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Table of Contents
Troubleshooting
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Summarization of Contents
GENERAL INFORMATION
OIL SYSTEM
Describes the flow of engine oil, including the pressure pump, filter, and various oil ducts for lubrication and cooling.
INTAKE SYSTEM
Explains how fresh air is drawn into the filter box, cleaned, and delivered to the combustion chamber via carburetors or throttle body.
COOLING SYSTEM
Explains the operation of the cooling system with thermostat in both closed and open states, including water pump and fan activation.
ABS (ANTILOCK BRAKE SYSTEM)
Describes the ABS as a safety system preventing wheel lock-up, its components, and operation during braking.
SPECIAL TOOLS
SPECIAL TOOLS – ENGINE
Lists various tools required for engine-specific maintenance and repair procedures.
SPECIAL TOOLS – CHASSIS
Lists various tools required for chassis-specific maintenance and repair procedures.
REMOVING AND REFITTING ENGINE
REMOVING THE ENGINE - 950 ADVENTURE
Step-by-step instructions for dismounting the engine from the 950 Adventure model, covering various components.
REFITTING THE ENGINE - 990 ADVENTURE
Details the procedure for reassembling the engine into the 990 Adventure model, including connecting various hoses and components.
DISMOUNTING THE ENGINE - 990 SUPER DUKE
Outlines the procedure for dismounting the engine from the 990 Super Duke, noting preparatory work differences.
REMOVING THE ENGINE - 990 SUPERMOTO
Provides step-by-step instructions for removing the engine from the 990 Supermoto.
DISASSEMBLING THE ENGINE
VALVE COVERS
Instructions for removing valve covers and spark plugs, including specific tools and steps for different models.
WATER PUMP
Outlines the procedure for removing the water pump cover, bolt, and wheel, and pressing out the shaft.
CLUTCH
Details the process of removing bolts, pressure cap, clutch push rod, and clutch disks from the clutch hub.
ENGINE CASE HALF
Describes the process of removing the gear shift sensor, oil filter cover, and separating the engine case halves.
SERVICING INDIVIDUAL COMPONENTS
REPLACING THE MAIN BEARINGS-GENERAL INFORMATION
Details the procedure for pressing main bearing shells in and out of engine case halves, and measuring crankshaft.
REPLACING THE CONROD BEARINGS
Covers clamping conrods, removing bearing covers, measuring conrod journal diameter, and installing new bearing shells.
DISASSEMBLING THE CYLINDER HEAD AND CHECKING PARTS FOR WEAR
Guides through disassembling the cylinder head, checking valve seats, valves, guides, and springs for wear.
CHECKING THE PISTONS
Details how to check piston marks, press pistons out, check bearing surfaces, ring grooves, and piston pin movement.
CLUTCH – CHECKING PARTS FOR WEAR
Details checking the thrust bearing, pushrod, clutch springs, clutch disks, inner clutch hub teeth, and needle bearing for wear.
ASSEMBLING THE ENGINE
OIL PUMPS
Details the installation of pressure and suction pump rotors, shafts, housing, and O-rings, including proper lubrication.
CASE HALF
Describes how to slide the protective sleeve, case halves, and screw in HH case bolts, ensuring proper alignment.
TIMING CHAIN AND BALANCING WEIGHT
Outlines steps to screw in the timing chain tensioning rail, insert woodruff keys, and mount the balancing weight.
CLUTCH DISKS
Guides on mounting the supporting plate, spring washer, inserting lining and clutch disks alternately, and oiling them.
ELECTRICAL SYSTEM
ELECTRIC STARTER SYSTEM
Explains the starter system's safety features and operational conditions, including how it works with battery voltage and switches.
IGNITION SYSTEM, ECU
Describes the digital battery ignition system, its components like ECU, pulse generator, ignition coils, and fuel pump relay.
ABS SYSTEM
Guides on checking ABS fuses, fault memory using the diagnostics tool, and checking ABS sensors.
TROUBLESHOOTING IN THE STARTER SYSTEM
Provides checks for starter system issues, covering ignition, battery, fuses, relays, and starter motor.
THE EPC SYSTEM
Explains the mode of operation of the EPC system, how the ECU controls valves via ground, and the effect on carburetor slides.
COMPONENT TESTS
Offers tests for fuel pump, pressure regulator, injection valves, and sensors, guiding on checks before component replacement.
FUEL SYSTEM
KEIHIN CARBURETOR CVRD 43
Provides an exploded view and identification of the Keihin CVRD 43 carburetor components.
Disassembling the carburetor
Guides through disassembling the carburetor, including removing linkage, sensor, connecting rods, and diaphragm cover.
Assembling the carburetor
Details the process of assembling the carburetor, including installing the throttle shaft, jets, and mixture control screw.
INJECTION SYSTEM
Covers dismounting/mounting the throttle body, fuel pump, pressure regulator, and fuel level sensor.
Checking the fuel pressure
Explains how to check fuel pressure at idle and full load after disconnecting the fuel connection.
TROUBLE SHOOTING
ERROR CODES
Lists diagnostic trouble codes (DTC) with blink codes, signal components, error descriptions, and engine status.
CHASSIS
DISMOUNTING/MOUNTING THE FRONT WHEEL
Provides detailed steps for removing and installing the front wheel, including brake caliper and spindle procedures.
REPLACING THE REAR WHEEL BEARING
Details replacing rear wheel bearings, including removing sprocket carrier, lock ring, and pressing in new bearings.
REPLACING THE FRONT BRAKE PADS
Guides on replacing front brake pads, including pressing pistons, removing retainers, and cleaning calipers.
REPLACING THE STEERING HEAD BEARING
Explains how to replace steering head bearings, including dismounting fork legs and loosening triple clamp bolts.
REPLACING THE SWING ARM BEARING
Guides on replacing swing arm bearings, including dismounting the rear wheel and removing the swing arm bolt.
REPLACING THE ABS UNIT
Guides on replacing the ABS unit, including removing brake lines and connecting the DL connector.
TECHNICAL SPECIFICATIONS
ENGINE 950 ADVENTURE
Provides detailed technical specifications for the 950 Adventure engine, including design, displacement, and fuel type.
CHASSIS 950 ADVENTURE/ADVENTURE S
Details technical specifications for the 950 Adventure/Adventure S chassis, covering frame, suspension, brakes, tires, and lighting.
STANDARD ADJUSTMENT – FORK
Provides standard adjustment settings for the WP USD 4860 MXMA fork for 950 Adventure models.
ENGINE 990 SUPER DUKE / SUPER DUKE R
Lists technical specifications for the 990 Super Duke / Super Duke R engine, including design, displacement, and fuel type.
ENGINE 950 SUPER ENDURO
Lists technical specifications for the 950 Super Enduro engine, including design, displacement, and fuel type.
TIGHTENING TORQUES – ENGINE
Provides a table of tightening torques for various engine components, including nuts, bolts, and studs.
TIGHTENING TORQUES – CHASSIS
Lists tightening torques for chassis components like suspension, brakes, wheels, and frame bolts.
PERIODIC MAINTENANCE SCHEDULE
950 ADVENTURE
Outlines the periodic maintenance schedule for the 950 Adventure, detailing service intervals and required checks.
990 SUPER DUKE/R
Presents the periodic maintenance schedule for the 990 Super Duke/R, specifying service intervals for engine, injection, and chassis.
950 SUPERMOTO/R
Details the periodic maintenance schedule for the 950 Supermoto/R, covering engine, carburetor, and chassis checks.
950 SUPER ENDURO
Provides the periodic maintenance schedule for the 950 Super Enduro, detailing service intervals and checks for various systems.
Lubrication and maintenance work - engine
Covers changing engine oil and filter, cleaning oil screens, and magnets on drain plugs.
Changing the front brake fluid
Details how to change front brake fluid, including extracting used fluid, adding fresh fluid, and pressing pistons.
LUBRICATION AND MAINTENANCE WORK - CHASSIS
Covers cleaning dust boots, bleeding fork legs, checking swing arm support, and steering head bearing.
WIRING DIAGRAMS
950 ADVENTURE
Provides wiring diagrams for the 950 Adventure from 2003-2004 and 2005, including explanations of connectors and cable colors.
990 SUPER DUKE / SUPER DUKE R
Contains wiring diagrams and connector explanations for the 990 Super Duke and Super Duke R models.
950 SUPERMOTO / SUPERMOTO R
Provides wiring diagrams and connector explanations for the 950 Supermoto and Supermoto R models.
990 ADVENTURE
Lists wiring diagrams and connector explanations for the 990 Adventure models from 2006/2007 and 2007 onwards.
CONNECTOR LIST 950 ADVENTURE
Lists all connectors for the 950 Adventure, detailing their type, pin count, and location.
SWITCH DIAGRAMS
Illustrates the wiring configurations for various switches including ignition, start, light, horn, and brake switches.
INSTRUMENTS-TACHOMETER
Details the wiring for the instruments and tachometer system, including sensors and connectors.
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