Table Of Contents - KTM 990 Adventure Repair Manual

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
Removing And Refitting Engine31
Table Of Contents31
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
Double Timing Gear82
Cylinder Head Rear With Cylinder82
Setting Cylinder Front To Tdc82
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 Suction Pump For Wear101
Checking The Pressure 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
Piston And Cylinder Identification104
Assembling The Cylinder Head104
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
General Information On Servicing The Transmission110
Assembling The Main Shaft110
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
Primary Pinion122
Outer Clutch Hub122
Clutch Disks123
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
Ecu 950 Adventure/Supermoto/Super Enduro157
Checking The Pulse Generator 950 Adventure/950 Supermoto157
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
Adventure Carburetor Heater 950 Adventure, 950 Supermoto/R, 950 Super Enduro164
Checking The Heating Elements164
Checking The Temperature Switch164
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
Manifold Air Pressure Sensor176
Ambient Air Pressure Sensor176
Throttle Valve Sensor176
Sensor For The 2Nd Throttle Valve176
Pulse Generator (Crankshaft)177
Lambda Probes177
Catalytic Converter178
Idle Speed Control Motor178
Servomotor For The 2Nd Throttle Valve178
Ignition Coils179
Secondary Air Valve179
Octane Selector Connections (990 Adventure Only)179
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
Dismounting/Mounting The Throttle Body213
Dismounting/Mounting The Fuel Pump With Pressure Regulator213
Replacing The Fuel Filter213
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 Abs Unit235
Replacing The Front Abs Sensor235
Replacing The Rear Abs Sensor235
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
Lubrication And Maintenance Work – Carburetor280
Check The Carburetor Synchronization With An Vacuum Gauge And Adjust If Necessary280
Checking The Idle Setting (950 Adventure)280
Checking The Idle Setting (950 Supermoto/Super Enduro)281
Lubrication And Maintenance Work - Injection281
Lubrication And Maintenance Work – Add-On Parts281
Lubricating The Cables281
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
Lubrication And Maintenance Work – Additional Work286
Completely Servicing The Shock Absorber286
Changing The Cooling Liquid287
Wiring Diagrams288
Multifunctional Digital Speedometer315
Start/Stop/Light Switch315
Front Light315
Light/Turn Signal/Horn Switch315
Tachometer316
Turn Signal Relay316
Rear Brake Light Switch316
Left Front Turn Signal316
Diode Neutral Switch317
Diode Side Stand Switch317
Rear Lighting317
Right Front Turn Signal317
Pick Up318
Carburetor Potentiometer318
Gear Sensor318
Tripmaster Switch319
Ecu (Control Unit)319
Ignition Lock319
Connector For Auxiliary Devices319
Speed Sensor320
Rear Ignition Coil320
Fuel Sender320
Radiator Fan Motor321
Regulator321
Temperature Switch For The Radiator Fan321
Epc Front Cylinder321
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