KTM 990 Super Duke/R Manuals

Manuals and User Guides for KTM 990 Super Duke/R. We have 1 KTM 990 Super Duke/R manual available for free PDF download: Repair Manual

KTM 990 Super Duke/R Repair Manual

KTM 990 Super Duke/R Repair Manual (448 pages)

Brand: KTM | Category: Motorcycle | Size: 30.17 MB

Table of Contents

Important Information/Updating Instructions
7
Storing the Repair Manual in the Binder
7
General Information
15
Oil System
17
Intake System
18
Secondary Air System
19
Cooling System
20
Closed Thermostat
20
Open Thermostat
20
ABS (Antilock Brake System)
21
ABS Warning Lamp
21
ABS Button
21
Special Tools – Engine
22
Special Tools – Chassis
24
Checking the Oil Level of the Hydraulic Clutch
25
Bleeding of the Hydraulic Clutch
25
Resetting the Control Unit after Replacing/Repairing the Engine
26
Adjusting the Throttle Cable for Models with Fuel Injection
27
ECU Software Update/Mapping
28
Starting the DMT (Data Maintenance Tool)
29
Starting the FAN (Flash Download System)
29
Checking the Oil Pressure
30
Table of Contents
31
Removing and Refitting Engine
31
Removing the Engine - 950 Adventure
33
Refitting the Engine - 950 Adventure
38
Removing the Engine - 990 Adventure
43
Refitting the Engine
49
- Dismounting the Engine - 990 Super Duke
  55
- Mounting the Engine - 990 Super Duke
  56
- Dismounting the Engine - 990 Super Duke R
  63
- Removing the Engine - 990 Supermoto
  66
- Refitting the Engine - 990 Supermoto
  71
- Disassembling the Engine
  77
- Valve Covers
  79
- Spark Plug Shaft Inserts
  79
- Starter Motor
  79
- Setting Cylinder Rear to TDC
  80
- Camshafts Cylinder Rear
  80
- Chain Tensioner Cylinder Rear
  81
- Timing Chain Cylinder Rear
  81
- Setting Cylinder Front to TDC
  82
- Double Timing Gear
  82
- Cylinder Head Rear with Cylinder
  82
- Camshafts Cylinder Front
  83
- Oil Pressure Switch
  83
- Chain Tensioner Cylinder Front
  83
- Timing Chain Cylinder Front
  84
- Cylinder Head Front with Cylinder
  84
- Water Pump
  85
- Oil Screen
  85
- Clutch Cover
  85
- Clutch
  86
- Primary Pinion and Clutch
  87
- Rotor
  88
- Freewheel
  89
- Balancer Shaft
  89
- Shift Mechanism
  89
- Engine Case Half
  90
- Transmission
  91
- Oil Pumps
  92
- Servicing Individual Components
  93
- Replacing the Roller Bearing
  95
- Replacing the Main Bearings-General Information
  96
- Replacing Bearing Shells, Output End
  97
- Replacing Bearing Shells, Generator End
  97
- Replacing the Conrod Bearings
  98
- Selecting the Bearing Shells
  98
- Replacing the Supporting Bearings in the Clutch Cover
  99
- Overhauling the Water Pump
  100
- Checking the Pressure Pump for Wear
  101
- Checking the Suction Pump for Wear
  101
- Disassembling the Cylinder Head and Checking Parts for Wear
  102
- Sealing Area
  102
- Valve Seats
  102
- Valve Guides
  102
- Checking the Pistons
  103
- Checking the Piston Ring End Gap
  103
- Assembly Instructions for Piston Rings
  103
- Measuring Pistons and Cylinders, Establishing the Piston Mounting Clearance
  103
- Assembling the Cylinder Head
  104
- Piston and Cylinder Identification
  104
- Generator Cover
  106
- Torque Limiter
  106
- Valve Gear – Checking Parts for Wear
  106
- Preassembling the Spreader Drive
  107
- Clutch – Checking Parts for Wear
  108
- Shift Mechanism – Checking Parts for Wear
  109
- Preassembling the Shift Shaft
  109
- Assembling the Main Shaft
  110
- General Information on Servicing the Transmission
  110
- Assembling the Countershaft
  111
- Checking the Freewheel
  112
- Replacing the Freewheel Hub
  112
- Starter
  112
- Assembling the Engine
  113
- Axial Clearance of the Main Shaft
  116
- Case Half
  118
- Aligning the Return Spring
  119
- Timing Chain and Balancing Weight
  121
- Outer Clutch Hub
  122
- Primary Pinion
  122
- Clutch Disks
  123
- Water Pump
  125
- Cylinder Head Rear with Timing Chain
  126
- Electrical
  137
- Abs-System
  139
- Checking for Loss of Current
  141
- Checking the Charging Voltage / Rectifier Regulator
  141
- Checking the Generator Coils
  141
- Electric Starter System 950 Adventure
  142
- Electric Starter System 990 Super Duke/R
  143
- Electric Starter System 950 Supermoto/R, 950 Super Enduro
  144
- Electric Starter System 990 Adventure -2007
  145
- Starting System 990 Adventure 2007-
  146
- Starting System 990 Supermoto
  147
- Checking the Auxiliary Starter Relay
  148
- 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 Diodes
  150
- Checking the Starter Relay
  151
- Checking the Starter Motor
  151
- Checking the Clutch Switch
  152
- Checking the Tip Switch and Emergency off Switch
  153
- Troubleshooting in the Starter System
  153
- Ignition System, ECU 950 Adventure
  154
- Ignition System, ECU 950 Supermoto
  155
- Ignition System, ECU 950 Super Enduro
  156
- Checking the Pulse Generator 950 Adventure/950 Supermoto
  157
- ECU 950 Adventure/Supermoto/Super Enduro
  157
- Checking the Fuel Pump Relay 950 Adventure/950 Supermoto
  158
- Checking the Ignition Coils 950 Adventure/Supermoto/Super Enduro
  158
- Troubleshooting in the Ignition System 950 Adventure/950 Supermoto
  159
- The EPC System 950 Adventure
  160
- The EPC System 950 Supermoto/R
  161
- EPC System 950 Super Enduro
  162
- Checking the Solenoid Valve for the EPC 950 Adventure, 950 Supermoto/R, 950 Super Enduro
  163
- Checking the Gear Sensor 950 Adventure, 950 Supermoto/R, 950 Super Enduro
  163
- Checking the Temperature Switch
  164
- Checking the Heating Elements
  164
- Adventure Carburetor Heater 950 Adventure, 950 Supermoto/R, 950 Super Enduro
  164
- Injection/Ignition System
  165
- Establishing the Injection Period (Injection Volume)
  165
- Correction Sensors and Inputs
  165
- System Diagram
  166
- Wiring Diagram 990 Super Duke
  168
- Schaltplan 990 Super Duke R
  169
- Wiring Diagram 990 Supermoto
  170
- Wiring Diagram 990 Adventure -2007
  171
- Wiring Diagram 990 Adventure 2007-
  172
- Block Diagram
  173
- Description of the Electric System
  174
- Fuel Pump Relay
  174
- Main Relay
  174
- Sensors
  174
- Description of the Components
  175
- Fuel Pump
  175
- Pressure Regulator
  175
- Injection Valves
  175
- Sensor for the 2Nd Throttle Valve
  176
- Manifold Air Pressure Sensor
  176
- Throttle Valve Sensor
  176
- Ambient Air Pressure Sensor
  176
- Pulse Generator (Crankshaft)
  177
- Lambda Probes
  177
- Catalytic Converter
  178
- Idle Speed Control Motor
  178
- Servomotor for the 2Nd Throttle Valve
  178
- Octane Selector Connections (990 Adventure Only)
  179
- Secondary Air Valve
  179
- Ignition Coils
  179
- Roll Angle Sensor
  180
- Diagnostics Connector
  180
- Side Stand Switch
  180
- Clutch Switch
  180
- Safety against Failure/Emergency Operation
  181
- Component Tests
  182
- Coolant Temperature Sensor
  183
- Air Temperature Sensor
  183
- Intake Pressure Sensors
  184
- Sensor for 2Nd Throttle Valve
  185
- Pulse Generator
  186
- Control Motor for the 2Nd Throttle Valve
  187
- Gear Sensor (Neutral, 2, 3)
  191
- Error Lamp
  191
- Speed Signal
  192
- Coolant Temperature Signal
  192
- Diagnostics Line
  192
- Abbreviations, Limit Values 990 Super Duke/R
  194
- Abbreviations, Limit Values 990 Adventure / 990 Supermoto
  195
- Alarm System for 990 Super Duke/R (Optional)
  196
- Order for Additional Hand-Held Transmitters
  197
- Adapting the Hand-Held Transmitter
  197
- Starting with the Emergency Code
  198
- ABS System 990 Adventure
  199
- Checking the Fuses
  199
- Checking the ABS Fault Memory Using the KTM Diagnostics Tool
  199
- Checking the ABS Sensor with the KTM Diagnostics Tool
  199
- Fuel System
  200
- Carburator - Keihin Cvrd 43
  202
- Description of the ACV (Air Cut Valve) System
  203
- Disassembling the Carburetor
  204
- Assembling the Carburetor
  207
- Adjusting the Float Level
  210
- Adjusting the Idle Mixture Control Screw
  210
- Checking the Throttle Sensor
  211
- Adjusting the Throttle Sensor
  211
- Adjusting the Choke Cable
  211
- Adjusting the Throttle Cable (Carburetor Models Only)
  211
- Carburetor Heater
  212
- Replacing the Fuel Filter
  213
- Dismounting/Mounting the Throttle Body
  213
- Dismounting/Mounting the Fuel Pump with Pressure Regulator
  213
- Checking the Fuel Pressure
  214
- Trouble Shooting
  216
- Chassis
  220
- Dismounting/Mounting the Front Wheel
  222
- Dismounting/Mounting the Rear Wheel
  223
- Replacing the Front Wheel Bearing
  224
- Replacing the Rear Wheel Bearing
  225
- Replacing the Front Brake Pads (950/990 Adventure)
  226
- Replacing the Rear Brake Pads (990 Super Duke/R)
  227
- Replacing the Fork Legs
  228
- Replacing the Shock Absorber (950/990 Adventure)
  229
- Replacing the Steering Head Bearing
  231
- Replacing the Swing Arm Bearing
  232
- Replacing the Chain, Pinion and Rear Sprocket
  233
- Opening the Chain with a Separating/Rivet Tool
  234
- Riveting the Chain
  234
- Replacing the Rear ABS Sensor
  235
- Replacing the Front ABS Sensor
  235
- Replacing the ABS Unit
  235
- Technical Specifications
  236
- Technical Specifications – Engine 950 Adventure
  238
- Basic Carburetor Setting
  238
- Technical Specifications – Chassis 950 Adventure/Adventure S
  239
- Technical Specifications – Engine 990 Super Duke / Super Duke R
  241
- Technical Specifications – Chassis 990 Duke / Super Duke R
  242
- Technical Specifications – Engine 950 Supermoto / Supermoto R
  244
- Technical Specifications – Chassis 950 Supermoto / Supermoto R
  245
- Technical Specifications – Engine 990 Adventure
  247
- Technical Specifications – Chassis 990 Adventure/Adventure S
  248
- Technical Specifications – Engine 990 Supermoto
  250
- Technical Specifications – Chassis 990 Supermoto
  251
- Technical Specifications – Engine 950 Super Enduro
  253
- Technical Specifications – Chassis 950 Super Enduro
  254
- Tolerances and Fitting Clearances
  256
- Tightening Torques – Engine
  258
- Tightening Torques – Chassis
  259
- Periodic Maintenance Schedule
  260
- Lubrication and Maintenance Work - Engine
  273
- Engine Oil
  274
- Checking the Engine Oil Level
  275
- Replacing the Spark Plugs
  275
- Checking and Adjusting the Valve Clearance
  276
- Number/Thickness of the Demounted Compensating Washer (Shim) in MM
  277
- Checking the Clutch Lining
  279
- Checking the Clutch Pressure Booster System
  279
- Cleaning the Oil Jet for the Clutch Lubrication
  279
- Checking the Idle Setting (950 Adventure)
  280
- Check the Carburetor Synchronization with an Vacuum Gauge and Adjust if Necessary
  280
- Lubrication and Maintenance Work – Carburetor
  280
- Lubricating the Cables
  281
- Checking the Idle Setting (950 Supermoto/Super Enduro)
  281
- Lubrication and Maintenance Work – Add-On Parts
  281
- Lubrication and Maintenance Work - Injection
  281
- Changing the Front Brake Fluid
  282
- Changing the Rear Brake Fluid
  283
- Lubrication and Maintenance Work - Chassis
  284
- Checking/Adjusting the Steering Head Bearing
  284
- Lubrication and Maintenance Work - Wheels
  285
- Checking the Spoke Tension and Rim Run-Out
  285
- Completely Servicing the Shock Absorber
  286
- Lubrication and Maintenance Work – Additional Work
  286
- Changing the Cooling Liquid
  287
- Wiring Diagrams
  288
- Multifunctional Digital Speedometer
  315
- Start/Stop/Light Switch
  315
- Front Light
  315
- Light/Turn Signal/Horn Switch
  315
- Left Front Turn Signal
  316
- Tachometer
  316
- Rear Brake Light Switch
  316
- Turn Signal Relay
  316
- Diode Neutral Switch
  317
- Diode Side Stand Switch
  317
- Rear Lighting
  317
- Right Front Turn Signal
  317
- Gear Sensor
  318
- Carburetor Potentiometer
  318
- Pick up
  318
- Tripmaster Switch
  319
- ECU (Control Unit)
  319
- Ignition Lock
  319
- Connector for Auxiliary Devices
  319
- Speed Sensor
  320
- Rear Ignition Coil
  320
- Fuel Sender
  320
- EPC Front Cylinder
  321
- Temperature Switch for the Radiator Fan
  321
- Regulator
  321
- Radiator Fan Motor
  321
- Temperature Sensor for the Multifunctional Digital Speedometer
  322
- Rear Turn Signal
  322
- Octane Selector
  322
- 990 Super Duke 2005/06 Wiring Diagram
  325
- Battery Generator Starter Diagram
  327
- ECU Diagram
  331
- Turn Signal, Horn, Fan Diagram
  335
- Light-Brake System Diagram
  337
- Instruments-Tachometer Diagram
  339
- Ground Connection
  343
- Positive Connection
  344
- Controller Outlet
  380
- Temperature Switch
  380
- Front EPC
  380
- 950 Super Enduro 2006/07 Diagram
  420
- 950 Super Enduro 2007-2008 Wiring Diagram
  422
- 990 Supermoto 2008 Diagram
  445

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