KTM 390 Duke EU 2013 Repair Manual page 5

TABLE OF CONTENTS
14.11 Adding rear brake fluid .................................... 73
14.12 Changing the rear brake fluid ........................... 73
15 LIGHTING SYSTEM, INSTRUMENTS ........................... 75
15.1 Setting kilometers or miles............................... 75
15.2 Adjusting the shift speed RPM 1 ...................... 75
15.3 Adjusting the shift speed RPM 2 ...................... 75
15.4 Setting the time.............................................. 76
15.5 Resetting the service interval display ................ 76
15.6 Checking the headlight setting ......................... 76
15.7 Adjusting the headlight range........................... 77
15.8 Changing the parking light bulb........................ 78
15.9 Changing the headlight bulb ............................ 79
16 ENGINE .................................................................... 81
16.1 Removing the engine....................................... 81
16.2 Installing the engine........................................ 85
16.3 Disassembling the engine ................................ 90
16.3.1 Preparations ............................................... 90
16.3.2 Draining the engine oil ................................ 90
16.3.3 Removing the chain securing guide .............. 90
16.3.4 Removing the valve cover............................. 91
16.3.5 Removing the spark plug ............................. 91
16.3.6 Removing the clutch cover........................... 91
16.3.7 Setting the engine to ignition top dead
center........................................................ 92
16.3.8 Removing the timing chain tensioner ............ 93
16.3.9 Removing the camshaft ............................... 93
16.3.10 Removing the cylinder head ......................... 94
16.3.11 Removing the piston ................................... 95
16.3.12 Removing the starter motor.......................... 95
16.3.13 Removing the timing chain .......................... 95
16.3.14 Removing the water pump wheel .................. 96
16.3.15 Removing the alternator cover ...................... 96
16.3.16 Removing the rotor...................................... 97
16.3.17 Removing the starter drive ........................... 97
16.3.18 Removing the balancer shaft drive wheel....... 98
16.3.19 Removing the gear position sensor................ 98
16.3.20 Removing the suction pump......................... 99
16.3.21 Removing the spacer................................. 100
16.3.22 Removing the clutch cage.......................... 100
16.3.23 Removing the primary gear ........................ 101
16.3.24 Removing the force pump.......................... 102
16.3.25 Removing the shift shaft............................ 103
16.3.26 Removing the shift drum locating ............... 103
16.3.27 Removing the locking lever ........................ 103
16.3.28 Removing the oil filter ............................... 103
16.3.29 Removing the left engine case.................... 104
16.3.30 Removing the shift rails............................. 105
16.3.31 Removing the shift drum ........................... 105
16.3.32 Removing the shift forks............................ 106
16.3.33 Removing the transmission shafts............... 106
16.3.34 Removing the balancer shaft...................... 106
16.3.35 Removing the crankshaft ........................... 106
16.4 Work on individual parts ................................ 107
16.4.1 Work on the left section of the engine
case ........................................................ 107
16.4.2 Work on the right section of the engine
case ........................................................ 108
16.4.3 Changing the shaft seal ring of the water
pump ...................................................... 108
16.4.4 Checking the radial play of the lower
conrod bearing ......................................... 109
16.4.5 Changing the conrod bearing...................... 110
16.4.6 Changing the balancer shaft bearing ........... 111
16.4.7 Work on the cylinder head ......................... 112
16.4.8 Checking the cylinder head........................ 113
16.4.9 Checking the pivot point of the
camshafts ................................................ 113
16.4.10 Checking/measuring the cylinder ................ 114
16.4.11 Checking the piston ring end gap ............... 114
16.4.12 Checking/measuring the piston................... 115
16.4.13 Checking the piston/cylinder mounting
clearance ................................................. 115
16.4.14 Checking the oil pump .............................. 115
16.4.15 Checking the oil pressure regulator valve ..... 116
16.4.16 Checking the clutch .................................. 117
16.4.17 Checking the shift mechanism ................... 118
16.4.18 Preassembling the shift shaft ..................... 119
16.4.19 Disassembling the main shaft .................... 119
16.4.20 Dismantling the countershaft ..................... 120
16.4.21 Checking the transmission ......................... 120
16.4.22 Assembling the main shaft......................... 121
16.4.23 Assembling the countershaft ...................... 122
16.4.24 Checking the timing assembly.................... 124
16.4.25 Changing the stator................................... 124
16.4.26 Checking the electric starter drive .............. 125
16.4.27 Checking the freewheel ............................. 126
16.5 Assembling the engine .................................. 126
16.5.1 Installing the crankshaft ............................ 126
16.5.2 Installing the balancer shaft....................... 126
16.5.3 Installing the transmission shafts ............... 127
16.5.4 Installing the shift forks............................. 127
16.5.5 Installing the shift drum ............................ 127
16.5.6 Installing the shift rails ............................. 127
16.5.7 Installing the left engine case .................... 128
16.5.8 Installing the oil filter................................ 129
16.5.9 Installing the locking lever ......................... 129
16.5.10 Installing the shift drum locating................ 130
16.5.11 Installing the shift shaft ............................ 130
16.5.12 Installing the oil pump .............................. 130
16.5.13 Installing the primary gear ......................... 131
16.5.14 Installing the clutch cage .......................... 132
16.5.15 Installing the spacer.................................. 133
16.5.16 Installing the suction pump ....................... 134
16.5.17 Installing the gear position sensor .............. 135
16.5.18 Installing the balancer shaft drive wheel ..... 135
16.5.19 Installing the starter drive.......................... 136
16.5.20 Installing the rotor .................................... 137
16.5.21 Installing the alternator cover..................... 137
16.5.22 Installing the water pump cover.................. 137
16.5.23 Installing the timing chain ......................... 138
16.5.24 Installing the starter motor......................... 138
16.5.25 Installing the piston .................................. 138
16.5.26 Installing the cylinder head........................ 140
16.5.27 Installing the camshafts ............................ 141
16.5.28 Installing the timing chain tensioner........... 141
16.5.29 Checking the valve clearance ..................... 142
16.5.30 Adjusting the valve clearance ..................... 143
16.5.31 Installing the clutch cover ......................... 143
16.5.32 Installing the spark plug ............................ 144
16.5.33 Installing the valve cover ........................... 144
16.5.34 Installing the chain securing guide ............. 145
16.5.35 Installing the oil screen ............................. 145
16.5.36 Removing the engine from the engine
assembly stand......................................... 146
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