Мануал на мотоциклы ктм

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

• 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