Werkstatthandbuch ktm



ISBN: 281681663


Werkstatthandbuch ktm

Manuals Brands KTM Manuals Motorcycle DUKE EU Repair manual KTM DUKE EU Repair Manual. Quick Links. See also: Owner's ManualInstruction and Installation Manual. REPAIR MANUAL. Related Manuals for KTM DUKE EU Motorcycle KTM DUKE EU Owner's Manual pages. Motorcycle KTM Duke EU Setup Instructions 16 pages. Summary of Contents for KTM DUKE EU Page 1 REPAIR MANUAL Duke EU Duke DE Duke EU Duke COL Art.

Page 3 KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as misprints and other errors. Page 4: Table Of Contents TABLE OF CONTENTS 11 FUEL TANK, SEAT, TRIM Page 5 TABLE OF CONTENTS Page 6 TABLE OF CONTENTS Page 7 TABLE OF CONTENTS Indicates an expected reaction e.

Indicates an unexpected reaction e. Indicates a page reference more information is provided on the specified page. Indicates information with more details or tips. Page 9: Safety Advice Read this Repair Manual carefully and thoroughly before beginning work. It contains useful information and tips that will help you repair and maintain your vehicle.

This manual assumes that the necessary special KTM tools and KTM workplace and workshop equipment are available. Safety advice A number of safety instructions need to be followed to operate the vehicle safely. The type label is on the right of the frame behind the steering head. The key number Info You need the key number to order a spare key.

Attach the lifting gear to the steering stem. Adapter p. C Taking the motorcycle off of the front wheel stand Note Work stand p. Page Fork, Triple Clamp FORK, TRIPLE CLAMP Cleaning the dust boots of the fork legs — Push dust boot of both fork legs downwards. Info The dust boots should remove dust and coarse dirt particles from the fork tubes.

Over time, dirt can penetrate behind the dust boots. If this dirt is not removed, the oil seals behind can start to leak. Page Installing The Fork Legs FORK, TRIPLE CLAMP — Loosen screws. Remove the fork legs from the bottom. Main work — Page Disassembling The Fork Legs FORK, TRIPLE CLAMP — Clean screw and the wheel spindle.

Page 20 FORK, TRIPLE CLAMP — Loosen the screw cap Info The screw cap cannot be removed yet. Info Use soft jaws. Page Checking The Fork Legs FORK, TRIPLE CLAMP — Clamp the outer tube in the area of the lower triple clamp. Clamping stand TS p. Page Assembling The Fork Legs FORK, TRIPLE CLAMP — Measure the outside diameter of the inner tube in several places.

External diameter of inner tube Page 23 FORK, TRIPLE CLAMP — Slide on lock ring — Grease and slide on seal ring Lubricant T p. Page Removing The Lower Triple Clamp FORK, TRIPLE CLAMP — Mount screw cap onto the piston rod. Info must be turned all the way down. Guideline Nut, piston rod on screw cap M12x1 30 Nm Page 25 FORK, TRIPLE CLAMP — Detach connectors — Detach connectors — Disconnect connector — Remove the combination instrument.

Page Installing The Lower Triple Clamp FORK, TRIPLE CLAMP — Remove the upper triple clamp with the handlebar and set aside. Info Protect the vehicle and its attachments from damage by covering them. Guideline Screw, top steering head M16x1. Page Checking The Steering Head Bearing Play FORK, TRIPLE CLAMP — Fold the headlight mask up. Finishing work — Remove the motorcycle from the work stand. Page Handlebar, Controls HANDLEBAR, CONTROLS Checking the play in the throttle cable — Check the throttle grip for smooth operation.

Move the throttle grip back- wards and forwards to ascertain the play in the throttle cable. Throttle cable play 3… Page Adjusting The Clutch Cable Play HANDLEBAR, CONTROLS Adjusting the clutch cable play — Move the handlebar to the straight-ahead position. Info The spring preload defines the initial situation of the spring process on the shock absorber. Page Removing The Spring SHOCK ABSORBER, SWINGARM — Lift the link fork. Page 34 SHOCK ABSORBER, SWINGARM Alternative 1 — Tension the spring to the prescribed position by turning the adjusting ring.

Guideline Spring preload Standard 3 clicks Full payload 6 clicks Hook wrench TS p. Do not touch hot components. Page Installing The Exhaust Manifold EXHAUST — Remove the exhaust manifold toward the front. Guideline Nut, exhaust flange Duke 22 Nm Page Installing The Main Silencer EXHAUST Installing the main silencer Main work — Position the main silencer.

Page Air Filter AIR FILTER Preparatory work — Page Fuel Tank, Seat, Trim FUEL TANK, SEAT, TRIM Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. Page Mounting The Seat FUEL TANK, SEAT, TRIM Do not breathe in the fuel vapors. If contact occurs with the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with soap and water.

Page 43 FUEL TANK, SEAT, TRIM — Remove screw — Mount and tighten another special screw — Open the filler cap. Page Installing The Fuel Tank Cover FUEL TANK, SEAT, TRIM — Lift the fuel tank cover. Page 45 FUEL TANK, SEAT, TRIM — Mount the vent hose. Page Removing The Fuel Tank FUEL TANK, SEAT, TRIM — Mount plug of the compensating tank. Guideline Screw, fuel tank 11 Nm 8. Page 47 FUEL TANK, SEAT, TRIM Main work — Remove screw — Hang the EFI control unit to one side.

Info Protect the frame and attachments from damage. Page Installing The Fuel Tank FUEL TANK, SEAT, TRIM Page Removing The Front Spoiler FUEL TANK, SEAT, TRIM — Mount and tighten screws Guideline Screw, fuel tank 11 Nm 8. Page Dismounting The Front Fender FUEL TANK, SEAT, TRIM — Mount and tighten screws Guideline Remaining screws, chassis 10 Nm 7.

Remove the front fender. Page 51 FUEL TANK, SEAT, TRIM — Detach the fuel line with a suitable tool. Page Changing The Fuel Filter FUEL TANK, SEAT, TRIM Page Replacing The Fuel Pump FUEL TANK, SEAT, TRIM — Position fuel filter in the holder. Page 54 FUEL TANK, SEAT, TRIM — Position the fuel pump with the gasket.

Guideline Screw, fuel pump 5 Nm 3. Info The type, condition and air pressure of the tires all have a major impact on the riding behavior of the motorcycle. Page Removing The Brake Disc Of The Front Brake WHEELS Main work — Check the wheel bearing for damage and wear.

Long-life grease p. Page Rear Wheel WHEELS Remove chain adjuster — Holding the rear wheel, withdraw wheel spindle — Page Removing The Brake Disc Of The Rear Brake WHEELS — Pull the rear wheel back and mount wheel spindle Info Mount the left and right chain adjusters in the same position. Page Checking The Chain Tension WHEELS In addition to premature wear, this can cause the chain or the countershaft of the transmission to break in extreme cases.

Page Checking The Chain, Rear Sprocket, And Engine Sprocket WHEELS Main work — Loosen nut — Loosen nuts — Adjust the chain tension by turning adjusting screws on the left and right. Guideline Chain tension 5… 7 mm 0. Page Cleaning The Chain WHEELS — Remove screws and release screw. Push the chain guard aside.

Manuals Brands KTM Manuals Engine Repair manual KTM Repair Manual. Quick Links Download this manual. Table of Contents. Troubleshooting Troubleshooting 87 trouble shooting Related Manuals for KTM Engine KTM EXC Repair Manual Ktm automobile parts user manual pages. Engine KTM SX-F Repair Manual pages. Page 7 C C bis C KTM REPAIR MANUAL IN LOOSE-LEAF FORM STORING THE REPAIR MANUAL IN THE BINDER — Put the index into the binder. Manual 3. Use only ORIGINAL KTM SPARE PARTS when replacing parts.

The KTM high performance engine is only able to meet user expectations if the maintenance work is performed regularly and professionally. Page 13 REPLY FAX FOR REPAIR MANUALS We have made every effort to make our repair manuals as accurate as possible but it is always possible for a mistake or two to creep in. To keep improving the quality of our repair manuals, we request mechanics and shop foremen to assist us as follows: If you find any errors or inaccuracies in one of our repair manual — Page 17 C main jet jet needle jet needle idle jet throttle valve air control screw idle adjusting screw mixture too lean: not enough fuel in proportion to air mixture too rich: too much fuel in proportion to air Idling range Operation with closed throttle valve.

This range is influenced by the position of the air control screw and the idle adjusting screw. Page Carburetor Adjustment The original carburetor setting was adapted for an altitude of approx. Page Bleeding Of The Hydraulic Clutch C Bleeding of the hydraulic clutch — Remove screws and take off cover together with rubber bellows. Page 20 — If the oil pump has been adjusted correctly, the mark must coincide with the notch on the cable pulley except EXE and Supermoto. Page 21 C Check of the exhaust control engine running — Remove the left side cover from the cylinder.

Page 23 C REMOVING AND REFITTING ENGINE INDEX REMOVING THE ENGINE Page 25 C Removing the engine NOTE: The cylinder head and the cylinder can be removed without previously removing the engine. It is also possible to work on the clutch, the primary drive and the shift drum locating device without previously removing the engine. The water pump can be removed and installed without previously removing the clutch cover.

Page 26 C Installing the engine — Lift the engine into the frame from the left side, slightly grease and mount the swingarm pivot. Tighten collar nut with Nm 74 ft. For this purpose twist out the bleeder screws at the cylinder head and at the right radiator.

Page Draining The Gear Oil — Undo the 6 bolts and remove the cylinder head together with the gasket. Page Ignition C — Cover the crankcase. An appropriate mandrel can be used if necessary. Page Reed Valve Housing, Intake Flange And Clutch Cover C Reed valve housing, intake flange and clutch cover — Remove 5 bolts together with the corrugated washers, remove the intake flange and the reed valve housing. NOTE: The following step need not be performed unless you intend to take the centrifugal timer out of the clutch cover.

Page Removing Clutch And Primary Drive C Reed valve housing, intake flange and oil pump separate lubrication — When dismounting the clutch cover additionally remove the bolt — Pull the oil pump wheel off the oil pump — Remove the cover from the oil pump housing. Page Shift Drum Locating, Kickstarter C — Open the lock washer of the inner clutch hub. Page Dividing The Engine Housing C — Carefully unhook the kickstarter spring from bore pretensioned spring and release it.

Keep in mind the stop disc behind! Page Removing Shift Mechanism And Transmission C Removing shift mechanism and transmission — Pull out the shift rails and swing the shift forks including rollers sideways. NOTE: When dismounting the shift forks, make sure that you do not lose the rollers on the shift forks.

Page Crankshaft — The smallest cylinder diameter minus the largest piston diameter determines the piston fitting clearance. Piston ring must be approx. Page Checking Cylinder For Wear Page System In The Cylinder Check the control flap axles for wear, especially at the pins.

NOTE: to prevent sticking of the control flap on EXE- and Supermoto models, there are nitrogenized control flap axles bright surface available which subseed the original fitted axles dark surface. Page Preassembling The Cylinder C Control flap Clean the control flap and check the pins in the control flap for tight fit.

Measure the distance between the two pins see illustration. When mounted, the control flap must not scrape against the exhaust port. Distance : min. Page 47 C — Grease the pins in the cylinder and mount the 3 roller guides with the large collar facing the cylinder. Page 48 C Page Clutch Cover C Dismounting the exhaust control system in the clutch cover, and checking parts for wear.

For this purpose, push the rocker arm of the centrifugal timer forward in the direction of the grooved ball bearing. Page Water Pump C Disassembling and checking the water pump — Remove the 2 bolts of the water pump cover and take off the water pump cover. Page Checking Clutch For Wear C Checking clutch for wear Thrust bearing - check it for score marks and easy operability.

Push rod - place it on a flat surfacecheck for bents. Clutch springs - minimum length 38 mm 1. Page Reed Valve Housing, Intake Flange C Reed valve housing, intake flange NOTE: The reed paddles slowly lose their tension during operation, thus reducing the overall performance. Damaged or worn reed paddles must therefore be replaced. The entire reed valve housing must be exchanged if the sealing surfaces of the reed valve housing are also damaged.

Page Kickstarter C Kickstarter Take all components off the kickstarter shaft and clean them. Kickstarter gear Check the bearing for play and grooves. Intermediate kickstarter gear Check the bearing for play and grooves. Locking pawl Check for wear and damage. Kickstarter shaft Check for wear and damage, paying particular attention to pivot points and teeth. Page 54 C Shifting mechanism from model on Needle bearing from model Page 55 C Shifting mechanism Shift forks Check the blade for wear.

Shift roller Check the shift grooves for wear. Ensure that the shift roller rests properly in the grooved ball bearing Check the grooved ball bearing in the shift roller for wear. To replace it, remove the Seeger circlip ring and pull the grooved ball bearing out of the shift roller slide seat.

Page Transmission C! When replacing gears, watch out for this mark! Transmission Clamp the main shaft or counter shaft, respectively, into the vise use protective jaws. Page Assembling The Countershaft C! Page 58 C Ignition General information The measurements described below will only reveal severe problems.

Coil short circuits leading to weak ignition sparks or low generator output, respectively, can only be detected with the help of an ignition test bench. In the case of malfunction always check the cables and the plug and socket connections of the ignition system first. Page 61 C — Clamp the right housing half onto the mounting rack. Mounting the crankshaft — Oil the grooved ball bearing of the crankshaft.

Page 62 C M6x Page 63 C — Mount the rotor. Shift drum locating device — Mount the locking drum on the shift roller. Page 64 C — Grease the shaft seal ring of the shift shaft. Do not forget the stop disc! When mounting the shift shaft make sure that both legs of the return spring rest against the prolongation of the shift rail Kickstarter — Page 65 C — Mount the outer clutch hub and the supporting disc 20x Page 66 C Oil pump, reed valve housing and intake flange separate lubrication — Insert the reed valve housing into the engine case, and position the intake flange such that the bolt can be mounted.

Mount the bolt, but only tighten it such that it is still possible to rotate the intake flange. Page 67 C Clutch cover — Check if both dowels have been mounted in the engine housing. Page 68 C Piston, cylinder — Carefully oil the sliding points of all components before mounting. Page 70 C Ignition cover — Apply silicone to several points of the gasket to fix it in the ignition cover.

Page 71 C Mounting the clutch slave cylinder — Verify that the ball has been correctly mounted in the piston of the clutch slave cylinder. Apply Loctite onto the bolt's thread. Page 73 SX, MXC, EXC Page 74 C Checking the voltage regulator-rectifier Shindengen — Start the engine and switch on the low beam.

Page 75 C CDI unit Check the cables and plug and socket connections of the CDI unit. The CDI unit function can only be checked on an ignition test bench. Page 77 C STATIC IGNITION VALUES SX, MXC, EXC KOKUSAN 2K-1, 2K-3 Measuring conditions: — cold engine — seat and tank removed — all connectors and the ground connection in a non-corroding condition, connectors tightly connected — spark plug screwed out and spark plug connector attached to ground — Page 79 C STATIC GENERATOR VALUES EXC KOKUSAN 2K-3 Measuring conditions: — cold engine — seat and tank removed — all connectors and the ground connection in a non-corroding condition, connectors tightly connected — light switch turned off — kick the kick starter forcefully at least 5 times for each measurement Page 80 C Page 81 C STATIC IGNITION AND GENERATOR VALUES MXC, EXC USA KOKUSAN 2K-2 Measuring conditions: — cold engine — seat and tank removed — all connectors and the ground connection in a non-corroding condition, connectors tightly connected — spark plug screwed out and spark plug connector attached to ground — Page Trouble Shooting C TROUBLE SHOOTING If you let the specified maintenance work on your motorcycle be carried out, disturbances can hardly be expected.

Should an error occur nevertheless, we advise you to use the trouble shooting chart in order to find the cause of error.