cover ................................................. 55
Checking the fuel pressure ............................................. 55
Changing the fuel filter .................................................. 56
09/FRONT WHEEL ............................................................ 59
Removing front wheel .................................................... 59
Installing the front wheel................................................ 59
Checking the tire air pressure ......................................... 60
Checking the tire condition............................................. 60
Checking the brake discs................................................ 61
10/REAR WHEEL .............................................................. 62
Removing rear wheel...................................................... 62
Installing the rear wheel................................................. 62
Checking the chain tension ............................................ 63
Adjusting the chain tension ............................................ 63
Adjusting chain guide .................................................... 64
Checking the chain, rear sprocket and engine sprocket...... 64
Cleaning the chain......................................................... 65
Checking the rear hub rubber dampers ............................ 66
Checking the spoke tension ............................................ 66
Checking the rim run-out................................................ 67
11/WIRING HARNESS, BATTERY ....................................... 68
Removing the battery ..................................................... 68
Installing the battery...................................................... 68
Disconnecting the battery............................................... 68
Connecting the battery ................................................... 69
Recharging the battery ................................................... 69
Checking the charging voltage ........................................ 70
Changing the main fuse ................................................. 70
Changing fuses of individual power consumers ................. 71
Adjusting the engine characteristic.................................. 72
13/BRAKE SYSTEM........................................................... 73
Checking the front brake linings...................................... 73
Changing the front brake linings ..................................... 73
Adjusting the basic position of the hand brake lever.......... 74
Checking the front brake fluid level ................................. 74
Adding front brake fluid ................................................. 75
Changing the front brake fluid ........................................ 75
Checking the rear brake linings ....................................... 76
Changing rear brake linings ............................................ 77
Checking the free travel of foot brake lever....................... 78
Adjusting the basic position of the foot brake lever ........... 78
Checking rear brake fluid level........................................ 79
Adding rear brake fluid .................................................. 79

CONTENTS 3
Changing the rear brake fluid.......................................... 80
14/LIGHT SYSTEM, INSTRUMENTS ................................... 82
Setting kilometers or miles ............................................. 82
Setting the clock ........................................................... 82
Combination instrument - setting/resetting TRIP 1............ 82
Combination instrument - setting/resetting TRIP 2............ 83
Combination instrument - setting the wheel
circumference ............................................................... 83
Checking the headlight setting........................................ 84
Adjusting the headlight range ......................................... 84
Removing the headlight mask with the headlight .............. 84
Installing the headlight mask with the headlight............... 85
Changing the parking light bulb ...................................... 85
Changing the headlight bulb........................................... 86
Changing the flasher bulb .............................................. 86
30/ENGINE....................................................................... 88
Removing the engine ..................................................... 88
Installing the engine ...................................................... 90
30/DISASSEMBLING THE ENGINE..................................... 94
Clamping engine into engine work stand .......................... 94
Draining the engine oil................................................... 94
Removing starter motor .................................................. 94
Removing valve cover..................................................... 94
Removing the alternator cover......................................... 95
Removing spacer ........................................................... 95
Removing gear position sensor ........................................ 95
Removing oil filter ......................................................... 95
Removing thermostat ..................................................... 96
Setting engine to ignition top dead center........................ 96
Removing water pump wheel .......................................... 96
Removing clutch cover ................................................... 97
Removing spacer and spring ........................................... 97
Removing spark plug ..................................................... 97
Removing timing chain tensioner .................................... 98
Removing camshafts...................................................... 98
Removing cylinder head ................................................. 98
Removing piston............................................................ 98
Removing rotor.............................................................. 99
Removing timing chain rails ........................................... 99
Removing timing chain and timing chain sprocket .......... 100
Removing crankshaft position sensor ............................. 100
Removing clutch cage.................................................. 100
Removing primary gear................................................. 102
Removing starter drive ................................................. 102
Removing shift shaft.................................................... 102
Removing shift drum locating ....................................... 102
Removing locking lever ................................................ 103
Removing oil pumps .................................................... 103
Removing left engine case............................................ 103
Removing crankshaft and balancer shaft........................ 104
Removing transmission shafts....................................... 104
30/ENGINE - WORK ON INDIVIDUAL PARTS..................... 106
Work on the right section of the engine case .................. 106
Work on the left section of the engine case .................... 107
Work on the clutch cover.............................................. 108
Removing crankshaft bearing inner ring ......................... 109
Removing balancer shaft drive wheel ............................. 109
Changing the conrod bearing ........................................ 109
Checking crankshaft run-out at bearing pin .................... 111
Installing balancer shaft drive wheel.............................. 111
Installing crankshaft bearing inner ring.......................... 111
Measuring axial clearance of crankshaft and balancer
shaft .......................................................................... 112
Cylinder - Nikasil®coating............................................ 112
Checking/measuring the cylinder................................... 113
Checking/measuring the piston ..................................... 113
Checking piston ring end gap........................................ 114
Checking piston/cylinder mounting clearance ................. 115
Checking oil pumps for wear......................................... 115
Replacing autodecompressor ........................................ 115
Preparing timing chain tensioner for installation ............. 116
Checking timing assembly ............................................ 117
Removing rocker arm ................................................... 117
Changing camshaft bearing .......................................... 117
Removing valves.......................................................... 118
Checking valves........................................................... 119
Checking valve springs ................................................. 119
Checking valve spring retainer ...................................... 119
Checking cylinder head ................................................ 119
Installing valves .......................................................... 120
Installing rocker arm.................................................... 121
Dismantling antihopping clutch .................................... 121
Checking the clutch..................................................... 122
Preassembling antihopping clutch................................. 123
Checking shift mechanism ........................................... 124
Preassembling shift shaft ............................................. 124
Disassembling the main shaft ....................................... 125
Dismantling countershaft ............................................. 125
Checking the transmission............................................ 126
Assembling the main shaft ........................................... 127
Assembling countershaft .............................................. 128
Checking electric starter drive....................................... 129
Removing freewheel..................................................... 129
Checking freewheel...................................................... 130
Installing freewheel ..................................................... 130
30/ASSEMBLING THE ENGINE ........................................ 132
Installing transmission shafts ....................................... 132
Installing crankshaft and balancer shaft......................... 133
Installing left engine case ............................................ 133
Installing oil pumps ..................................................... 134
Installing locking lever ................................................. 134
Installing shift drum locating ........................................ 134
Installing shift shaft..................................................... 135
Installing starter drive .................................................. 135
Installing primary gear ................................................. 135
Installing clutch cage................................................... 136
Installing crankshaft position sensor.............................. 137
Installing timing chain and timing chain sprocket........... 137
Installing timing chain rails .......................................... 138
Installing rotor............................................................. 138
Adjusting crankshaft position sensor distance................. 138
Setting engine to top dead center.................................. 139
Installing piston .......................................................... 139
Installing cylinder head................................................ 140
Installing camshafts .................................................... 141
Installing timing chain tensioner ................................... 141
Checking valve clearance ............................................. 142
Adjusting valve clearance ............................................. 142
Installing spark plug .................................................... 143
Installing spacer and spring.......................................... 143
Installing clutch cover.................................................. 143
Mounting water pump cover.......................................... 144
Installing thermostat.................................................... 144

CONTENTS 4
Installing the oil filter .................................................. 144
Installing gear position sensor....................................... 145
Installing the spacer .................................................... 145
Installing oil screens.................................................... 146
Installing alternator cover ............................................. 146
Installing starter motor................................................. 147
Installing valve cover ................................................... 147
Taking engine off universal mounting rack ..................... 147
32/CLUTCH .................................................................... 148
Checking/rectifying the fluid level of the hydraulic
clutch ........................................................................ 148
35/WATER PUMP, COOLING SYSTEM .............................. 149
Draining coolant .......................................................... 149
Filling the cooling system............................................. 149
Checking the antifreeze and coolant level ...................... 150
Checking the coolant level............................................ 151
38/LUBRICATION SYSTEM .............................................. 152
Oil circuit ................................................................... 152
Checking the engine oil level ........................................ 152
Checking the engine oil pressure................................... 153
Changing the engine oil and filter, cleaning the oil
screens....................................................................... 154
Draining engine oil ...................................................... 154
Removing the oil filter.................................................. 155
Installing the oil filter .................................................. 155
Cleaning the oil screens ............................................... 156
Filling up with engine oil.............................................. 157
Adding engine oil ........................................................ 157
39/IGNITION SYSTEM ..................................................... 158
Alternator - checking the stator winding......................... 158
Checking the spark plug connector................................ 158
Ignition coil - checking the secondary winding................ 159
41/THROTTLE VALVE BODY............................................. 160
Checking the basic setting of the motor drive ................. 160
Adjusting the basic setting of the motor drive................. 161
Flashing the EFI control unit and/or the EPT control
unit............................................................................ 164
Requesting the enabling code....................................... 165
Coding the EFI control unit and/or EPT control unit ........ 166
TECHNICAL DATA - ENGINE ............................................ 168
Capacity - engine oil .................................................... 168
Capacity - coolant........................................................ 168
TECHNICAL DATA - TOLERANCE, WEAR LIMITS OF
ENGINE ......................................................................... 169
TECHNICAL DATA - ENGINE TIGHTENING TORQUES........ 171
TECHNICAL DATA - CHASSIS .......................................... 173
Lighting equipment ..................................................... 173
Capacity - fuel............................................................. 174
TECHNICAL DATA - FORK................................................ 175
TECHNICAL DATA - SHOCK ABSORBER ........................... 176
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ...... 177
CLEANING/PROTECTIVE TREATMENT .............................. 179
Cleaning the motorcycle ............................................... 179
Protective treatment for winter operation ....................... 180
STORAGE ....................................................................... 181
Storage....................................................................... 181
Putting into operation after storage ............................... 181
SERVICE SCHEDULE....................................................... 182
Service schedule ......................................................... 182
WIRING DIAGRAM .......................................................... 184
Page 1 of 10............................................................... 184
Page 2 of 10............................................................... 186
Page 3 of 10............................................................... 188
Page 4 of 10............................................................... 190
Page 5 of 10............................................................... 192
Page 6 of 10............................................................... 194
Page 7 of 10............................................................... 196
Page 8 of 10............................................................... 198
Page 9 of 10............................................................... 200
Page 10 of 10............................................................. 202
SUBSTANCES................................................................. 204
AUXILIARY SUBSTANCES................................................ 206
SPECIAL TOOLS.............................................................. 208
STANDARDS................................................................... 220
INDEX ............................................................................ 221

MEANS OF REPRESENTATION 5
Symbols used
The symbols used are explained in the following.
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).
Indicates information with more details or tips.
Indicates the result of a testing step.
Identifies a voltage measurement.
Identifies a current measurement.
Identifies a resistance measurement.
Formats used
The typographical and other formats used are explained below.
Specific name Indicates a proprietary name.
Name®Identifies a protected name.
Brand™ Identifies a trademark.

IMPORTANT NOTES 6
Warranty
The work prescribed in the service plan must only be carried out in an authorized KTM workshop and confirmed in the service record;
otherwise all warranty claims will be disregarded. No warranty claim can be met for damage resulting from manipulation and/or other
changes to the vehicle.
Fuel, oils, etc.
You should use the fuels, oils and greases according to specifications as listed in the repair manual.
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 certain tasks. The tools are not contained in the vehicle but can be ordered under the number in paren-
theses. Example: 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 a 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 miss-
ing, you or others may not recognize potential hazards 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.

LOCATION OF SERIAL NUMBERS 7
3.1Chassis number/type label (690 SMC EU, 690 SMC AUS/UK)
500006-01
The chassis number is stamped on the right of the steering head.
The type label is on the right of the frame behind the steering head.
3.2Chassis number/type label (690 SMC USA)
500006-01
The chassis number is stamped on the right of the steering head.
The USA type label is on the right of the frame behind the steering head.
700218-01
The Canada type label is on the right of the frame behind the steering head.
3.3Key number
100179-10
The key number can be found on the KEYCODECARD.
Info
You need the key number to order a spare key. Keep the KEYCODECARD in a safe
place.
3.4Engine number
600479-10
The engine number is stamped on the left side of the engine under the engine
sprocket.

LOCATION OF SERIAL NUMBERS 8
3.5Fork part number
600480-10
The fork part number is stamped on the inner side of the fork stub.
3.6Shock absorber part number
100216-10
The shock absorber part number is on the right of the shock absorber.

MOTORCYCLE 9
4.1Raising the motorcycle with the rear wheel stand
Note
Danger of damage The parked vehicle may roll away or fall over.
–Always place the vehicle on a firm and even surface.
600492-01
–Insert the adapter into the rear wheel stand and screw into the swingarm on both
sides.
Adapter (61029055110) ( p. 210)
Rear wheel stand (61029055100) ( p. 210)
–Position the motorcycle upright, align the stand and raise the motorcycle.
4.2Taking the motorcycle off of the rear wheel stand
Note
Danger of damage The parked vehicle may roll away or fall over.
–Always place the vehicle on a firm and even surface.
–Secure the motorcycle against falling over.
–Remove the rear wheel stand and lean the vehicle on the side stand.
4.3Raising the motorcycle with the front wheel stand
Note
Danger of damage The parked vehicle may roll away or fall over.
–Always place the vehicle on a firm and even surface.
–Raise the motorcycle with the rear wheel stand. ( p. 9)
600493-01
–Move the handlebar to the straight-ahead position. Align the front wheel stand with
the fork legs using the adapters.
Front wheel stand (61029055300) ( p. 211)
Info
Always raise the rear of the motorcycle first.
–Raise the front of the motorcycle.
4.4Taking the motorcycle off of the front wheel stand
Note
Danger of damage The parked vehicle may roll away or fall over.
–Always place the vehicle on a firm and even surface.
–Secure the motorcycle against falling over.
–Remove the front wheel stand.

MOTORCYCLE 10
4.5Raising the motorcycle with the work stand
Note
Danger of damage The parked vehicle may roll away or fall over.
–Always place the vehicle on a firm and even surface.
300579-10
–Mount the special tool on the footrest.
Work stand adapter (75029036000) ( p. 213)
300201-10
–Position the motorcycle upright, align the special tool and raise the motorcycle.
Work stand (62529055000) ( p. 211)
4.6Removing the motorcycle from the work stand
Note
Danger of damage The parked vehicle may roll away or fall over.
–Always place the vehicle on a firm and even surface.
300201-10
–Secure the motorcycle against falling over.
–Remove the work stand and lean the vehicle on the side stand.
300579-10
–Remove the special tool.

MOTORCYCLE 11
4.7Starting
Danger
Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and/or death.
–When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed
space without an effective exhaust extraction system.
Caution
Danger of accidents If the vehicle is operated with a discharged battery or without a battery, electronic components and safety
equipment may be damaged.
–Never operate the vehicle with a discharged battery or without a battery.
Note
Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine.
–Always warm up the engine at low engine speeds.
B00103-10
–Turn the emergency OFF switch to the position .
–Switch on the ignition by turning the ignition key in the position (690 SMC EU,
690 SMC AUS/UK) (690 SMC USA).
After you switch on the ignition, you can hear the fuel pump working for about
2 seconds. At the same time, the function test of the combination instrument
is run.
–Shift gear to neutral.
The green idling speed indicator lamp Nlights up.
–Press the electric starter button .
Info
Do not press the electric starter button until the function test of the combi-
nation instrument is finished.
When starting, DO NOT open the throttle. If you open the throttle during the
starting procedure, fuel is not injected by the engine management system
and the engine cannot start.
Press the starter for a maximum of 5 seconds. Wait for at least 5 seconds
before trying again.
This motorcycle is equipped with a safety start system. You can only start
the engine if the gearbox is in neutral or if the clutch is pulled when a
gear is engaged. If the side stand is folded out and you shift into gear and
release the clutch, the engine stops.
–Take the weight off the side stand and swing it back up with your foot as far as it
will go.
4.8Starting the motorcycle to make checks
Danger
Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and/or death.
–When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed
space without an effective exhaust extraction system.
Info
Press the starter for a maximum of 5 seconds. Wait for a least 5 seconds before trying again.
B00103-10
–Turn the emergency OFF switch to the position .
–Shift gear to neutral.
–Switch on the ignition.
–Press the electric starter button .
Info
Do not open the throttle.

01/FORK, TRIPLE CLAMP 12
5.1Adjusting compression damping of fork
Info
The hydraulic compression damping determines the fork suspension behavior.
600490-10
–Turn adjusting screws clockwise until they stop.
Info
The adjusting screws are located at the bottom end of the fork legs.
Make the same adjustment on both fork legs.
–Turn back counterclockwise the number of clicks corresponding to the fork type.
Guideline
Compression damping
Comfort 20 clicks
Standard 15 clicks
Sport 10 clicks
Full payload 10 clicks
Info
Turn clockwise to increase damping, turn counterclockwise to reduce sus-
pension damping.
5.2Adjusting rebound damping of fork
Info
The hydraulic rebound damping determines the fork suspension behavior.
100244-10
–Turn adjusting screws clockwise until they stop.
Info
The adjusting screws are located at the top end of the fork legs.
Make the same adjustment on both fork legs.
–Turn back counterclockwise the number of clicks corresponding to the fork type.
Guideline
Rebound damping
Comfort 15 clicks
Standard 10 clicks
Sport 5 clicks
Full payload 5 clicks
Info
Turn clockwise to increase damping, turn counterclockwise to reduce sus-
pension damping.
5.3Bleeding the fork legs
–Lean the motorcycle on the side stand.
100248-10
–Remove bleeder screws briefly.
Any excess pressure escapes from the interior of the fork.
–Mount and tighten bleeder screws.
Info
Carry out this action on both fork legs.

01/FORK, TRIPLE CLAMP 13
5.4Cleaning the dust boots of the fork legs
–Jack up the motorcycle and secure it against falling over.
The front wheel is no longer in contact with the ground and the fork legs are no
longer under tension.
–Remove the fork protector. ( p. 13)
600634-10
–Push dust boot of both fork legs downwards.
Info
The dust boots should remove dust and coarse dirt particles from the fork
tubes. Over time, dirt can penetrate behind the dust boots. If this dirt is not
removed, the oil seals behind can start to leak.
Warning
Danger of accidents Reduced braking efficiency due to oil or grease on the
brake discs.
–Always keep the brake discs free of oil and grease, and clean them with
brake cleaner when necessary.
–Clean and oil the dust boots and inner fork tube of both fork legs.
Universal oil spray ( p. 207)
–Press the dust boots back into their normal position.
–Remove excess oil.
–Install the fork protector. ( p. 13)
–Remove the motorcycle from the lift stand.
5.5Removing the fork protector
600633-11
–Remove screws and take off clamp.
–Remove screws on left fork leg. Remove the fork protector.
–Remove the screws on the right fork leg. Remove the fork protector.
5.6Installing the fork protector
600633-10
–Position the fork protection on the left fork leg. Mount and tighten screws .
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
–Position the brake line and cable harness. Put the clamp on, mount and tighten
screws .
–Position the fork protection on the right fork leg. Mount and tighten the screws.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

01/FORK, TRIPLE CLAMP 14
5.7Removing fork legs
–Raise the motorcycle with the work stand. ( p. 10)
–Tie the rear of the vehicle down.
201374-10
–Remove screws and spacers .
–Press back the brake linings with a light lateral tilting of the brake caliper on the
brake disc. Carefully pull the brake caliper backwards from the brake disc.
Info
Do not pull the handbrake lever when the brake caliper is removed.
201375-10
–Loosen screws and .
–Unscrew screw about 6 turns and press your hand on the screw to push the
wheel spindle out of the axle clamp. Remove screw .
Warning
Danger of accidents Reduced braking efficiency caused by damaged brake
discs.
–Always lay the wheel down in such a way that the brake disc is not dam-
aged.
–Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of
the fork.
201376-10
–Remove screws and the clamp. Take the brake line and wiring harness out of the
holder.
201377-10
–Remove the screws of the wheel speed sensor . Hang the wheel speed sensor to
one side.
201378-10
–Remove screws . Take off the fork protector.

01/FORK, TRIPLE CLAMP 15
201379-10
–Loosen the screws of the triple clamp. Remove the fork legs from the bottom.
5.8Installing the fork legs
201379-11
–Slide the fork legs into the triple clamps on both sides.
Info
The bleeder screws must face forwards.
The topmost milled groove in the fork leg must be flush with the top edge of
the upper triple clamp.
The upper fork projection must be the same on both sides.
–Tighten screws on both sides.
Guideline
Screw, top triple clamp M8 17 Nm
(12.5 lbf ft)
Screw, bottom triple clamp M8 12 Nm (8.9 lbf ft)
201378-11
–Position the fork protection. Mount and tighten screws .
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
201377-11
–Position the wheel speed sensor. Mount and tighten screws .
Guideline
Screw, wheel speed sensor M4 2 Nm
(1.5 lbf ft)
Loctite®243™
201376-11
–Position the brake line, wiring harness and clamp.
–Mount and tighten screws .

01/FORK, TRIPLE CLAMP 16
201380-10
Warning
Danger of accidents Reduced braking efficiency due to oil or grease on the
brake discs.
–Always keep the brake discs free of oil and grease, and clean them with
brake cleaner when necessary.
–Clean screw and the wheel spindle.
–Lift the front wheel into the fork, position it, and insert the wheel spindle.
–Mount and tighten screw .
Guideline
Screw, front wheel spindle M24x1.5 40 Nm
(29.5 lbf ft)
201374-11
–Position the brake caliper and check that the brake linings are seated correctly.
–Mount screws spacers but do not tighten.
–Operate the hand brake lever repeatedly until the brake linings lie on the brake disc
and there is a pressure point. Fix the hand brake lever in the activated position.
The brake caliper straightens.
–Fully tighten screw .
Guideline
Screw, front brake caliper M10x1.25 45 Nm
(33.2 lbf ft)
Loctite®243™
–Remove the fixation of the hand brake lever.
–Unload the rear of the vehicle.
–Remove the motorcycle from the work stand. ( p. 10)
201375-11
–Pull the front brake and compress the fork powerfully a few times.
The fork legs straighten.
–Tighten screws .
Guideline
Screw, fork stub M8 15 Nm
(11.1 lbf ft)
5.9Servicing the fork
Info
These operations are the same on both fork legs.
Condition
The fork legs have been removed.

01/FORK, TRIPLE CLAMP 17
201240-01
–Disassemble the fork legs. ( p. 17)
–Check the fork legs. ( p. 20)
–Assemble the fork legs. ( p. 21)
5.10Disassembling the fork legs
Info
These operations are the same on both fork legs.
Condition
The fork legs have been removed.
200660-01
–Establish and note the current state of the rebound damping and compression
damping .
–Completely open the adjusters of the rebound and compression damping.
200643-10
–Clamp the fork leg in the area of the lower triple clamp.
Clamping stand (T1403S) ( p. 219)
200644-12
–Loosen screw cover .
Info
The screw cover cannot be removed yet.

01/FORK, TRIPLE CLAMP 18
200661-01
–Release the fork leg and clamp it with the axle clamp.
Info
Use soft jaws.
200646-12
–Push the outer tube downward.
–Pull the spring downwards. Mount the special tool on the hexagon.
Open-end wrench (T14032) ( p. 219)
Info
The preload spacers should be above the special tool.
200647-12
–Clamp the special tool in the vise. Loosen screw cover .
200648-12
–Remove screw cover with preload spacers .
–Remove adjusting tube .
200649-01
–Pull the spring downward. Remove the special tool.
–Remove the spring.
200650-01
–Drain the fork oil.
Info
Pull out and push in the piston rod a few times to empty the cartridge.