Install pinion (1).
Install new locking washer (3) and nut (4), do not tighten.

86
Adjusting chain sag

ATTENTION
Rear wheel skewed at a slight angle because tensioning screws not adjusted to same setting
Accelerated wear at rear wheel and chain drive
Make sure that the rear wheel is aligned to track correctly (same scale reading on both sides of the rear wheel
swinging arm).
Adjust chain tension (A) with tensioning screw (3) on left
and right, making sure the toe adjustment (same scale
value (4) on both sides of the rear wheel swinging arm)
is correct.
Technical data
Chain deflection

Motorcycle with
no weight
applied,
supported on
its side
stand

45...50 mm

Tighten lock nuts (2) on left and right, counter-holding
tensioning screws (3).
Tightening torques
Locknut of the final-drive chain tensioning screw
M8
Tighten the nut (1).

65

19 Nm

Tightening torques
Rear quick-release axle in swinging arm
M24 x 1.5

125 Nm

Thread-locking compound (mechanical)

87
Securing exhaust manifold, rear
Secure exhaust manifold (3) with bolt (1) and washer (2).
Tightening torques
Exhaust manifold to holder
M8 x 70, Renew screw

18 Nm

Thread-locking compound (micro-encapsulated)

88
Securing the clutch cable
Secure the clutch cable (1) in holder (2).

66

Secure the clutch cable (3) in holder (5).
Attach clutch cable (3) in lever (4).
Hand-tighten adjusting nuts (1) and (2).

89
Securing Bowden cables to exhaust-flow
control valve
Attach cable (1) and fit actuating cable (2).
Attach cable (3) and position retention cable(4).
Position nuts (5) between stops (arrows).
Tighten bolts (6) and counter-hold nuts (5) where needed.

with M titanium exhaust system OE (019H)

Attach cable (1) and fit actuating cable (2).
Attach cable (3) and position retention cable(4).
Position nuts (5) in stops (arrows).
Tighten bolts (6) and counter-hold nuts (5) where
needed.

67

90
Installing cover of exhaust-flow control valve
Install cover (2) in locators (arrows).
Install bolt (1).

with M titanium exhaust system OE (019H)

Position cover (4) with preassembled bolts (1) and washers (2) and (3).
Install screws (1).

91
Secure the right footrest plate
Hold footrest plate (2) in position and install screws (1).
Tightening torques
Front footrest holder to main frame
M8 x 25

68

19 Nm

92
Installing silencer
Push silencer (1) onto front silencer (2).
Install screw (3) and shaped washer (4).
Tightening torques
Silencer to footrest system
M8 x 40

19 Nm

Position clamp (5) with the recess in the lug (arrow).
Tighten the nut (6).
Tightening torques
Clamping collar for rear silencer
M8

24 Nm

with M titanium exhaust system OE (019H)

or
with M Sports silencer OE (019G)

Lightly lubricate inner surface (arrow) of silencer (1).
Lubricant
Optimoly TA

18 21 9 062 599

with M titanium exhaust system OE (019H)

or
with M Sports silencer OE (019G)

Connect silencer (1) to exhaust pipe of front silencer (2).
Position the shaped washer (3) and install the screw(4), do
not tighten.
Tighten clamping collar (5) hand-tight.

69

with M titanium exhaust system OE (019H)

or
with M Sports silencer OE (019G)

Align silencer (1).
Tighten clamping collar (2).
Tightening torques
Clamping collar for rear silencer
M8

14 Nm

Tighten the screw (3).
Tightening torques
Silencer to footrest system
M8 x 40

19 Nm

93
Filling cooling system
Push on coolant hose (1).
Lug (2) engages in recess of coolant hose (1).
Secure clamp (3) using pliers (17 5 571) and align to
mark (arrow).
Install bolt (4).
Tightening torques
Coolant line to bracket
M5 x 16

5 Nm

Preparing and priming radiator filler for cooling system
Fill canister (17 5 553) with an adequate quantity of
coolant.
Technical data
Coolant, total
capacity

2.95 l
General consumable (Antifreeze and
corrosion inhibitor)

Connect canister (17 5 553), venturi nozzle (17 5 552) and
distributor unit (17 5 551).
Put the end of the drain hose of venturi nozzle (17 5 552)
into a suitable container.

ATTENTION
Connecting compressor to distributor unit of filler adapter with compressed-air valve open
Damage to pressure meter due to pressure peaks
Make sure the valves are closed when you connect the
compressor to the distributor unit.
70

Connect the compressor to the venturi nozzle (17 5 552).
Technical data
Minimum
requirement,
compressor

Print

min 8 bar

Delivery
rate

min 125 l/
min

Begin by fully opening coolant cock (1) and then fully
opening negative-pressure cock (2) of distributor unit (17 5
551).
Coolant is drawn in by vacuum from the tank.
Draw in coolant until the hose to distributor unit (17 5 551)
is full of bubble-free coolant.
Close coolant cock (1) and negative-pressure cock (2).
Disconnect the compressor from venturi nozzle (17 5 552).

Connecting radiator filler to cooling system
Requirement
The coolant canister must be higher than the motorcycle's
radiator.
Position coolant canister (17 5 553) on a higher level.
Secure the preassembled radiator filler in position at the
motorcycle.
Connect radiator port (17 5 554) to distributor unit (17 5
551) and radiator filler neck.
Put the end of the drain hose of venturi nozzle (17 5 552)
into a suitable container.
Prepare the compressor.
Technical data
Minimum
requirement,
compressor

Print

min 8 bar

Delivery
rate

min 125 l/
min

Evacuating cooling system

ATTENTION
Connecting compressor to distributor unit of filler adapter with compressed-air valve open
Damage to pressure meter due to pressure peaks
Make sure the valves are closed when you connect the
compressor to the distributor unit.
Connect the compressor to the venturi nozzle (17 5 552).
Open negative-pressure cock (2) of distributor unit (17 5
551).
A vacuum builds up in the system.

71

Evacuate the cooling system until the requisite negative
pressure is established and the needle of the pressure
gauge is steady.
Technical data
Requisite vacuum for filling
the cooling system

min -0.8 bar

Close negative-pressure cock (2).
Disconnect the compressor from venturi nozzle (17 5 552).
Observe the needle of the pressure gauge of distributor
unit (17 5 551) for a time and check that the partial vacuum in the cooling system does not rise to ambient pressure.
Technical data
Requisite vacuum for filling
the cooling system

min -0.8 bar

Slowly open coolant cock (1) until it is fully open.
Coolant flows into the cooling system.
When the level of fluid in the canister (17 5 553) ceases
to drop and the vacuum corresponds to ambient pressure,
shut coolant cock (1).

Disconnecting radiator filler from radiator
Disconnect the radiator filler from the radiator and remove
it from the vehicle.

Check the coolant level; top up if necessary. (Cooling system must be filled with coolant up to the lower edge (arrow) of coolant filler neck (1).)
General consumable
Antifreeze and corrosion
inhibitor

72

83 51 2 445 463

Install the radiator cap
Install the radiator cap (2).
Remove hose clip (13 3 010) from overflow hose (1).

94
Connecting starter motor
Fit grounding cable (4) and install screw (3).
Tightening torques
Wiring harness (earth) to crankcase
M6 x 12

8 Nm

Fit the positive wire for the starter motor (2) and install the
bolt (1).
Tightening torques
Wiring harness (positive wire) to starter motor
M5 x 10

3 Nm

Install holders (3) and retaining brackets (2).
Install bolt (1).

73

95
with Dynamic Damping Control (DDC) OE (0223)

Securing control unit for electronic
suspension adjustment
Fit control unit (1) observing locators (arrows).
Install the O-ring (2).

96
Connecting engine wiring harness on cylinder head cover
Information for connecting vibration-resistant connectors
Check if the contact carrier (1) protrudes significantly from
the connector housing (2).
If necessary, hold down the connector housing (2) and
slide contact carrier from the rear at the cable inlet (3) toward the front until the contact carrier (1) is visible

Ensure that the release tab (1) is unlocked.
Slide connector (2) in direction of arrow (arrow 1).
The connector (2) engages audibly.
Slide connector (2) in direction of arrow (arrow 2) further.
The connector (2) engages audibly.
Slide locking tab (1) in direction of arrow (arrow 3).
The locking tab (1) engages audibly.

74

Connect connectors (1) for switching cam adjusters.
Connect connector (2) for direct ignition coils.

Connect connector for switching cam sensor (1).

97
Installing secondary air system line
Feed in and fit secondary air system line (2).
Slide on hose connections (1) for secondary air system
until the locks engage with an audible click.
Close the cable strap (arrows).

98
Installing throttle-valve assembly

NOTICE
Connect the connector of the throttle-valve assembly first,
then install throttle-valve assembly; otherwise, there is a risk
of damaging the connectors.
75

Information for connecting vibration-resistant connectors
Check if the contact carrier (1) protrudes significantly from
the connector housing (2).
If necessary, hold down the connector housing (2) and
slide contact carrier from the rear at the cable inlet (3) toward the front until the contact carrier (1) is visible

Ensure that the release tab (1) is unlocked.
Slide connector (2) in direction of arrow (arrow 1).
The connector (2) engages audibly.
Slide connector (2) in direction of arrow (arrow 2) further.
The connector (2) engages audibly.
Slide locking tab (1) in direction of arrow (arrow 3).
The locking tab (1) engages audibly.

Remove cap from intake ducts.
Position throttle valve assembly (2), connect connector (3)
and (4).
Secure fuel line (1) in holder (arrow).

Lubricate connecting piece of throttle valve assembly (2)
and connections (arrows) for bypass lines.
Installation tool
Silicone spray

83 19 2 208 609

Install throttle valve assembly (2) while observing connections (arrows) for bypass lines.
Tighten screw clamp (1).

76

Connect connector (5) for fuel pressure sensor.
Connect connector (4) for fuel injectors.
Position wiring harness (3) and fasten cable ties (arrows).
Connect hose (1) of tank vent valve to distributor (2).

99
Installing rear air intake duct
When installing the rear air intake duct, make sure the
hoses are routed correctly.
Hose (1) to carbon filter
Hose (2) to tank vent valve

Fit air intake duct (2) and connect connector (1).

77

Install air intake duct (2), and let left and right locators (arrow) engage for this purpose.
Install screws (1).
Tightening torques
Rear air guide to frame
M6 x 12

8 Nm

100
Install the intake air silencer
Make sure that rubber grommets (1) for idle controller are
installed on intake silencer (2).
Lubricate rubber grommets (1) and intake rubbers (3).
Installation tool
Tyre-fitting paste

81 22 0 433 046

Fit intake silencer (3) and feed in hose (2) for crankcase
ventilation.
Install intake silencer (3).

NOTICE
When installing the intake silencer make sure that the carb
mount rubbers are not pushed into the intake silencer.
Check the position of the carb mount rubbers again after
installation and correct where required.
Connect hose (2) for crankcase ventilation with clamp (1).
Align clamp (1) with mark and secure with pliers (17 5
500).

78

Install screws (1).
Tightening torques
Intake silencer to throttle-valve assembly
M6 x 12

6 Nm

Fit holder (2) and install bolts (3).
Tightening torques
Intake silencer to frame
M6 x 30

8 Nm

Check O-rings (arrow); replace if necessary.
Lubricate O-rings (arrow).
Installation tool
Silicone spray

83 19 2 208 609

Secure fuel injection pipe with injector nozzles (1).
Install screws (2).
Tightening torques
Fuel injection pipe to intake silencer
TS5 x 14

3 Nm

Secure tank vent valve (3) to holder (4).
Slide on hose connection (2) for secondary air system until
it locks with an audible click and secure hose in holder (arrow).
Secure hose (1).

79

101
Attaching engine control unit with wiring
harness
Place the control unit (1) with cable duct and wiring harness toward the front.
Connect connector (3) for the intake air temperature
sensor.
Connect connector (2) for DISA servomotor.
Position control unit (1) with cable duct and wiring harness.

Install screws (2).
Connect connector (1) for the tank vent valve.

Connect connector (2) for secondary air control valve and