KTM 2005 990 Super Duke User Manual (English)

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950/990 ADVENTURE

990 SUPER DUKE

950 SUPERMOTO

950 SUPER ENDURO

REPARATURANLEITUNG

MANUALE DI RIPARAZIONE

MANUEL DE RÉPARATION

MANUAL DE REPARACIÓN

ART.NR.: 3.206.035-E

REPAIRMANUAL2003-2006

Table of Contents5
Updating Instructions7
Introduction11
General Information Index15
Oil System17
Intake System18
Secondary Air System19
Cooling System20
Closed Thermostat20
Open Thermostat20
ABS (Antilock Brake System)21
ABS Warning Lamp21
ABS Button21
Special Tools - Engine22
Chassis24
Checking the Oil Level of the Hydraulic Clutch25
Bleeding of the Hydraulic Clutch25
Resetting the Control Unit after Replacing/Repairing the Engine26
Adjusting the Throttle Cable for Models with Fuel Injection27
ECU Software Update/Mapping28
Downloading the Software28
Starting the DMT (Data Maintenance Tool)29
Starting the FAN (Flash Download System)29
Checking the Oil Pressure30
Removing and Refitting Engine Index31
Removing the Engine33
Refitting the Engine - 950 Adventure38
Dismounting the Engine - 990 Super Duke43
Mounting the Engine - 990 Super Duke44
Dismounting/Mounting the Engine - 950 Supermoto51
Removing the Tank51
Disassembling the Engine Index53
Table of Contents53
Valve Covers55
- Spark Plug Shaft Inserts55
- Starter Motor55
- Camshafts Cylinder Rear56
Setting Cylinder Rear to TDC56
Timing Chain Cylinder Rear57
Chain Tensioner Cylinder Rear57
- Cylinder Head Rear with Cylinder58
- Setting Cylinder Front to TDC58
Double Timing Gear58
- Oil Pressure Switch59
- Chain Tensioner Cylinder Front59
Camshafts Cylinder Front59
Cylinder Head Front with Cylinder60
Timing Chain Cylinder Front60
- Clutch Cover61
- Oil Screen61
Water Pump61
Clutch62
Primary Pinion and Clutch63
Rotor64
Generator Cover64
- Balancer Shaft65
- Shift Mechanism65
Freewheel65
Engine Case Half66
Transmission67
Oil Pumps68
- Servicing Individual Components Index69
- Replacing the Roller Bearing71
- Replacing the Main Bearings-General Information72
- Replacing Bearing Shells, Output End73
- Replacing Bearing Shells, Generator End73
- Replacing the Conrod Bearings74
- Selecting the Bearing Shells74
- Replacing the Supporting Bearings in the Clutch Cover75
- Overhauling the Water Pump76
- Checking the Suction Pump for Wear77
- Checking the Pressure Pump for Wear77
- Bypass Valve77
- Valves78
- Sealing Area78
- Valve Seats/Guides/Springs78
- Disassembling the Cylinder Head and Checking Parts for Wear78
- Checking the Pistons79
- Checking the Piston Ring End Gap79
- Assembly Instructions for Piston Rings79
- Measuring Pistons/Cylinders, Establishing Piston Mounting Clearance79
- Piston and Cylinder Identification80
- Assembling the Cylinder Head80
- Torque Limiter82
- Valve Gear – Checking Parts for Wear82
- Preassembling the Spreader Drive83
- Clutch – Checking Parts for Wear84
- Shift Mechanism – Checking Parts for Wear85
- Preassembling the Shift Shaft85
- General Information on Servicing the Transmission86
- Assembling the Main Shaft86
- Assembling the Countershaft87
- Checking the Freewheel88
- Replacing the Freewheel Hub88
- Starter88
- Assembling the Engine Index89
- Axial Clearance of the Main Shaft92
- Case Half94
- Aligning the Return Spring95
- Freewheel96
- Timing Chain and Balancing Weight97
- Primary Pinion98
- Outer Clutch Hub98
- Clutch Disks99
- Clutch Cover100
- Cylinder Head Rear with Timing Chain102
- Cylinder Head Front with Cylinder and Timing Chain106
- Valve Cover111
- Electrical Index113
- Abs-System113
- Checking the Generator Coils115
- Checking the Charging Voltage / Rectifier Regulator115
- Charging the Battery115
- Checking for Loss of Current115
- Electric Starter System 950 Adventure116
- Starting System 990 Super Duke117
- 950 Supermoto/950 Super Enduro Electric Starter System118
- 990 Adventure Electric Starter System119
- Checking the Auxiliary Starter Relay120
- Functional Check of the Auxiliary Starter Relay121
- Functional Check of the Auxiliary Start Relay121
- Checking the Diodes122
- Checking the Starter Relay123
- Checking the Starter Motor123
- Checking the Clutch Switch124
- Checking the Tip Switch and Emergency off Switch125
- Troubleshooting in the Starter System125
- Ignition System, ECU 950 Adventure126
- Ignition System, ECU 950 Supermoto127
- Ignition System, ECU 950 Super Enduro128
- ECU 950 Adventure/Supermoto/Super Enduro129
- Checking the Pulse Generator 950 Adventure/950 Supermoto129
- Checking the Fuel Pump Relay 950 Adventure/950 Supermoto130
- Checking the Ignition Coils 950 Adventure/Supermoto/Super Enduro130
- Troubleshooting in the Ignition System 950 Adventure/950 Supermoto131
- The EPC System 950 Adventure132
- The EPC System 950 Supermoto133
- EPC System 950 Super Enduro134
- Checking the Solenoid Valve for the EPC 950135
- Checking the Gear Sensor 950135
- Adventure Carburetor Heater 950 Adventure136
- Checking the Heating Elements136
- Checking the Temperature Switch136
- Injection/Ignition System137
- Correction Sensors and Inputs137
- Establishing the Injection Period (Injection Volume)137
- System Diagram138
- Basic Description of the System139
- Wiring Diagram 990 Duke140
- Wiring Diagram 990 Adventure141
- Block Diagram142
- Description of the Electric System143
- Descriptiopn of the Components144
- Fuel Pump144
- Pressure Regulator144
- Injection Valves144
- Manifold Air Pressure Sensor145
- Ambient Air Pressure Sensor145
- Throttle Valve Sensor145
- Sensor for the 2Nd Throttle Valve145
- Pulse Generator (Crankshaft)146
- Lambda Probes146
- Servomotor for the 2Nd Throttle Valve147
- Catalytic Converter147
- Idle Speed Control Motor147
- Ignition Coils148
- Fuel Pump/Main Relay148
- Secondary Air Valve148
- Octane Selector Connections148
- Roll Angle Sensor149
- Diagnostics Connector149
- Side Stand Switch149
- Clutch/Gear Switch149
- Safety against Failure/Emergency Operation150
- Component Tests151
- Coolant Temperature Sensor152
- Air Temperature Sensor152
- Intake Pressure Sensors153
- Sensor for 2Nd Throttle Valve154
- Pulse Generator155
- Lambda Probe Heater155
- Control Motor for the 2Nd Throttle Valve156
- Ignition Coil157
- Fuel Pump Relay157
- Main Relay158
- Error Lamp160
- Gear Sensor (Neutral, 2, 3)160
- Clutch Switch160
- Speed Signal161
- Coolant Temperature Signal161
- Diagnostics Line161
- Error Codes162
- Abbreviations, Limit Values 990 Super Duke163
- Abbreviations, Limit Values 990 Adventure164
- Alarm System for 990 Super Duke165
- Order for Additional Hand-Held Transmitters166
- Adapting the Hand-Held Transmitter166
- Starting with the Emergency Code167
- Checking the ABS Fault Memory Using the KTM Diagnostics Tool168
- Checking the ABS Sensor with the KTM Diagnostics Tool168
- Checking the Fuses168
- ABS System 990 Adventure168
- Fuel System Index169
- Carburetor Exploded View171
- Description of the ACV (Air Cut Valve) System172
- Disassembling the Carburetor173
- Assembling the Carburetor176
- Adjusting the Float Level179
- Adjusting the Idle Mixture Control Screw179
- Checking the Throttle Sensor180
- Adjusting the Throttle Sensor180
- Adjusting the Choke Cable180
- Adjusting the Throttle Cable180
- Carburetor Heater181
- Replacing the Fuel Filter182
- Injection System182
- Dismounting/Mounting Fuel Pump with Pressure Regulator/Level Sensor182
- Dismounting/Mounting the Throttle Body182
- Checking the Fuel Pressure183
- Troubleshooting Index185
- Chassis Index189
- Dismounting/Mounting the Front Wheel191
- Dismounting/Mounting the Rear Wheel192
- Replacing the Front Wheel Bearing193
- Replacing the Rear Wheel Bearing194
- Replacing the Front Brake Pads195
- Replacing the Rear Brake Pads196
- Replacing the Fork Legs197
- Replacing the Shock Absorber198
- Replacing the Fork Leg199
- Replacing the Steering Head Bearing200
- Replacing the Swing Arm Bearing201
- Replacing the Chain, Pinion and Rear Sprocket202
- Opening the Chain with a Separating/Rivet Tool203
- Riveting the Chain203
- Replacing the ABS Unit204
- Replacing the Rear ABS Sensor204
- Technical Specifications Index205
- Engine 950 Adventure207
- Chassis Engine 950 Adventure/Adventure S208
- Engine 990 Super Duke210
- Chassis 990 Duke211
- Engine 950 Supermoto213
- Engine 990 Adventure216
- Chassis 990 Adventure/Adventure S217
- Engine 950 Super Enduro219
- Chassis 950 Super Enduro220
- Tolerance and Fitting Clearances222
- Tightening Torques224
- Periodic Maintenance Schedule Index227
- Cleaning the Oil Screens and Magnets on the Drain Plugs238
- Changing the Engine Oil and Filter238
- Lubrication and Maintenance Work - Engine238
- Engine Oil239
- Checking the Engine Oil Level240
- Replacing the Spark Plugs240
- Checking the Clutch Lining244
- Checking the Clutch Pressure Booster System244
- Cleaning the Oil Jet for the Clutch Lubrication244
- Lubrication and Maintenance Work - Carburetor245
- Check the Carburetor Synchronization with Vacuum Gauge and Adjust245
- Checking the Idle Setting245
- Replacing the O-Ring on the Fuel Hose Connector246
- Add-On Parts246
- Brakes246
- Injection246
- Changing the Front Brake Fluid247
- Changing the Rear Brake Fluid248
- Cleaning the Dust Boots249
- Checking the Swing Arm Support249
- Checking/Adjusting the Steering Head Bearing249
- Checking All Chassis Bolts for Force Fit249
- Wheels250
- Checking the Spoke Tension and Rim Run-Out250
- Checking the Chain and Chain Guides for Wear, Force Fit and Tension250
- Checking the Wheel Bearing and Jerk Damper for Clearance250
- Additional Work251
- Cleaning and Greasing the Steering Head Bearing and Sealing Elements251
- Changing the Cooling Liquid252
- Wiring Diagrams Index253
- Start System262
- Charging Circuit264
- Ecu266
- Turn Indicator System268
- Light-Brake System270
- Light System USA272
- Instruments Tachometer274
- Ground Connection276
- Positive Connection277
- Light/Turn Signal/Horn Switch278
- Multifunctional Digital Speedometer278
- Front Light278
- Start/Stop/Light Switch278
- Tachometer279
- Turn Signal Relay279
- Rear Brake Light Switch279
- Left/Right Front Turn Signal279
- Diode Neutral Switch280
- Diode Side Stand Switch280
- Rear Lighting280
- Right Front Turn Signal280
- Speed Sensor281
- Pick up281
- Carburetor Potentiometer281
- Fuel Sender281
- Tripmaster Switch282
- ECU (Control Unit)282
- Ignition Lock282
- Connector for Auxiliary Devices282
- Rear/Front Ignition Coil283
- Radiator Fan Motor284
- Regulator284
- Temperature Switch for the Radiator Fan284
- EPC Front/Rear Cylinder284
- Octane Selector285
- Temperature Sensor for the Multifunctional Digital Speedometer285
- Rear Turn Signal285
- Battery Generator Starter290
- Turn Signal, Horn, Fan294
- Instruments - Tachometer298
- Front Lighting302
- Turn Signal, Horn, High Beam Switch302
- Start Relay/Main Fuse302
- Auxiliary Starter Relay303
- Speedometer303
- Front Brake Light Switch303
- Diodes304
- Throttle Sensor for the 2Nd Throttle305
- Throttle Sensor305
- Gear Sensor305
- Side Stand305
- Ignition Switch306
- Diagnosis Connector306
- Rollover Sensor306
- Rear Ignition Coil307
- Front Ignition Coil307
- Temperature Switch308
- Fan Motor308
- Regulator Output308
- Rear Blinker309
- Pressure Sensor for Rear Cylinder312
- Manifold Air Pressure Sensor for Front Cylinder312
- Ambiant Air Pressure Sensor312
- Rear/Front Lambda Probe312
- Control Motor for 2Nd Throttle313
- Front Wiring Harness313
- Secondary Air System Valve313
- Rear Injection Valve314
- Front Injection Valve314
- Wiring Harness EFI314
- Connector315
- Connector for the Alarm System Control Unit315
- Connector for Attachments315
- Lighting Relay331
- Start Relay331
- Temperature Switch for Carburetor Heater331
- Neutral Switch Diode332
- Diode for Side Stand Switch332
- Diode for Turn Signal Control332
- Rear Lighting System332
- Controller Outlet337
- Front EPC337
- EPC Rear337
- Turn Signal/Horn/High Beam Switch338
- Radiator Fan339
- Alarm LED339
- Seat Switch339
- Headlight340
- Parking Light341
- Connector for the Alarm ECU341
- Dummy Plug341
- Battery, Generator, Starter344
- Efi346
- Abs353
- ABS Connection358
- Temperature Switch for Radiator Fan362
- Controller362
- Front Lambda Probe365
- Control Motor for the 2Nd Throttle365
- Rear Lambda Probe365
- EFI Wiring Harness366
- ABS-ECU (Control Unit)367
- Rear ABS Sensor367
- Front ABS Sensor367
- ABS Control Lamp368
- Manifold Air Pressure Sensor for the Rear Cylinder368
- Manifold Air Pressure Sensor for the Front Cylinder368
- Engine Stop Relay384
- Starter Relay384
- Light/Horn/Stop Switch384
- Temperature Switch for the Carburetor Heater385
- Flasher Relay385
- Diode for Neutral Switch385
- Diode for Side Stand385
- Flasher Switch386
- Control Unit388
- Controller Output390
- Front EPC Cylinder391
- Rear EPC Cylinder391
- Rear Flasher391
- Emergency off Switch392
- Tip Switch393

KTM 2005 990 Super Duke User Manual

Table of Contents

KTM 2005 990 Super Duke Specifications

Summary

General Information

ABS (Antilock Brake System)

Removing and Refitting Engine

Disassembling the Engine

Servicing Individual Components

Cylinder Head Disassembly and Wear Check

Assembling the Engine

Electrical System

Ignition System and ECU (950 Adventure)

ABS System (990 Adventure)

Wiring Diagrams

950 Adventure Wiring Diagrams

990 Super Duke Wiring Diagram

950 Super Enduro Wiring Diagram

Related product manuals

Brand	KTM
Model	2005 990 Super Duke
Category	Motorcycle
Language	English