KTM 990 ADVENTURE - Repair Manual

KTM 990 ADVENTURE

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950/990 ADVENTURE

990 SUPER DUKE/R

950/990 SUPERMOTO/R

950 SUPER ENDURO

REPARATURANLEITUNG

MANUALE DI RIPARAZIONE

MANUEL DE RÉPARATION

MANUAL DE REPARACIÓN

ART.NR.: 3.206.056-E

REPAIRMANUAL2003-2008

Table of Contents

Important Information/Updating Instructions7
Storing the Repair Manual in the Binder7
General Information15
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
Special Tools – 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
Starting the DMT (Data Maintenance Tool)29
Starting the FAN (Flash Download System)29
Checking the Oil Pressure30
Table of Contents31
Removing and Refitting Engine31
Removing the Engine - 950 Adventure33
Refitting the Engine - 950 Adventure38
Removing the Engine - 990 Adventure43
Refitting the Engine49
- Dismounting the Engine - 990 Super Duke55
- Mounting the Engine - 990 Super Duke56
- Dismounting the Engine - 990 Super Duke R63
- Removing the Engine - 990 Supermoto66
- Refitting the Engine - 990 Supermoto71
- Disassembling the Engine77
- Valve Covers79
- Spark Plug Shaft Inserts79
- Starter Motor79
- Setting Cylinder Rear to TDC80
- Camshafts Cylinder Rear80
- Chain Tensioner Cylinder Rear81
- Timing Chain Cylinder Rear81
- Setting Cylinder Front to TDC82
- Double Timing Gear82
- Cylinder Head Rear with Cylinder82
- Camshafts Cylinder Front83
- Oil Pressure Switch83
- Chain Tensioner Cylinder Front83
- Timing Chain Cylinder Front84
- Cylinder Head Front with Cylinder84
- Water Pump85
- Oil Screen85
- Clutch Cover85
- Clutch86
- Primary Pinion and Clutch87
- Rotor88
- Freewheel89
- Balancer Shaft89
- Shift Mechanism89
- Engine Case Half90
- Transmission91
- Oil Pumps92
- Servicing Individual Components93
- Replacing the Roller Bearing95
- Replacing the Main Bearings-General Information96
- Replacing Bearing Shells, Output End97
- Replacing Bearing Shells, Generator End97
- Replacing the Conrod Bearings98
- Selecting the Bearing Shells98
- Replacing the Supporting Bearings in the Clutch Cover99
- Overhauling the Water Pump100
- Checking the Pressure Pump for Wear101
- Checking the Suction Pump for Wear101
- Disassembling the Cylinder Head and Checking Parts for Wear102
- Sealing Area102
- Valve Seats102
- Valve Guides102
- Checking the Pistons103
- Checking the Piston Ring End Gap103
- Assembly Instructions for Piston Rings103
- Measuring Pistons and Cylinders, Establishing the Piston Mounting Clearance103
- Assembling the Cylinder Head104
- Piston and Cylinder Identification104
- Generator Cover106
- Torque Limiter106
- Valve Gear – Checking Parts for Wear106
- Preassembling the Spreader Drive107
- Clutch – Checking Parts for Wear108
- Shift Mechanism – Checking Parts for Wear109
- Preassembling the Shift Shaft109
- Assembling the Main Shaft110
- General Information on Servicing the Transmission110
- Assembling the Countershaft111
- Checking the Freewheel112
- Replacing the Freewheel Hub112
- Starter112
- Assembling the Engine113
- Axial Clearance of the Main Shaft116
- Case Half118
- Aligning the Return Spring119
- Timing Chain and Balancing Weight121
- Outer Clutch Hub122
- Primary Pinion122
- Clutch Disks123
- Water Pump125
- Cylinder Head Rear with Timing Chain126
- Electrical137
- Abs-System139
- Checking for Loss of Current141
- Checking the Charging Voltage / Rectifier Regulator141
- Checking the Generator Coils141
- Electric Starter System 950 Adventure142
- Electric Starter System 990 Super Duke/R143
- Electric Starter System 950 Supermoto/R, 950 Super Enduro144
- Electric Starter System 990 Adventure -2007145
- Starting System 990 Adventure 2007-146
- Starting System 990 Supermoto147
- Checking the Auxiliary Starter Relay148
- Functional Check of the Auxiliary Starter Relay (950 Adventure)149
- Functional Check of the Auxiliary Start Relay (990 Adventure/ 990 Super Duke/R)149
- Functional Check of the Auxiliary Start Relay (950 Supermoto/R, 990 Supermoto)149
- Checking the Diodes150
- Checking the Starter Relay151
- Checking the Starter Motor151
- Checking the Clutch Switch152
- Checking the Tip Switch and Emergency off Switch153
- Troubleshooting in the Starter System153
- Ignition System, ECU 950 Adventure154
- Ignition System, ECU 950 Supermoto155
- Ignition System, ECU 950 Super Enduro156
- Checking the Pulse Generator 950 Adventure/950 Supermoto157
- ECU 950 Adventure/Supermoto/Super Enduro157
- Checking the Fuel Pump Relay 950 Adventure/950 Supermoto158
- Checking the Ignition Coils 950 Adventure/Supermoto/Super Enduro158
- Troubleshooting in the Ignition System 950 Adventure/950 Supermoto159
- The EPC System 950 Adventure160
- The EPC System 950 Supermoto/R161
- EPC System 950 Super Enduro162
- Checking the Solenoid Valve for the EPC 950 Adventure, 950 Supermoto/R, 950 Super Enduro163
- Checking the Gear Sensor 950 Adventure, 950 Supermoto/R, 950 Super Enduro163
- Checking the Temperature Switch164
- Checking the Heating Elements164
- Adventure Carburetor Heater 950 Adventure, 950 Supermoto/R, 950 Super Enduro164
- Injection/Ignition System165
- Establishing the Injection Period (Injection Volume)165
- Correction Sensors and Inputs165
- System Diagram166
- Wiring Diagram 990 Super Duke168
- Schaltplan 990 Super Duke R169
- Wiring Diagram 990 Supermoto170
- Wiring Diagram 990 Adventure -2007171
- Wiring Diagram 990 Adventure 2007-172
- Block Diagram173
- Description of the Electric System174
- Fuel Pump Relay174
- Main Relay174
- Sensors174
- Description of the Components175
- Fuel Pump175
- Pressure Regulator175
- Injection Valves175
- Sensor for the 2Nd Throttle Valve176
- Manifold Air Pressure Sensor176
- Throttle Valve Sensor176
- Ambient Air Pressure Sensor176
- Pulse Generator (Crankshaft)177
- Lambda Probes177
- Catalytic Converter178
- Idle Speed Control Motor178
- Servomotor for the 2Nd Throttle Valve178
- Octane Selector Connections (990 Adventure Only)179
- Secondary Air Valve179
- Ignition Coils179
- Roll Angle Sensor180
- Diagnostics Connector180
- Side Stand Switch180
- Clutch Switch180
- Safety against Failure/Emergency Operation181
- Component Tests182
- Coolant Temperature Sensor183
- Air Temperature Sensor183
- Intake Pressure Sensors184
- Sensor for 2Nd Throttle Valve185
- Pulse Generator186
- Control Motor for the 2Nd Throttle Valve187
- Gear Sensor (Neutral, 2, 3)191
- Error Lamp191
- Speed Signal192
- Coolant Temperature Signal192
- Diagnostics Line192
- Abbreviations, Limit Values 990 Super Duke/R194
- Abbreviations, Limit Values 990 Adventure / 990 Supermoto195
- Alarm System for 990 Super Duke/R (Optional)196
- Order for Additional Hand-Held Transmitters197
- Adapting the Hand-Held Transmitter197
- Starting with the Emergency Code198
- ABS System 990 Adventure199
- Checking the Fuses199
- Checking the ABS Fault Memory Using the KTM Diagnostics Tool199
- Checking the ABS Sensor with the KTM Diagnostics Tool199
- Fuel System200
- Carburator - Keihin Cvrd 43202
- Description of the ACV (Air Cut Valve) System203
- Disassembling the Carburetor204
- Assembling the Carburetor207
- Adjusting the Float Level210
- Adjusting the Idle Mixture Control Screw210
- Checking the Throttle Sensor211
- Adjusting the Throttle Sensor211
- Adjusting the Choke Cable211
- Adjusting the Throttle Cable (Carburetor Models Only)211
- Carburetor Heater212
- Replacing the Fuel Filter213
- Dismounting/Mounting the Throttle Body213
- Dismounting/Mounting the Fuel Pump with Pressure Regulator213
- Checking the Fuel Pressure214
- Trouble Shooting216
- Chassis220
- Dismounting/Mounting the Front Wheel222
- Dismounting/Mounting the Rear Wheel223
- Replacing the Front Wheel Bearing224
- Replacing the Rear Wheel Bearing225
- Replacing the Front Brake Pads (950/990 Adventure)226
- Replacing the Rear Brake Pads (990 Super Duke/R)227
- Replacing the Fork Legs228
- Replacing the Shock Absorber (950/990 Adventure)229
- Replacing the Steering Head Bearing231
- Replacing the Swing Arm Bearing232
- Replacing the Chain, Pinion and Rear Sprocket233
- Opening the Chain with a Separating/Rivet Tool234
- Riveting the Chain234
- Replacing the Rear ABS Sensor235
- Replacing the Front ABS Sensor235
- Replacing the ABS Unit235
- Technical Specifications236
- Technical Specifications – Engine 950 Adventure238
- Basic Carburetor Setting238
- Technical Specifications – Chassis 950 Adventure/Adventure S239
- Technical Specifications – Engine 990 Super Duke / Super Duke R241
- Technical Specifications – Chassis 990 Duke / Super Duke R242
- Technical Specifications – Engine 950 Supermoto / Supermoto R244
- Technical Specifications – Chassis 950 Supermoto / Supermoto R245
- Technical Specifications – Engine 990 Adventure247
- Technical Specifications – Chassis 990 Adventure/Adventure S248
- Technical Specifications – Engine 990 Supermoto250
- Technical Specifications – Chassis 990 Supermoto251
- Technical Specifications – Engine 950 Super Enduro253
- Technical Specifications – Chassis 950 Super Enduro254
- Tolerances and Fitting Clearances256
- Tightening Torques – Engine258
- Tightening Torques – Chassis259
- Periodic Maintenance Schedule260
- Lubrication and Maintenance Work - Engine273
- Engine Oil274
- Checking the Engine Oil Level275
- Replacing the Spark Plugs275
- Checking and Adjusting the Valve Clearance276
- Number/Thickness of the Demounted Compensating Washer (Shim) in MM277
- Checking the Clutch Lining279
- Checking the Clutch Pressure Booster System279
- Cleaning the Oil Jet for the Clutch Lubrication279
- Checking the Idle Setting (950 Adventure)280
- Check the Carburetor Synchronization with an Vacuum Gauge and Adjust if Necessary280
- Lubrication and Maintenance Work – Carburetor280
- Lubricating the Cables281
- Checking the Idle Setting (950 Supermoto/Super Enduro)281
- Lubrication and Maintenance Work – Add-On Parts281
- Lubrication and Maintenance Work - Injection281
- Changing the Front Brake Fluid282
- Changing the Rear Brake Fluid283
- Lubrication and Maintenance Work - Chassis284
- Checking/Adjusting the Steering Head Bearing284
- Lubrication and Maintenance Work - Wheels285
- Checking the Spoke Tension and Rim Run-Out285
- Completely Servicing the Shock Absorber286
- Lubrication and Maintenance Work – Additional Work286
- Changing the Cooling Liquid287
- Wiring Diagrams288
- Multifunctional Digital Speedometer315
- Start/Stop/Light Switch315
- Front Light315
- Light/Turn Signal/Horn Switch315
- Left Front Turn Signal316
- Tachometer316
- Rear Brake Light Switch316
- Turn Signal Relay316
- Diode Neutral Switch317
- Diode Side Stand Switch317
- Rear Lighting317
- Right Front Turn Signal317
- Gear Sensor318
- Carburetor Potentiometer318
- Pick up318
- Tripmaster Switch319
- ECU (Control Unit)319
- Ignition Lock319
- Connector for Auxiliary Devices319
- Speed Sensor320
- Rear Ignition Coil320
- Fuel Sender320
- EPC Front Cylinder321
- Temperature Switch for the Radiator Fan321
- Regulator321
- Radiator Fan Motor321
- Temperature Sensor for the Multifunctional Digital Speedometer322
- Rear Turn Signal322
- Octane Selector322
- 990 Super Duke 2005/06 Wiring Diagram325
- Battery Generator Starter Diagram327
- ECU Diagram331
- Turn Signal, Horn, Fan Diagram335
- Light-Brake System Diagram337
- Instruments-Tachometer Diagram339
- Ground Connection343
- Positive Connection344
- Controller Outlet380
- Temperature Switch380
- Front EPC380
- 950 Super Enduro 2006/07 Diagram420
- 950 Super Enduro 2007-2008 Wiring Diagram422
- 990 Supermoto 2008 Diagram445

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