KTM 390 Duke 2014 COL 2013 Manuals

Manuals and User Guides for KTM 390 Duke 2014 COL 2013. We have 1 KTM 390 Duke 2014 COL 2013 manual available for free PDF download: Repair Manual

KTM 390 Duke 2014 COL 2013 Repair Manual

KTM 390 Duke 2014 COL 2013 Repair Manual (204 pages)

Brand: KTM | Category: Motorcycle | Size: 10 MB

Table of Contents

Table of Contents
4
1 Means of Representation

7
- Symbols Used
  7
- Formats Used
  7
2 Safety Advice

8
- Repair Manual
  8
- Degrees of Risk and Symbols
  8
- Work Rules
  8
3 Important Information

9
4 Serial Numbers

10
- Chassis Number/Type Label
  10
- Key Number
  10
- Engine Number
  10
5 Motorcycle

11
6 Fork, Triple Clamp

16
7 Handlebar, Controls

30
8 Shock Absorber, Swingarm

32
9 Exhaust

35
10 Air Filter

39
- Removing the Air Filter
  39
- Installing the Air Filter
  39
11 Fuel Tank, Seat, Trim

40
- Opening the Filler Cap
  40
- Closing the Filler Cap
  40
- Removing the Seat
  40
- Mounting the Seat
  41
- Removing the Passenger Seat
  41
- Mounting the Passenger Seat
  41
- Removing the Fuel Tank Cover
  41
- Installing the Fuel Tank Cover
  44
- Removing the Fuel Tank
  46
- Installing the Fuel Tank
  47
- Removing the Front Spoiler
  49
- Fitting Front Spoiler
  49
- Dismounting the Front Fender
  50
- Installing the Front Fender
  50
- Checking the Fuel Pressure
  50
- Changing the Fuel Filter
  51
- Replacing the Fuel Pump
  53
12 Wheels

54
13 Wiring Harness, Battery

63
14 Brake System

67
15 Lighting System, Instruments

77
16 Engine

83
- Removing the Engine
  83
- Installing the Engine
  87
- Disassembling the Engine
  92
- Preparations
  92
- Draining the Engine Oil
  92
- Removing the Chain Securing Guide
  92
- Removing the Valve Cover
  93
- Removing the Spark Plug
  93
- Removing the Clutch Cover
  93
- Setting the Engine to Ignition Top Dead Center
  94
- Removing the Timing Chain Tensioner
  95
- Removing the Camshaft
  95
- Removing the Cylinder Head
  96
- Removing the Piston
  97
- Removing the Starter Motor
  97
- Removing the Timing Chain
  97
- Removing the Water Pump Wheel
  98
- Removing the Alternator Cover
  98
- Removing the Rotor
  99
- Removing the Starter Drive
  99
- Removing the Balancer Shaft Drive Wheel
  100
- Removing the Gear Position Sensor
  100
- Removing the Suction Pump
  101
- Removing the Spacer
  102
- Removing the Clutch Cage
  102
- Removing the Primary Gear
  103
- Removing the Force Pump
  104
- Removing the Shift Shaft
  105
- Removing the Shift Drum Locating
  105
- Removing the Locking Lever
  105
- Removing the Oil Filter
  105
- Removing the Left Engine Case
  106
- Removing the Shift Rails
  107
- Removing the Shift Drum
  107
- Removing the Shift Forks
  108
- Removing the Transmission Shafts
  108
- Removing the Balancer Shaft
  108
- Removing the Crankshaft
  108
- Work on Individual Parts
  109
- Work on the Left Section of the Engine Case
  109
- Work on the Right Section of the Engine Case
  110
- Changing the Shaft Seal Ring of the Water Pump
  110
- Checking the Radial Play of the Lower Conrod Bearing
  111
- Changing the Conrod Bearing
  112
- Changing the Balancer Shaft Bearing
  113
- Work on the Cylinder Head
  114
- Checking the Cylinder Head
  115
- Checking the Pivot Point of the Camshafts
  115
- Checking/Measuring the Cylinder
  116
- Checking the Piston Ring End Gap
  116
- Checking/Measuring the Piston
  117
- Checking the Piston/Cylinder Mounting Clearance
  117
- Checking the Oil Pump
  117
- Checking the Oil Pressure Regulator Valve
  118
- Checking the Clutch
  119
- Checking the Shift Mechanism
  120
- Preassembling the Shift Shaft
  121
- Disassembling the Main Shaft
  121
- Dismantling the Countershaft
  122
- Checking the Transmission
  122
- Assembling the Main Shaft
  123
- Assembling the Countershaft
  124
- Checking the Timing Assembly
  126
- Changing the Stator
  126
- Checking the Electric Starter Drive
  127
- Checking the Freewheel
  128
- Assembling the Engine
  128
- Installing the Crankshaft
  128
- Installing the Balancer Shaft
  128
- Installing the Transmission Shafts
  129
- Installing the Shift Forks
  129
- Installing the Shift Drum
  129
- Installing the Shift Rails
  129
- Installing the Left Engine Case
  130
- Installing the Oil Filter
  131
- Installing the Locking Lever
  131
- Installing the Shift Drum Locating
  132
- Installing the Shift Shaft
  132
- Installing the Oil Pump
  132
- Installing the Primary Gear
  133
- Installing the Clutch Cage
  134
- Installing the Spacer
  135
- Installing the Suction Pump
  136
- Installing the Gear Position Sensor
  137
- Installing the Balancer Shaft Drive Wheel
  137
- Installing the Starter Drive
  138
- Installing the Rotor
  139
- Installing the Alternator Cover
  139
- Installing the Water Pump Cover
  139
- Installing the Timing Chain
  140
- Installing the Starter Motor
  140
- Installing the Piston
  140
- Installing the Cylinder Head
  142
- Installing the Camshafts
  143
- Installing the Timing Chain Tensioner
  143
- Checking the Valve Clearance
  144
- Adjusting the Valve Clearance
  145
- Installing the Clutch Cover
  145
- Installing the Spark Plug
  146
- Installing the Valve Cover
  146
- Installing the Chain Securing Guide
  147
- Installing the Oil Screen
  147
- Removing the Engine from the Engine Assembly Stand
  148
17 Shift Mechanism

149
- Adjusting the Shift Lever
  149
18 Water Pump, Cooling System

150
- Draining the Coolant
  150
- Filling/Bleeding the Cooling System
  150
- Checking the Antifreeze and Coolant Level
  151
- Checking the Coolant Level
  152
19 Lubrication System

154
- Oil Circuit
  154
- Checking the Engine Oil Level
  154
- Checking the Engine Oil Pressure
  154
- Changing the Engine Oil and Oil Filter, Cleaning the Oil Screen
  156
- Adding Engine Oil
  157
20 Ignition System

158
- Alternator - Checking the Stator Winding
  158
21 Technical Data

159
- Engine
  159
- Engine Tolerance, Wear Limits
  159
- Engine Tightening Torques
  160
- Capacities
  161
- Engine Oil
  161
- Coolant
  161
- Fuel
  161
- Chassis
  161
- Electrical System
  162
- Tires
  162
- Fork
  162
- Shock Absorber
  162
- Chassis Tightening Torques
  163
22 Cleaning/Protective Treatment

165
- Cleaning the Motorcycle
  165
- Checks and Maintenance Steps for Winter Operation
  166
23 Storage

167
- Preparing for Use after Storage
  167
24 Service Schedule

168
25 Wiring Diagram

170
- Page 2 of
  172
- Page 3 of
  174
- Page 4 of
  176
- Page 5 of
  178
- Page 6 of
  180
- Page 7 of
  182
- Page 8 of
  184
- Page 9 of
  186
26 Substances

188
27 Auxiliary Substances

189
28 Special Tools

191
29 Standards

200
- Index
  201

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