KTM 990 adventure

REPAIRMANUAL2003-2008
950/990 ADVENTURE
990 SUPER DUKE/R
950/990 SUPERMOTO/R
950 SUPER ENDURO
REPARATURANLEITUNG
MANUALE DI RIPARAZIONE
MANUEL DE RÉPARATION
ART.NR.: 3.206.056-E
MANUAL DE REPARACIÓN
REPAIRMANUAL2003-2008
950/990 ADVENTURE
990 SUPER DUKE/R
950/990 SUPERMOTO/R
950 SUPER ENDURO
KTM Group Partner
1 SERVICE-INFORMATIONS
2 GENERAL INFORMATION
3 REMOVING AND REFITTING ENGINE
4 DISASSEMBLING ENGINE
5 SERVICING INDIVIDUAL COMPONENTS
6 ASSEMBLING ENGINE
7 ELECTRICAL / INJECTION
8 FUEL SYSTEM
9 TROUBLE SHOOTING
10 CHASSIS
11 TECHNICAL SPECIFICATIONS
12 PERIODIC MAINTENANCE SCHEDULE
13 WIRING DIAGRAMS
14
15
16
I MPORTANT I NFORMATION /U PDATING
INSTRUCTIONS
To be able to continue using the existing loose-leaf repair instructions, simply print the
following pages and insert them in the existing repair instructions:
1,3,7,9,13,43-75,78-80,83,128,134,135-196,219,220,223,224,227,228,230,233,247256,258,261,263,267-285,287-446
Remove pages (s)
3-1
3-12 to 3-20
4-2 to 4-4
4-7
6-16
6-22
7-1 to 7-55
10-2 to 10-3
10-6 to 10-7
10-10 to 10-11
10-13
11-1
11-14 to 11-20
12-1
12-4
12-6
12-10 to 12-26
13-2 to 13-141
Replace by page (s)
3-1
3-12 to 3-44
4-2 to 4-4
4-7
6-16
6-22
7-1 to 7-61
10-2 to 10-3
10-6 to 10-7
10-10 to 10-11
10-13
11-1
11-14 to 11-23
12-1
12-4
12-6
12-10 to 12-28
13-2 to 13-159
Insert page (s)
after page
KTM REPAIR MANUAL IN LOOSE-LEAF FORM
STORING THE REPAIR MANUAL IN THE BINDER
– Put the index into the binder.
– Put the front page of the repair manual (210x297 mm) into the transparent pocket provided for this purpose on the outside of
the binder.
– Put the spine label (170x45 mm) into the transparent pocket provided for this purpose on the spine of the binder.
– Put the summary list of contents (150x297 mm) into the transparent pocket provided for this purpose on the inside of the
binder or insert this page on the beginning of the manual.
– Then insert the individual chapters of the manual between the sheets of the index according to the page number printed in
the right bottom corner of each page.
Example: page no. 3-5; 3 = chapter 3; 5 = page 5
All pages with a page number that begins with the digit 3, for example, must be put under the index heading „Chapter 3“.
– Index sheets that have not been marked with a certain chapter are for your personal convenience. The respective headings can
be entered in the list of contents.
EXPLANATION - UPDATING
3.206.009-E Repair Manual LC8
Basicversion Modelyear 2003
4/2003
3.206.016-E Updating of Rep.Manual 3.206.009-E
Modelyear 2004
(Engine number with first digit “4“)
11/2003
3.206.025-E Updating of Rep.Manual 3.206.009-E
Modelyear 2005
(Engine number with first digit “5“)
01/2005
3.206.035-E Updating of Rep.Manual 3.206.009-E
Modelyear 2005/06
(Engine number with first digit “5“ and “6”)
01/2006
3.206.044-E Updating of Rep.Manual 3.206.009-E
Modelyear 2007
(Engine number with first digit “7“)
02/2007
3.206.056-E Updating of Rep.Manual 3.206.009-E
Modelyear 2008
(Engine number with first digit “8“)
7/2008
technical details, technical data,
technical specifications, wiring diagrams
Edition: 07/2008
INTRODUCTION
This repair manual offers extensiv repair-instructions and is an up-to-date version that describes
the latest models of the series. However, the right to modifications in the interest of technical
improvement is reserved without updating the current issue of this manual.
A description of general working modes common in work shops has not been included. Safety
rules common in the work shop have also not been listed. We take it for granted that the repairs
are made by qualified profesionally trained mechanics.
Read through the repair manual before beginning with the repair work.

WARNING

STRICT
COMPLIANCE
WITH
THESE
INSTRUCTIONS
ESSENTIAL TO AVOID DANGER TO LIFE AND LIMB.
!
CAUTION
IS
!
NON-COMPLIANCE WITH THESE INSTRUCTIONS CAN LEAD TO
DAMAGE OF MOTORCYCLE COMPONENTS OR RENDER MOTORCYCLES
UNFIT FOR TRAFFIC !
„NOTE” POINTS OUT USEFUL TIPS.
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.
In accordance with the international quality management ISO 9001 standard, KTM uses quality
assurance processes that lead to the highest possible product quality.
KTM Sportmotorcycle AG reserves the right to modify any equipment, technical specifications,
colors, materials, services offered and rendered, and the like so as to adapt them to local
conditions without previous announcement and without giving reasons, or to cancel any of the
above items without substituting them with others. It shall be acceptable to stop manufacturing a
certain model without previous announcement. In the event of such modifications, please ask your
local KTM dealer for information.
KTM Sportmotorcycle AG
5230 Mattighofen, Austria
All design and assembly modification rights reserved.
C by KTM SPORTMOTORCYCLE AG, AUSTRIA
All rights reserved
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 – whether these are technical errors,
incorrect or unclear repair procedures, tool problems, missing technical data or torques, inaccurate or
incorrect translations or wording, etc. – please enter the error(s) in the table below and fax the completed
form to us at 0043/7742/6000/5349.
NOTE to table:
– Enter the complete item no. for the repair manual in column 1 (e.g.: 3.206.056-E).
You will find the number on the cover page or in the left margin on each right page of the manual.
– Enter the corresponding page number in the repair manual (e.g.: 5-7) in column 2.
– Enter the current text (inaccurate or incomplete) in column 3 by quoting or describing the respective
passage of the text. If your text deviates from the text contained in the repair manual, please write
your text in German or English if possible.
– Enter the correct text in column 4.
Your corrections will be reviewed and incorporated in the next issue of our repair manual.
Item no. of repair manual
Page
Current text
Correct text
Additional suggestions, requests or comments on our Repair Manuals (in German or English):
Name mechanic/shop foreman
Company/work shop
2-1
GENERAL INFORMATION
Repair manual KTM LC8
Art.-No. 3.206.056-E
INDEX
OIL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
AIR INTAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
SLS-SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
ABS-SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
SPECIAL TOOLS – ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7
SPECIAL TOOLS – CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9
BLEEDING THE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10
RESETTING THE CONTROL UNIT AFTER REPLACING/REPAIRING THE ENGINE . . .2-11
ADJUSTING THE THROTTLE CABLE FOR MODELS WITH FUEL INJECTION . . . . . . .2-12
ECU-SOFTWARE UPDATE/MAPPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13
BLEEDING THE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . .SEE CHAPTER 12
CHECKING THE OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15
2
2-2
Oil system
Pressure pump 1 draws engine oil from oil tank
2 through oil filter 3 and the oil return valve
4 and pumps it past the pressure relief valve 5
through the oil filter 6 into the annular groove
7.
The main bearing 8, the conrod bearings 9
and the spraying nozzle bk (front timing chain)
are supplied with oil through holes in the
crankshaft. An oil duct leads to spraying nozzle
bl (piston cooling), the timing chain tensioner
bm, the camshaft bn and the oil pressure switch
bo in the front cylinder.
Another oil duct leads from the annular groove
to a distributor groove bp in the clutch cover.
From there an oil duct leads to the spraying
nozzle bq (piston cooling). Another oil duct
supplies the timing chain tensioner br, the
spraying nozzle bs (timing chain) and the
camshaft bt on the rear cylinder with oil.
2
3
4
bn
Another oil duct leads to the oil injection tube
ck which lubricates the transmission gears. Oil
is conducted to the pushrod and to the clutch
through the injection tube, another oil duct and
the reducing jet.
bo
bl
bk
Art.-No. 3.206.056-E
bm
The suction pump cl draws the oil from the oil
sump cn through the screen cm into the oil tank
2.
9
8
NOTE: each piston is lubricated and cooled by 2
jets starting with the 2005 model.
7
br
8
bq
bp
bs
bt
1
Repair manual KTM LC8
cl
5
cm
6
cn
ck
2-3
Intake system
Fresh air is drawn into the filter box through the intake snorkel 1, past the carburetors 2 and through the air filter 3.
The cleaned air is conducted to the combustion chamber through the carburetors and intake ports.
The diagram for the injection engine is similar; the air flows to the intake ports through the throttle body instead of through the
carburetor.
1
2
3
3
2-4
Secondary air system
The secondary air system supplies fresh air to the emissions in the exhaust port, resulting in the afterburning (oxidation) of the
emissions. A line leads from the filter box 1 to the control valve 2 which opens as soon as the throttle valves 3 are opened.
The line continues to the reed valves 4 in the cylinder heads which are actuated by the pressure pulsation in the exhaust
system. As a result, cleansed fresh air arrives in the exhaust port. The oxygen content in the air and the high exhaust gas
temperature cause the emissions to oxidize.
If the throttle valves are closed and the engine goes into an overrun condition, the underpressure in the intake port will rise and
the control valve will close. This prevents exhaust backfire (combustion of the unburned fuel/air mixture).
The secondary air system operates in a similar manner in models equipped with an injection engine; a solenoid valve controlled
by the control unit is used instead of the control valve.
1
2
Repair manual KTM LC8
Art.-No. 3.206.056-E
3
4
3
4
4
2-5
Cooling system
3
2
2
1
Closed thermostat
The thermostat is closed if the temperature of the cooling liquid drops below 75° C. The water pump 1 pumps the cooling liquid
through the cylinder and cylinder heads 2 and the thermostat 3.
5
6
7
4
3
2
2
1
Open thermostat
The thermostat 3 opens at 75° C. The water pump 1 pumps the cooling liquid through the cylinder and cylinder heads 2, the
aluminum cooler 4 and the thermostat. The pressure in the cooling system (max. 1.4 bar) is regulated by a valve in the radiator
cap 5. The cooling liquid level in the compensating tank 6 must be between the MIN and MAX marks when the engine is cold.
The fan 7 switches on at 102° C.
2-6
ABS (antilock brake system)
The ABS is a safety system that prevents the wheels from locking when
driving straight ahead without the influence of lateral forces. The ABS
unit 1, consisting of a hydraulic unit, an electronic control unit and the
electric pump motor, is located under the seat. Sensors 2 on the front
and rear wheel send pulses to the control unit to indicate how fast the
wheel is turning.
2
The KTM 990 Adventure ABS operates with two independent brake
circuits (front and rear wheel brake). During normal service the brake
system works just like a conventional brake without the ABS. The ABS
control phase sets in when the control unit detects that one of the
wheels is starting to lock. It releases the pressure in the respective
brake circuit and prevents the wheel from locking. You can feel the
control function as a slight pulsing in the brake lever.
The ABS warning lamp 3 must light up when the ignition is switched
on and go out at a speed of approx. 5 KPH after you drive off. If it stays
on or lights up while driving, the ABS is defective.
The ABS can be switched off with the ABS button 4.
!
1
2
Art.-No. 3.206.056-E
!
NOT MOUNT WHEELS WITH A DIFFERENT RIM DIAMETER. THE ABS
FUNCTION CAN NO LONGER BE GUARANTEED.
THE ABS IS DESIGNED TO BE USED WITH THE TIRES AUTHORIZED BY KTM.
THE ABS FUNCTION CANNOT BE GUARANTEED IF OTHER TIRES ARE USED.
MAXIMUM ABS CONTROL CAN NO LONGER BE GUARANTEED IF THE TIRE
PRESSURE IS INCORRECT.
THE ABS SYSTEM IS DESIGNED FOR THE 990 ADVENTURE MODEL AND MAY
NOT BE INSTALLED IN THE 990 ADVENTURE S SINCE THE 990 ADVENTURE S
MODEL HAS A DIFFERENT CENTER OF GRAVITY; 990 ADVENTURE S
FORKS/SHOCK ABSORBERS MAY NOT BE MOUNTED ON 990 ADVENTURE MODELS
WITH ABS.
ALL OTHER MODIFICATIONS THAT DISPLACE THE MOTORCYCLE'S CENTER OF
GRAVITY (E.G. LOWERING) JEOPARDIZE THE PROPER FUNCTIONING OF THE ABS
SYSTEM.
– DO
–
–
–
–
ABS warning lamp
The ABS warning lamp 3 must light up when the ignition is switched
on and go out at a speed of approx. 5 KPH after you drive off. If it stays
on or lights up while driving, the ABS is defective. The ABS is no longer
active and the wheels can lock when braking.
3
4
Repair manual KTM LC8
CAUTION
NOTE:
– The brake system will still function but ABS control will no longer be
active.
– The ABS warning lamp can also light up if there is a large deviation
between the speed of the front and rear wheel in extreme driving
situations, e.g. during a wheelie or if the rear wheel slips when
accelerating on loose ground. The ABS will no longer be active and
the wheels can lock when braking. To activate the ABS again, stop
and switch the ignition off/on. If the warning lamp goes off again at a
speed of approx. 5 KPH after you drive off, the ABS is active and
fully operative.
ABS button
The ABS button 4 switches off the ABS. To switch off the ABS, stop
the motorcycle and press the ABS button for at least 3 seconds with the
engine running. Let go of the ABS button as soon as the ABS warning
lamp starts blinking fast. The ABS warning lamp will blink slowly to
indicate that the ABS is switched off.
To switch the ABS on again, stop and switch off the ignition. The ABS
will be active again when you switch on the ignition.
See the KTM ABS training documents for a detailed description of the
ABS system.
2-7
SPECIAL TOOLS – ENGINE
FIG
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
PART NO
309098
0113 080802
151.12.017.000
451.29.075.000
503.29.050.000
560.12.001.000
584.29.059.000
585.29.005.000
590.29.019.000
590.29.021.044
590.29.026.006
590.29.041.000
6 899 785
600.29.002.000
600.29.003.000
600.29.005.000
600.29.006.000
600.29.009.000
600.29.009.010
600.29.009.110
600.29.010.000
600.29.011.000
600.29.012.000
600.29.015.000
600.29.016.000
600.29.018.000
600.29.031.000
600.29.033.000
600.29.041.000
600.29.043.010
600.29.043.020
600.29.043.030
600.29.043.040
600.29.043.050
600.29.043.060
600.29.044.050
600.29.046.028
600.29.050.000
600.29.051.000
600.29.058.000
600.29.073.000
600.29.075.000
600.29.081.000
600.29.082.000
600.29.083.000
610.29.094.000
625.29.093.000
DESCRIPTION
Seal Three-Bond
Crankshaft locking bolt
Gear puller
Tachometer
Bleeding syringe for hydraulic clutch
Universal-engine work stand
Loctite 648 green 20 ml
Protection sleeve for shaft seal ring of water pump
Valve spring mounter
Puller
Limit plug gauge 6,05 mm
Feeler gauge for valve clearance
Loctite 243 blu 10 ml
Engine holder for engine work stand
Clutch holder
Protection sleeve for shaft seal ring of output shaft
Oil pressure adapter
Magneto extractor
Pressure screw for magneto extractor up to the 2004 model
Pressure screw for rotor extractor from the 2005 model
Degree wheel
Carburator synchronisation tool
Plastigauge-measuring strips
Piston ring mounting tool
Setting gauge for float level
Internal gear puller 28 mm
Protection sleeve for crankshaft (for pulling of the primary gear)
Puller for primary gear
Valve spring mounter insert
Pressing tool for seal of clutch release shaft
Pressing tool for seal of output shaft
Pressing tool for seal and bearing of shifting shaft
Pressing tool for seal of water pump
Pressing tool for seal of balancer shaft
Pressing tool for bearing of water pump
Pressing tool for main bearings (In/out)
Pressing tool for supporting bearing (In)
Pretensioning tool - lower part
Pretensioning tool - hook wrench
Puller for spreader components
Spark plug wrench 16 mm
Special nut for conrod
Special tool for cylinder head nuts
Holder for water pump wheel
Special nut for cylinder head nuts
EFi-tool for pressure check
Intermediate adapter for ignition cable
2-8
bo
6
4
2
1
3
5
bn
8
bp
LOCTITE
243
7
bq
br bs
bt
8
Art.-No. 3.206.056-E
64
bk
9
Repair manual KTM LC8
cr
cq
bl
ck
bm
cn
co
cp
cs ct dk dl dm dn
do
ds dt ek el
dq
cm
cl
dp
em en
eo
2
4
0
dr
ep
3
1
BAR
5
2-9
SPECIALTOOLS – CHASSIS
6
4
3
2
1
7
5
8
9
bk
bp
bl
bm
bn
bo
FIG
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
PART NO
151.12.017.000
584.29.086.000
584.29.089.000
584.29.091.000
584.29.092.000
600.03.022.000
600.10.013.000
600.29.018.000
600.29.020.000
600.29.055.000
600.29.055.100
600.29.056.000
600.29.057.000
600.29.057.100
625.29.055.000
DESCRIPTION
Gear puller
Pressing tool for swing arm bearing
Chassis tool holder
Press-in tool for bearing seat / rear wheel bearing
Knock-out tool for bearing seat
Center stand
Sleeve for pressing tool for swim arm bearing
Internal gear puller 28 mm
Chain rivet tool
Center stand lock
Floor jack attachment
Anvil dolly (for 584.29.086.000)
Pliers for Öttiker clamps
Pliers for spring-loaded band-type clamp
Assembly stand
2-10
Checking the oil level of the hydraulic clutch - 950/990
Adventure, 950 Supermoto/R
1
To check the oil level in the master cylinder of the clutch remove the
cover. For this purpose, remove bolts and cover together with the
rubber boot 1. The oil level in the horizontal-standing master cylinder
should be 4 mm below the upper edge. If necessary add SAE 10
biodegradable hydraulic oil (e.g. Motorex Kupplungs-Fluid 75).
ONLY
!
SAE 10
CAUTION
!
USE
BIODEGRADABLE HYDRAULIC OIL TO REFILL THE MASTER
CYLINDER. NEVER USE BRAKE FLUID NOR MIX BIODEGRADABLE HYDRAULIC OILS
WITH MINERAL OILS!
Checking the oil level of the hydraulic clutch - 990 Super
Duke/R
The oil level in the horizontal-standing master cylinder should be
between the "MIN" and "MAX" marks.
If necessary, add SAE 10 biodegradable hydraulic oil (Motorex
Kupplungsfluid 75).
!
CAUTION
!
USE SAE 10 BIODEGRADABLE HYDRAULIC OIL TO FILL THE MASTER
CYLINDER. DO NOT USE BRAKE FLUID AND DO NOT MIX WITH HYDRAULIC MINERAL
OIL.
ONLY
Art.-No. 3.206.056-E
Bleeding of the hydraulic clutch
For bleeding, the cover of the master cylinder of the clutch needs to be
removed. For this purpose, remove bolts and take off cover together
with rubber bellows 1. At the slave cylinder of the clutch, remove the
bleeder nipple. At its place, mount the bleeder syringe 2 which is
filled with biodegradable hydraulic oil (e.g. Motorex Kupplungs-Fluid
75).
2
Refill oil, until oil is discharged from the bore A of the master cylinder
in a bubble-free state. Make sure that the oil does not overflow.
!
Repair manual KTM LC8
A
CAUTION
!
HAVING COMPLETED THE BLEEDING PROCEDURE, YOU HAVE TO VERIFY THAT THE OIL
LEVEL IN THE MASTER CYLINDER IS CORRECT. FOR FILLING OF THE MASTER
CYLINDER, USE SAE 10 BIODEGRADABLE HYDRAULIC OIL ONLY (EX. MOTOREX
KUPPLUNGS-FLUID 75); NEVER USE BRAKE FLUID NOR MIX BIODEGRADABLE
HYDRAULIC OILS WITH MINERAL OILS.
2-11
Resetting the control unit after replacing/repairing the engine
NOTE: the control unit must be reset after replacing the engine or after
engine repair if replacing a piston, cylinder or cylinder head.
The engine may have a poor idle behavior if the control unit is not
reset.
– Connect the KTM diagnostics tool, turn the ignition switch on and
start the program.
– Select "Extend" 1.
1
– Select "Device operation" 2.
2
– Enter your password.
– Select "All reference reset operation" 3 and move to the right
window with the arrow 4.
4
– Acknowledge with "Execute" 5 to "Reset" the control unit.
– Wait until the "Reset" process is completed, exit the program, turn
the ignition switch off and disconnect the KTM diagnostics tool.
3
5
– Allow the vehicle to idle for 15 minutes. Do not open the throttle
during this time, observe the coolant temperature, stop if the engine
is likely to overheat.
2-12
Adjusting the throttle cable for models with fuel injection
NOTE: to adjust the throttle cable clearance, the throttle valves must
be closed. To close, retract the idle speed control stepper motor all the
way using the KTM diagnostics tool.
If this step is omitted, the throttle cable clearance cannot be correctly
adjusted.
– Connect the KTM diagnostics tool, turn the ignition switch on and
start the program.
– Select "Extend" 1.
1
– Select "Device operation" 2.
2
Art.-No. 3.206.056-E
– Enter your password.
– Select "Idle speed control stepper motor" 3 and move to the right
window with the arrow 4.
4
3
– Acknowledge with "Execute" 5. The idle speed control stepper
motor will be completely retracted and the throttle valves completely
closed.
– Remove the left side cover on the air filter box and check whether
the throttle valves are completely closed.
5
– Switch the ignition switch off and adjust the throttle cable clearance
as follows:
Repair manual KTM LC8
– Loosen the counter nut 6, turn the adjusting screw 7 as needed
and tighten the counter nut again.
6
7
NOTE:
– You should be able to feel 3-5 mm play in the throttle grip when you
start to turn it.
– Make sure the throttle grip returns to the neutral position
automatically when released.
– Turn the ignition switch on again, exit the program, turn the ignition
switch off and disconnect the KTM diagnostics tool.
To check whether the setting is correct, start the engine, steer left and
right all the way to the stop. The idle speed should not change.
2-13
ECU software update/mapping
1
2
NOTE:
– ECU software update or mapping means that the software for the
injection system control unit has been modified. The software can
be downloaded from KTM's dealer.net site; the software is
transferred to the control unit via the KTM diagnostics tool (FAN).
– Some exhaust systems require new "mapping". If these exhaust
systems are replaced by the production system again, the "mapping"
will need to be reverted to the original version.
!
CAUTION
!
NOT USE THE MODIFIED MAPPING WITH PRODUCTION EXHAUST SYSTEMS. THIS
CAN LEAD TO ENGINE DAMAGE AND YOU WILL RUN THE RISK OF BURNING/INJURING
YOURSELF.
DO
Downloading the software:
– Log into dealer.net.
– Select "Parts and Hard Equipment" 1.
– Select "Fichefinder" 2.
5
3
– Select the model year, model type and model 3 and click "Start
search" 4.
– Select "Technical documentation" 5.
4
– Select the required mapping 6.
– Click "Save" 7.
7
6
– Select the storage location 8.
8
9
NOTE:
– Save the file onto your "Desktop" to make it easier to locate.
– This can take a little time, depending on your Internet connection
and the size of the mapping file.
– The downloaded file is compressed and needs to be extracted with
"winzip".
– Double click the downloaded file 9.
– Click "I agree" in the "winzip" window bk.
– Mark the extracted file with the cursor and drag to your "Desktop".
bk
2-14
Starting the DMT (Data Maintenance Tool):
– Double click "DMT" 1 to start the DMT program.
2
1
8
NOTE:
– If the DMT is not installed yet, install with the KTM diagnostics tool
CD.
– If the program is already installed but the DMT icon does not appear
on your screen, start the program under "Start" (in the task bar at
the bottom of the screen) by clicking "Programs".
– Click the field in the DMT window with the 3 dots 2.
– Select the storage location of the downloaded mapping file in the
selection window ("Desktop") 3.
3
– Click "update" in the DMT window 4.
4
– Confirm "update" selection with "Yes" 5.
5
Art.-No. 3.206.056-E
– End "update" with "OK" 6.
6
– Confirm that you are ending the "update" with "YES" 7.
7
Starting the FAN (Flash Download System):
– Double click on "FAN" 8 to start the FAN program.
Reparaturanleitung KTM LC8
9
bk
NOTE:
– If the FAN is not installed yet, install with the KTM diagnostics tool
CD.
– If the program is already installed but the DMT icon does not appear
on your screen, start the program under "Start" (in the task bar at
the bottom of the screen) by clicking "Programs".
– Connect the motorcycle to the diagnostics adapter, switch on the
ignition.
– Click the mapping file 9 to be transferred to the ECU and confirm
with "Execute".
– Enter the password (Adapter number) and click "OK" to confirm.
2-15
– The mapping file will be transferred to the ECU.
!
CAUTION
!
DO
NOT SWITCH OFF THE IGNITION OR DISCONNECT THE DIAGNOSTICS CABLE WHILE
THE FILE IS BEING TRANSFERRED ("FLASHING"). THIS CAN DAMAGE THE ECU.
1
NOTE:
– All of the indicator lamps in the digital speedometer will light up
while the file is being transferred.
– The bar 1 will show download progress.
– Click "OK" to confirm when the operation is completed.
– End the program, switch off the ignition and disconnect the
diagnostics cable.
– Start the engine and allow to idle for 15 minutes.
NOTE: the engine must run in idle for 15 minutes after each mapping
operation (Mapping initializing). Do not accelerate during this time,
observe the coolant temperature and abort if the engine threatens to
overheat.
Checking the oil pressure
– Remove the plug from the timing chain tensioner 2.
2
– Screw on the oil pressure adapter 3 600.29.006.000 and tighten.
– Connect the EFI pressure gauge 610.29.094.000 (without the Tfitting) to the oil pressure adapter, tighten the banjo bolt.
3
!
CAUTION
– CONNECT ALL LOOSENED OIL AND FUEL LINES AGAIN
ENGINE.
– CHECK THE OIL LEVEL AND CORRECT IF NECESSARY.
!
BEFORE STARTING THE
– Allow the engine to warm up and check the oil pressure with the
engine at operating temperature:
min. 0.8 bar at 1500 rpm
min. 2.4 bar - max. 3.5 bar at 6000 rpm
NOTE: the engine is at operating temperature when the engine oil in
the oil tank is approx. 100ºC.
– Remove the special tools again, screw the plug in the timing chain
with a new gasket and tighten to 20 Nm.
3-1
REMOVING AND REFITTING ENGINE
INDEX
950 ADVENTURE
REMOVING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
REFITTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
Art.-No. 3.206.056-E
990 ADVENTURE
REMOVING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12
REFITTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17
990 SUPER DUKE
REMOVING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24
REFITTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25
990 SUPER DUKE R
REMOVING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32
REFITTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25
Repair manual KTM LC8
950 SUPERMOTO/R
REMOVING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-34
REFITTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-34
990 SUPERMOTO
REMOVING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-35
REFITTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-40
3
3-2
Removing the engine - 950 Adventure
– Screw the center stand 600.03.022.000 onto the frame 1 and jack
up the motorcycle on a firm, even surface.
– Remove the left bump rubber and lock the center stand with the
lock 600.29.055.000 2.
2
NOTE: if available, use the center stand already on the bike.
1
1
– Unlock the seat lock with the ignition key and remove.
– Remove the bolts 3 on the left and right of the front side covers,
disconnect the front turn signal, pull the tank vent hoses off of the
fuel tank and remove the side covers.
3
4
3
3
Art.-No. 3.206.056-E
4
– Remove the bolts 5 on the lower tank compartment and the fuse
box, take the cover off the fuse box and dismount the lower tank
compartment.
– Close the fuel cocks, disconnect the gasoline hoses, unscrew the
upper 6 and lower 7 fixing bolts on both fuel tanks and remove the
tanks together with the lower vent hoses.
5
5
6
6
5 5
7
Repair manual KTM LC8
NOTE: it is easier to disconnect the gasoline hoses if you remove the
front bolts on the underride protection and fold the engine guard down.
– Drain the engine oil from the oil tank and the engine: see Chapter 12.
– Remove the 4 bolts 8 on the underride protection and take off the
underride protection.
– Remove both bolts 9 on the front cover and take off the cover.
9
8
– Open the tank cover, unscrew the fixing bolts 4 and remove the
upper tank compartment.
8
– Open the lid on the battery compartment and disconnect the battery
terminals bk (starting with the negative pole).
– Take out the battery and remove the upper battery cover.
bk
bk
3-3
2
3
– Unscrew the bolts 1 and remove the intake snorkel 2 together with
the frame from the air filter box.
– Disconnect the vent hose and the EPC hose and remove the upper
half of the air filter box.
– Turn the intake trumpet 3 in a clockwise direction and remove.
Remove air filter.
1
– Unbolt both side covers on the lower air filter box and remove the
clamps on the carburetor connection boot.
– Detach the EPC hoses 4 from both carburetors and pull the hoses
out of the lower air filter box.
– Remove both vent hoses from the carburetors.
– Lift both carburetors, carefully draw the cable for the idle speed
adjustment and the gasoline hose through the openings in the lower
air filter box.
– Detach the fuel hoses from the carburetors.
– Pull the carburetor connection boots off of the intake manifolds.
4
4
5
– Detach the SLS valve 5 from the lower air filter box, pulling the
thin hose from the intake manifold and the thick hose from the
valve. Remove the valve.
– Remove the EPC valve 6 from the lower air filter box and
disconnect.
– Tilt up the carburetors and fasten to the handlebar with a wire or
rubber band. They do not need to be completely dismounted.
– Take the lower air filter box out of the frame.
NOTE: cover the intake ports with a cloth to prevent any parts from
falling inside.
6
7
8
– Unscrew both nuts 7 on the front exhaust manifold flange on the
cylinder head, loosen the exhaust clamp 8 on the front exhaust
manifold, pull the front exhaust manifold out of the rear exhaust
pipe and remove.
– Unscrew the rear exhaust manifold from the cylinder head.
3-4
2
– Disconnect the electric connections from the fan motor and the
temperature switch 1.
– Drain the cooling liquid from the radiator and engine: see
Chapter 12.
– Detach the water hoses from the radiator (special pliers
600.29.057.100) and unscrew the radiator 2 .
2
1
NOTE: fan and radiator shield do not need to be dismounted from the
radiator.
2
– Pull off the oil lines from the oil tank to the valve covers 3 and the
return line 4 (special pliers 600.29.57.100), unscrew the oil lines
from the oil terminal 5 and pull out. Remove the O-rings.
4
6
3
Art.-No. 3.206.056-E
– Loosen the fixing bolts 6 on the oil tank, remove the oil tank and
carefully pull out the oil line.
5
6
8
– Disconnect the side stand switch 7 and take the cable out of the
cable clips.
– Loosen the two bolts and the nut 8 and remove the side stand.
Repair manual KTM LC8
7
– Unscrew the clutch slave cylinder 9 and the chainguard bk and pull
the locking pin out of the pushrod.
– Dismount the chain roller and chain securing guide.
9
bk
3-5
– Unscrew the nut on the wheel spindle, pull out the rear wheel
spindle, take the chain off of the rear sprocket and place over the
side of the bracket 1. Remove the chain from the engine sprocket.
1
– Detach the connector 2.
– Remove the engine vent hose 3, discarding the hose clamp.
2
2
3
2
5
6
4
– Unscrew the positive starter engine cable and draw out the wiring
harness.
– Detach connector 4 on the starter relay.
– Pull out the gasoline pump vent hose 5 towards the bottom.
– Unscrew the ground connection 6.
4
– Disconnect the fuel hose 7.
– Loosen the bolts on the side support 8 and the nut on the bolt 9,
pull out the bolt and remove support together with the battery case.
8
8
7
9
– Unscrew the front oil line bk.
bk
3-6
– Use the trolley jack to position the attachment 600.29.055.100 on
the engine, insert the bolt 1 through the front of the engine bracket
and fasten with the nut. Screw one of the bolts 2 on the rear of the
side stand fixture and slightly lift the engine.
1
2
– Remove the bolt 3 and tilt the foot brake pedal to the side.
3
Art.-No. 3.206.056-E
– Unscrew the ground wire connection 4.
– Detach the connector from the pulse generator 5.
4
5
6
8
– Detach the connector from the oil pressure switch 6, the
temperature sensor 7 and from the front 8 and rear ignition coil.
Remove any cable clips necessary.
Repair manual KTM LC8
7
– Pull the bolt 9 out of the lower support (if necessary, raise or lower
the engine slightly).
bk
– Loosen the nut on the swing arm pivot bk and knock out the swing
arm pivot with a suitable pipe.
– Pull the engine towards the front with the trolley jack, lower and pull
away towards the side.
– Disconnect all hoses and lines from the engine.
9
3-7
Refitting the engine - 950 Adventure
– Before mounting the engine, attach the water, SLS and vacuum
hoses (Öttiger clamps - special pliers 600.29.057.000 or springloaded band-type clamps - special pliers 600.29.057.100)
– Position the swing arm and fix with the swing arm pivot on the right
and a suitable pipe on the left.
– Lift the engine into the frame with the trolley jack, insert the sealing
washer in the rear exhaust flange and secure with copper paste if
necessary.
– Guide the chain along the side of the pinion and insert the swing
arm pivot 1, screw on the nut but do not tighten yet.
– Insert the bolt 2 in the lower support (raise or lower the engine
slightly if necessary).
– Remove the trolley jack attachment 600.29.055.100 from the
engine.
1
2
3
– Plug the connector on the oil pressure switch 3, the temperature
sensor 4 and the front and rear ignition coil 5. Use cable clips to
fasten the wiring harnesses.
5
4
– Screw on the ground wire connection 6.
– Attach the pulse generator connector 7.
6
7
– Position the foot brake pedal, apply Loctite 243 to the bolt 8 and
tighten to 25 Nm.
8
3-8
– Mount the front oil line 1 inserting new O-rings. Tighten the bolts.
NOTE: up to engine number 2-600-1186 a washer must be used to
preload the O-rings on the oil terminal.
1
3
3
– Align the side supports and battery case against the engine, insert
the bolt 2 and mount the nut.
– Mount the bolts 3 (M10x23), lifting the engine slightly if necessary.
Tighten the nut and bolts to 45 Nm.
– Tighten the nut on the swing arm pivot to 130 Nm.
– Connect the fuel hose 4 and fasten with a cable clip.
4
Art.-No. 3.206.056-E
2
6
7
5
– Run the positive starter cable to the starter and screw on the starter
engine. Run the starter ground to the battery case.
– Attach both starter relay connectors 5.
– Run the gasoline pump vent hose 6 upwards along the wiring
harness to the engine bracket and back down, forming an arch see
Technical Information, Chapter 1.
!
CAUTION
!
YOU RUN THE HOSE STRAIGHT UP WITHOUT AN ARCH, WATER WILL BE ABLE TO
PENETRATE, CAUSING THE GASOLINE PUMP TO BE SOILED AND DAMAGED.
IF
– Screw on the ground wire 7 from the regulator.
5
– Attach the connector 8.
– Slip on the hose from the engine ventilation 9 and mount the new
Öttiker clamp with the special pliers 600.29.057.000.
Repair manual KTM LC8
8
8
8
9
3-9
1
1
– Place the chain over the pinion and rear sprocket, lift the rear wheel
and slide the wheel spindle through.
– Press the rear wheel towards the front to apply the chain tensioner
1 and tighten the nut on the wheel spindle to 90 Nm.
– Actuate the foot brake pedal to apply the brake shoes against the
brake disk.
– Check the chain tension, see owners manual.
– Mount the chain securing guide and the chain roller.
– Insert the locking pin in the pushrod and mount the clutch slave
cylinder 2. Screw on the chainguard 3.
2
3
– Position the side stand and tighten the two bolts and the nut 4
to 45 Nm (with Loctite 243).
– Mount the side stand switch 5 and fasten the cable with the cable
clips.
4
5
– Carefully install the oil line, mount the oil tank and tighten the
fixing bolts 6.
7
– Connect the return line 7 to the oil tank and mount the springloaded band-type clamp with the special pliers 600.29.057.100.
– Attach the oil lines from the oil tank to the valve covers 8 (special
pliers 600.29.057.100).
6
6
– Mount both oil lines on the oil terminal 9 with new O-rings, insert
the bolts (M6x20) in the retaining brackets bk and tighten to 10 Nm.
NOTE:
– up to engine number 2-600-1186 a washer must be used to preload
the O-rings on the oil terminal.
– to allow the oil pump to build up the oil pressure faster, remove the
suction line (left) from the oil tank and fill with engine oil.
– Check the hose part of the suction line for cracks.
8
bk
9
bk
3-10
– Screw on the radiator together with the fan and the radiator shield
1, tighten the bolts to 10 Nm.
– Connect the water hoses on the radiator (special pliers
600.29.057.100)
1
– Attach the electric connections for the fan motor and the
temperature switch 2.
1
2
1
– Screw the rear exhaust manifold on to the cylinder head.
– Insert the front exhaust manifold in the rear exhaust pipe, mount to
the front cylinder head together with the sealing washer and tighten
the exhaust nuts 3.
4
3
NOTE: the exhaust nuts should be tightened evenly without bending
the metal sheet.
– Tighten the exhaust clamp 4 on the front manifold.
Art.-No. 3.206.056-E
6
– Mount the lower air filter box on the intake ports, connect the drain
hose and push the fuel hose and the cable for the idle speed
adjustment down through the opening in the lower air filter box.
NOTE: if the carburetors are equipped with transparent vent hoses, the
vent hoses must be replaced with reinforced vent hoses.
!
CAUTION
!
– MAKE
–
5
SURE THERE ARE NO KINKS IN THE CARBURETOR VENT HOSES AND RUN
THEM DOWN BEHIND THE STARTER ENGINE WITHOUT FORMING AN UPWARD
ARCH.
REMOVE THE CLOTH USED TO COVER THE INTAKE PORTS.
– Mount the EPC valve 5 on the lower air filter box and connect.
– Mount the secondary air system valve 6 on the lower air filter box,
connecting the thin hose to the intake manifold and the thick hose
directly to the valve.
– Attach the carburetor connection boots to the intake manifold.
NOTE: the clamps on the carburetor connection boots must be aligned
so that they can be tightened through the openings in the side covers.
– Connect the fuel hoses to the carburetors.
Repair manual KTM LC8
8
7
8
NOTE: to make it easier to connect the fuel hoses, disconnect the fuel
hose from the connecting piece (on the side of the engine brace) and
pull the fuel hose up. Reconnect after mounting the carburetor.
– Insert the carburetor in the carburetor connection boots, tighten the
clamps on the carburetor connection boots and screw both side
covers on the lower air filter box.
– Connect both vent hoses to the carburetors and fasten the choke
cable 7 with a cable clip (see photo).
– Insert the EPC hoses 8 in the corresponding openings in the lower
air filter box and connect to the carburetors.
bk
9
– Mount the air filter, position the intake trumpet 9 and turn in a
counter-clockwise direction.
– Mount the intake snorkel bk with the frame to the filter housing.
– Screw on the upper air filter box half. Connect the vent hose and the
EPC hose.
3-11
– Fit the upper battery cover and place a battery with battery cover
into the battery compartment.
– Fit the front battery compartment lid and connect both battery
cables 1 together to the connections on the front lid (start with the
positive cable).
– Close the front battery compartment lid.
1
1
– Mount the underride protection, apply Loctite 243 to the 4 bolts 2
(M8x14 collar bolts) and tighten to 25 Nm.
– Mount the front cover, apply Loctite 243 to both bolts 3 (M8x16)
and tighten to 25 Nm.
3
2
2
– Mount the lower tank compartment and screw on the fuse box 4.
Mount the fuse box cover.
4
4
– Fill cooling liquid into the radiator, compensating tank and engine:
see Chapter 12.
5
5
4 4
– Fill engine oil: see Chapter 12.
7
– Connect the fuel sender to the right tank. Connect the gasoline and
vent hoses and mount the tanks.
– Screw in the upper 5 (M8x40) and lower 6 (M8x55) or 7 (M8x50)
fixing bolts and open the fuel cocks.
6
– Connect the front turn signal and attach the vent hoses to the tanks.
Fasten both side covers with the bolts 8 and tighten.
8
8
8
9
– Mount the upper tank compartment and fasten with the bolts 9.
– Close the tank compartment lid and mount the seat.
9
– Remove the center stand lock bk 600.29.055.000, remount the left
bump rubber and remove the center stand bl.
bk
– Check all hose connections for leakage before you take a trial run.
– Check all hoses, lines and cables for a proper fit.
bl
3-12
Removing the engine - 990 Adventure
– Screw the center stand 600.03.022.000 onto the frame 1 and jack
up the motorcycle on a firm, even surface.
– Remove the left bump rubber and lock the center stand with the
lock 600.29.055.000 2.
2
NOTE: if available, use the center stand already on the bike.
1
1
– Unlock the seat lock with the ignition key and remove.
– Remove the bolts 3 on the left and right of the front side covers,
disconnect the front turn signal, pull the tank vent hoses off of the
fuel tank and remove the side covers.
3
4
3
Art.-No. 3.206.056-E
4
– Remove the bolts 5 on the lower tank compartment and the fuse
box, take the cover off the fuse box and dismount the lower tank
compartment.
– Close the fuel cocks, disconnect the tank line, unscrew the upper 6
and lower 7 fixing bolts on both fuel tanks and remove the tanks
together with the lower vent hoses.
5
5
6
6
5 5
– Drain the engine oil from the oil tank and the engine: see Chapter 12.
7
– Remove the 4 bolts 8 on the underride protection and take off the
underride protection.
– Remove both bolts 9 on the front cover and take off the cover.
Repair manual KTM LC8
9
8
– Open the tank cover, unscrew the fixing bolts 4 and remove the
upper tank compartment.
8
– Open the lid on the battery compartment and disconnect the battery
terminals bk (starting with the negative pole).
– Take out the battery and remove the upper battery cover.
bk
bk
3-13
2
3
– Unscrew the bolts 1 and remove the intake snorkel 2 together with
the frame from the air filter box.
– Disconnect the vent hose and the EPC hose and remove the upper
half of the air filter box.
– Turn the intake trumpet 3 in a clockwise direction and remove.
Remove air filter.
1
– Disconnect the plug-in connection 4 of the SLS valve 5 and take
the SLS valve off of the lower section of the air filter box.
4
5
– Pull the drain hose off of the lower section of the air filter box.
– Unbolt both side covers on the lower air filter box.
– Remove the fuel line 6 (special pliers 600.29.57.100) and loosen
the hose clamps 7.
– Take the plug-in connection 8 of the throttle body off of the holder
and disconnect it.
– Fold the throttle body up toward the front and secure it on the
handlebar using a wire or rubber band; the throttle body does not
need to be removed completely.
– Take off the intake sleeves.
6
8
7
NOTE: The lower section of the air filter box must be raised slightly to
make room for the plug-in connection 8 of the throttle body.
– Take the lower section of the air filter box off of the intake flange.
NOTE: cover the intake ports with a cloth to prevent any parts from
falling inside.
– Disconnect the plug-in connections of the manifold pressure sensors
9, remove the manifold pressure sensors 9 from the holders and
set them down on the engine.
9
9
– Unscrew the heat shield bk at the front of the exhaust pipe and
remove it.
bk
3-14
– Expose the electric lines of the lambda probes at the front and rear
and disconnect plug-in connections 1.
1
1
3
Art.-No. 3.206.056-E
2
5
5
4
– Disconnect the electric connections from the fan motor and the
temperature switch 4.
– Drain the cooling liquid from the radiator and engine: see
Chapter 12.
– Detach the water hoses from the radiator (special pliers
600.29.057.100) and unscrew the radiator 5 .
NOTE: fan and radiator shield do not need to be dismounted from the
radiator.
5
7
Repair manual KTM LC8
– Unscrew both nuts 2 on the front exhaust manifold flange on the
cylinder head, loosen the exhaust clamp 3 on the front exhaust
manifold, pull the front exhaust manifold out of the rear exhaust
pipe and remove.
– Unscrew the rear exhaust manifold from the cylinder head.
– Pull off the oil lines from the oil tank to the valve covers 6 and the
return
line
7
(special
pliers
600.29.57.100),
unscrew the oil tank valve 8 on the oil tank and remove the seal
ring.
9
6
9
8
– Loosen the fixing bolts 9 on the oil tank, remove the oil tank and
carefully pull out the oil line.
3-15
23
– Disconnect the side stand switch 1 and take the cable out of the
cable clips.
– Loosen the two bolts 2 and the nut 3 and remove the side stand.
1
– Unscrew the clutch slave cylinder 4 and the chainguard 5.
4
5
7
– Remove the adapter for the clutch slave cylinder 6 and the chain
securing guide 7.
– Take off the adapter for the hydraulic coupling 8.
– Pull the locking pin out of the pushrod.
8
6
– Unscrew the nut on the wheel spindle.
– Take the chain off of the rear sprocket and place over the side of the
bracket 9.
– Remove the chain from the engine sprocket
9
– Detach the connector bk.
bk
– Remove the engine vent hose bl, discarding the hose clamp.
bk
bl
3-16
– Take off the positive starter cable cover 1. Unscrew the positive
starter engine cable 2 and draw out the wiring harness.
2
1
3
– Detach connector 3 on the starter relay.
– Unscrew the ground connection 4.
– Pull off the cover 5 from the positive terminal, unscrew the nut
beneath it and remove the lines from the stud.
– Pull the battery cable with the lock 6 from the holder.
5
6
4
– Loosen the bolts on the side support 7 and the nut on the bolt 8,
pull out the bolt and remove support together with the battery case.
Art.-No. 3.206.056-E
NOTE: When removing the lateral supports with the battery box, ensure
that the lines of the locks are not pinched.
7
8
Repair manual KTM LC8
9
– Use the trolley jack to position the attachment 600.29.055.100 on
the engine, insert the bolt 9 through the front of the engine bracket
and fasten with the nut.
– Remove the retaining pin bk by removing the lock on the retaining
pin bk.
– Detach the return spring of the brake lever.
– Remove the bolt bl and tilt the foot brake pedal to the side.
bl
bk
3-17
1
– Unscrew the ground wire connection 1.
– Detach the connector from the pulse generator 2.
2
1
3
5
– Detach the connector from the oil pressure switch 3, the
temperature sensor 4 and from the front 5 and rear ignition coil.
Remove any cable clips necessary.
4
– Pull the bolt 6 out of the lower support (if necessary, raise or lower
the engine slightly).
– Loosen the nut on the swing arm pivot 7 and knock out the swing
arm pivot with a suitable pipe.
7
– Pull the engine towards the front with the trolley jack, lower and pull
away towards the side.
– Disconnect all hoses and lines from the engine.
6
3-18
Refitting the engine - 990 Adventure
– Before mounting the engine, attach the water, SLS and vacuum
hoses (Öttiger clamps - special pliers 600.29.057.000 or springloaded band-type clamps - special pliers 600.29.057.100)
– Position the swing arm and fix with the swing arm pivot on the right
and a suitable pipe on the left.
– Lift the engine into the frame with the trolley jack, insert the sealing
washer in the rear exhaust flange and secure with copper paste if
necessary.
– Guide the chain along the side of the pinion and insert the swing
arm pivot 1, screw on the nut but do not tighten yet.
– Insert the bolt 2 in the lower support (raise or lower the engine
slightly if necessary).
– Remove the trolley jack attachment 600.29.055.100 from the
engine.
1
2
Art.-No. 3.206.056-E
3
– Plug the connector on the oil pressure switch 3, the temperature
sensor 4 and the front and rear ignition coil 5. Use cable clips to
fasten the wiring harnesses.
5
4
6
– Screw on the ground wire connection 6.
– Attach the pulse generator connector 7.
Repair manual KTM LC8
7
6
– Position the foot brake pedal, apply Loctite 243 to the bolt 8 and
tighten to 25 Nm.
– Attach the return spring to the foot brake pedal.
– Install the retaining pin 9 by installing the lock on the retaining pin.
9
8
3-19
– Align the side supports and battery case against the engine, insert
the bolt 1 and mount the nut.
– Mount the bolts 2 (M10x23), lifting the engine slightly if necessary.
Tighten the nut and bolts to 45 Nm.
– Tighten the nut on the swing arm pivot to 130 Nm.
2
1
– Run the positive starter cable to the starter and screw on the starter
motor 3 and mount the positive starter cable cover 4.
3
4
7
6
– Attach the locks 5 to the holder and connect the lines to the stud
of the positive terminal.
– Tighten the nut of the positive terminal with 4 Nm and mount the
cover 6 onto the stud of the positive terminal.
– Plug in the connector 7 of the starter relay.
– Screw on the ground wire 7 of the regulator.
5
8
– Attach the connector 9.
9
– Slip on the hose from the engine ventilation bk and mount the new
Öttiker clamp with the special pliers 600.29.057.000.
9
bk
bl
bl
– Place the chain over the pinion and rear sprocket.
– Tighten the chain using the chain adjuster bl; see the owner's
manual.
– Tighten the nut on the wheel spindle to 90 Nm.
3-20
– Insert the locking pin in the pushrod.
– Mount the adapter for the hydraulic clutch 1.
– Mount the chain securing guide 2 and the adapter for the clutch
slave cylinder 3.
2
1
3
– Screw on the clutch slave cylinder 4 and the chainguard 5.
4
5
– Position the side stand.
– Tighten the two bolts 6 and the nut 7 to 45 Nm (with Loctite
243).
– Mount the side stand switch 8 and fasten the cable with the cable
clips.
Art.-No. 3.206.056-E
67
8
– Mount the oil tank and tighten the fixing bolts 9.
9
– Connect the return line bk to the oil tank and mount the springloaded band-type clamp with the special pliers 600.29.057.100.
– Attach the oil lines from the oil tank to the valve covers bl (special
pliers 600.29.057.100).
Repair manual KTM LC8
– Mount the oil line onto the oil tank bm with a new O-ring, mount the
screws and tighten with 10 Nm.
NOTE:
– to allow the oil pump to build up the oil pressure faster, remove the
suction line (left) from the oil tank and fill with engine oil.
– Check the hose part of the suction line for cracks.
bm
bk
bl
9
3-21
– Screw on the radiator together with the fan and the radiator shield
1, tighten the bolts to 10 Nm.
– Connect the water hoses on the radiator (special pliers
600.29.057.100)
1
– Attach the electric connections for the fan motor and the
temperature switch 2.
1
1
2
4
3
– Screw the rear exhaust manifold on to the cylinder head.
– Insert the front exhaust manifold in the rear exhaust pipe, mount to
the front cylinder head together with the sealing washer and tighten
the exhaust nuts 3.
NOTE:
– on a stud, a washer must be mounted as a spacer between the
clamping plate and the cylinder.
– the exhaust nuts should be tightened evenly without bending the
metal sheet.
– Tighten the exhaust clamps 4 of the front and rear manifolds.
– Attach the heat shield 5 on the exhaust pipe at the front and screw
tight.
NOTE: Lubricate the screws of the heat shield 5 with copper paste.
5
– Route the electric lines of the lambda probes at the front and rear,
secure them with cable binders and create plug-in connections 6.
6
6
– Attach the manifold pressure sensors 7 to the holders and create
the plug-in connections.
7
7
3-22
– Place the lower section of the air filter box onto the intake flange.
3
!
REMOVE
CAUTION
!
THE CLOTH USED TO COVER THE INTAKE PORTS.
– Place the throttle body into the lower section of the air filter box.
NOTE: The lower section of the air filter box must be raised slightly to
make room for the plug-in connection 1 of the throttle body
2
– Connect the drain hose to the lower section of the air filter box.
– Connect the lower section of the air filter box to the intake flange.
– Attach the sleeves of the throttle body to the intake flange.
1
NOTE: the clamps on the carburetor connection boots must be aligned
so that they can be tightened through the openings in the side covers.
– Insert the throttle body into the sleeves and tighten the hose clamps
2 of the sleeves.
– Connect the fuel hose 3 to the throttle body.
– Create the plug-in connection 1 of the throttle body.
4
– Mount the SLS valve 4 on the lower section of the air filter box and
create the plug-in connection.
Art.-No. 3.206.056-E
6
5
– Mount the air filter, position the intake trumpet 5 and turn in a
counter-clockwise direction.
– Mount the intake snorkel 6 with the frame to the filter housing.
– Screw on the upper air filter box half. Connect the vent hose and the
EPC hose.
– Fit the upper battery cover and place a battery with battery cover
into the battery compartment.
– Fit the front battery compartment lid and connect both battery
cables 7 together to the connections on the front lid (start with the
positive cable).
– Close the front battery compartment lid.
Repair manual KTM LC8
7
7
– Mount the underride protection, apply Loctite 243 to the 4 bolts 8
(M8x14 collar bolts) and tighten to 25 Nm.
– Mount the front cover, apply Loctite 243 to both bolts 9 (M8x16)
and tighten to 25 Nm.
8
9
9
3-23
– Fill cooling liquid into the radiator, compensating tank and engine:
see Chapter 12.
– Fill engine oil: see Chapter 12.
2
2
– Attach both tanks and fix them with the screws 1 (M8x40).
– Connect the tank line.
1
1
2 2
– Mount the lower tank compartment and screw on the fuse box 2.
Mount the fuse box cover.
4
3
– Connect the tank gauge sender to the right tank and connect the
vent hoses.
– Mount screws 3 (M8x55) and 4 (M8x50) and open the fuel taps.
– Connect the front turn signal and attach the vent hoses to the tanks.
Fasten both side covers with the bolts 5 and tighten.
5
5
5
6
– Mount the upper tank compartment and fasten with the bolts 6.
– Close the tank compartment lid and mount the seat.
6
– Remove the center stand lock 7 600.29.055.000, remount the left
bump rubber and remove the center stand 8.
7
– Check all hose connections for leakage before you take a trial run.
– Check all hoses, lines and cables for a proper fit.
8
3-24
Dismounting the engine - 990 Super Duke
NOTE: the procedure for dismounting the engine is the same as the
procedure used for the 950 Adventure; the only deviations are in the
preparatory work:
– Remove the spoiler and tank side covers.
– Disconnect the fuel hose connection (see Chapter 8), remove the
front tank screw, pull off the vent line and fold up the tank.
– Dismounting the throttle body: remove both side covers on the air
filter box, loosen the clamps 1 on the throttle body and dismount
the fuel line 2.
Art.-No. 3.206.056-E
2
1
1
Repair manual KTM LC8
– Pull the throttle body up, disconnect the wiring harness, remove
both throttle cables and lift out the throttle body.
3 4
– Unscrew the ball joints from the shift rod and the foot brake lever,
remove both footrest screws on the left and right, screw the
assembly stand 625.29.055.000 in the lower screw holes 3 and 4
and tighten.
– Press down on the back of the assembly sand to jack up the
motorcycle.
3-25
Mounting the engine - 990 Super Duke
– Connect the water, SLS and vacuum hoses to the engine before
mounting (Öttiger clamps - special pliers 600.29.057.000 or
spring-loaded band-type clamps - special pliers 600.29.057.100).
– Position the exhaust system under the motorcycle according to the
installation position.
– Position the swing arm and hold in place with the swing arm bolt on
the right and a suitable pipe on the left.
– Lift the engine into the frame with a floor jack, insert the sealing
washer in the rear exhaust flange and, if necessary, secure with a
small amount of copper paste.
– Run the chain along the side of the pinion and push the swing arm
bolt 1 through the chain, screw on the nut but do not tighten yet.
– Insert the bolt 2 for the lower support through the chain (raise or
lower the engine if necessary).
– Remove the floor jack attachment 600.29.055.100 from the
engine.
1
2
3
5
– Connect the connectors for the oil pressure switch 3, the
temperature sensor 4 and the front 5 and rear ignition coil. Secure
the wiring harnesses with cable clips.
4
– Screw on the ground cable terminal 6.
6
7
8
– Insert the short manifold pipe into the exhaust with a new gasket.
– Position the front and rear exhaust manifold on the cylinder head
and slightly tighten the nuts 7 and 8; do not screw tight.
3-26
– Mount the exhaust pipe clamp 1 between the manifold and the
main silencer and slightly tighten.
– Slightly tighten the exhaust pipe clamp 2 on the rear manifold.
1
NOTE:
– Do not tighten the screw connections until the exhaust system is
completely installed and mounted stress-free.
– Tighten the exhaust nuts evenly without bending the sheet.
– Tightening torque for clamp 1: 35 Nm and clamp 2: 12 Nm.
2
4
– Position the side stays on the engine, insert the bolt 3 and mount
the nut.
– Turn in the screws 4 (M10x24), lifting the engine if necessary.
Tighten the nut and screws to 45 Nm.
– Tighten the nut on the swing arm bolt to 130 Nm.
4
3
Art.-No. 3.206.056-E
– Mount the battery case with the controller and horn, using the black
screw 5 in the position shown.
5
Repair manual KTM LC8
– Run the positive starter cable 6 to the starter engine 7 and screw
on, screw on the starter ground and run to the battery case.
6
7
3-27
– Place the battery in the battery case and attach the battery case
cover.
– Connect the positive starter relay cable to the positive pole on the
battery.
– Connect the two ground connections to the negative pole on the
battery (2 green cables from the controller and 1 black cable from
the starter engine).
– Close the battery case cover and screw on, mount the starter relay.
1
2
4
3
– Run the wiring harness from above behind the side stay, through the
recess 1 and to the starter relay.
– Connect connector 2 on the starter relay (2 red/white cables), the
regulator output 3 (2 red/white cables) and the generator 4 (3-pole
connector).
– Run the horn cable 5 in front of the controller, connect and fasten
with the clip.
5
– Position the side stand and tighten both screws and the nut to
45 Nm (+ Loctite 243).
NOTE:
– Run cable 6 for the lambda probe, the side stand switch and the
gear sensor behind the side stand console.
– Fasten the lambda probe cable to the frame with a cable clip.
6
– Connect the connector for the lambda probe, the side stand switch
and the gear sensor to the wiring harness.
– Align the wiring harnesses in a loop as shown in the photo and
fasten with clamp 7 and cable clips.
7
3-28
– Fasten the wiring harnesses and connector on the pulse generator 1
with cable clips.
1
2
2
– Run the chain over the pinion and rear sprocket, raise the rear wheel
and push the wheel spindle through.
– Push the rear wheel forward until the chain tensioner 2 rests
against the stop screw and tighten the wheel spindle nut to 90 Nm.
– Actuate the foot brake lever until the brake pads rest against the
brake disk again.
– Check the chain tension (see Owner's Manual).
Art.-No. 3.206.056-E
– Attach the lock pin to the pushrod and align with the recess in the
chainguard. Mount the chain clip and the chainguard.
– Mount the clutch slave cylinder 3 and screw on the chainguard 4.
3
4
– Mount the oil tank and tighten the fixing screws 5.
– Mount the suction line 6 with a new O-ring.
5
7
– Connect the oil lines from the oil tank to the valve covers 7 (special
pliers 600.29.057.100).
Repair manual KTM LC8
– Connect the return line 8 to the oil tank and mount the springloaded band-type clamps with the special pliers 600.29.057.100.
5
6
8
5
3-29
1
2
1
1
– Screw on the radiator, the fan and the radiator shield 1, tighten the
screws to 10 Nm.
– Mount the water hoses on the radiator (special pliers
600.29.057.100)
– Connect the electric connectors for the temperature switch 2 and
fan motor 3.
1
3
– Connect the hose on the front vacuum sensor 4 and the connector
on the front lambda probe 5; attach the connector to the frame
with a cable clip.
!
CAUTION
!
– ALWAYS
–
5
–
4
REPLACE THE VACUUM HOSES ON THE INTAKE MANIFOLD IF THEY WERE
PULLED OFF.
DO NOT USE SILICONE SPRAY WHEN MOUNTING THE VACUUM HOSES. IT CAN
DAMAGE THE MANIFOLD AIR PRESSURE SENSORS.
DO NOT EXCHANGE THE CONNECTIONS ON THE INTAKE MANIFOLD WITH THE
CONNECTIONS ON THE 950 ADVENTURE OTHERWISE THE INJECTION SYSTEM IS
LIKELY TO MALFUNCTION.
– Place the lower air filter box on the intake ports, connect the drain
hose and push the fuel hose down through the opening in the lower
air filter box.
!
REMOVE
CAUTION
!
THE CLOTH USED TO COVER THE INTAKE PORTS.
– Slip the throttle body bellows over the intake manifolds.
NOTE: align the clamps on the bellows so they can be tightened
through the openings in the side cover.
– Place the throttle body in the lower air filter box and mount the
throttle cables - see throttle cable adjustment, chapter 2.
– Insert the throttle body in the bellows and tighten the bellows
clamps.
– Connect the fuel hose to the throttle body.
3-30
– Mount the throttle cable duct 1.
1
– Screw on the left side cover of the lower air filter box together with
the bracket 2 for the vacuum hose to the rear vacuum sensor.
– Connect the hose on the rear vacuum sensor.
2
!
CAUTION
!
– ALWAYS
–
–
REPLACE THE VACUUM HOSES ON THE INTAKE MANIFOLD IF THEY WERE
PULLED OFF.
DO NOT USE SILICONE SPRAY WHEN MOUNTING THE VACUUM HOSES. IT CAN
DAMAGE THE MANIFOLD AIR PRESSURE SENSORS.
DO NOT EXCHANGE THE CONNECTIONS ON THE INTAKE MANIFOLD WITH THE
CONNECTIONS ON THE 950 ADVENTURE OTHERWISE THE INJECTION SYSTEM IS
LIKELY TO MALFUNCTION.
Art.-No. 3.206.056-E
– Screw on the right side cover of the lower air filter box together with
the bracket 3 for the secondary air system hose.
3
– Mount the intake snorkel 4 and frame on the air filter housing and
screw on.
– Mount the air filter and the intake trumpet 5.
4
Repair manual KTM LC8
– Mount the upper air filter box half and screw on, connect the vent
hose and SLS hose, attach the intake temperature sensor.
– Mount the secondary air system valve on the lower air filter box and
connect.
5
– Mount the radiator compensating tank, connect the short hose 6 to
the radiator, run the longer hose 7 in front of the intake snorkel
over the air filter box to the left side of the motorcycle and continue
along the frame to behind the battery case.
7
6
3-31
– Run the tank vent hose down parallel to the overflow hose on the
compensating tank, tilt the tank forward and screw on. Connect the
tank vent hose and fuel connector.
– Mount both tank side covers and the spoiler and tighten the screws.
– Remove the assembly stand.
– Apply Loctite 243 to the screws of the footrest support 1 and
tighten to 25 Nm.
– Mount the relay lever for the shift rod, apply Loctite 243 to screw 2
and tighten to 18 Nm.
– Apply Loctite 243 to the screw on the shift rod 3 and tighten to 12
Nm.
1
2
3
5
– Apply Loctite 243 to the screws of the footrest support 4 and
tighten to 25 Nm.
– Apply Loctite 243 to the screw of the foot brake push rod 5 and
tighten to 12 Nm.
– Bleed the cooling system (see Chapter 12).
4
– Add engine oil (see chapter 12).
– Check all hose connections for leakage before taking a test ride.
– Check all hoses, lines and cables for a tight fit.
3-32
Dismounting the engine - 990 Super Duke R
NOTE: the procedure for dismounting and mounting the engine is the
same as the procedure used for the 950 Adventure; the only deviations
are in the preparatory work:
– Remove the spoiler and tank side covers.
– Remove the holder for the seat.
– Disconnect the fuel hose connection (see Chapter 8), remove the
front tank screw, pull off the vent line
– Disconnect the plug-in connections.
– Disconnect the fuel supply line, loosen the tank fixation at the rear
and take off the tank.
!
CAUTION
!
To prevent damage to the tank, place it on a surface covered with a
cloth.
– Take off both side covers of the air filter box, loosen the hose clamps
1 of the throttle body and remove the fuel line 2.
– Expose the plug-in connection 3 of the throttle body and
disconnect it.
2
Art.-No. 3.206.056-E
– Fold the throttle body up toward the front and secure it on the
handlebar using a wire or rubber band; the throttle body does not
need to be removed completely.
1
3
Repair manual KTM LC8
4 4
NOTE: The lower section of the air filter box must be raised slightly to
make room for the plug-in connection 3 of the throttle body.
– Unscrew the ball joints from the shift rod and the foot brake lever,
remove both footrest screws on the left and right.
– Mount the fixing bolts of assembly stand 625.29.055.000 into the
lower screw holes 4 and tighten.
– Press down on the back of the assembly sand to jack up the
motorcycle.
– Drain the coolant out of the radiator and engine: see Chapter 12.
– Drain the engine oil out of the oil tank and engine: see Chapter 12.
5
– Disconnect the coolant hoses at the joint 5 by loosening the hose
clamps (special pliers 600.29.057.100).
5
5
3-33
– Expose the lines of the ignition coil connectors for the cylinder at
the front and rear, take the plug-in connections off of the holder and
disconnect the plug-in connections 1 for the cylinder at the front
and rear.
1
– Unscrew the holder 2 of the front exhaust manifold from the
engine.
2
– Loosen the exhaust clamps 3 of the front and rear exhaust
manifold.
3
3
– Unscrew both nuts 4 of the front exhaust manifold flange from the
cylinder head.
– Pull the front exhaust manifold out of the rear exhaust pipe and
remove it.
– Unscrew both nuts 5 of the rear exhaust manifold from the cylinder
head and remove them.
4
5
NOTE:
– on a stud, a sleeve must be mounted as a spacer between the
cylinder and the clamping plate.
– the nuts 4 of the front exhaust manifold and the nuts 5 of the rear
exhaust manifold must be tightened evenly without warping the
clamping plate.
– Assembly is performed in reverse order.
3-34
Dis-/Mounting the engine - 950 Supermoto/R
NOTE: the procedure for dismounting the engine is the same as the
procedure used for the 950 Adventure; the only difference is in the
preparatory work:
Jack up the motorcycle with the assembly stand 625.29.055.000:
– Remove the footrests on each side and screw off the foot brake
lever.
– Mount the retaining bolt insert 1 on the assembly stand.
– Raise the assembly stand in the back and slide the retaining bolts in
the footrest support on each side.
NOTE: if you have trouble sliding the retaining bolts into the footrest
support, loosen the counternuts 2 and tighten again after the retaining
bolts have been pushed in the footrest supports.
– Press down on the back of the assembly stand to jack up the
motorcycle.
2
Art.-No. 3.206.056-E
1
Removing the tank:
– Remove the tank covers 3 (3 screws on left; 2 screws on right).
– Remove both tank spoilers 4 (2 screws in the front and 2 from the
outside).
4
3
– Close both fuel taps and disconnect the fuel hoses.
– Disconnect the fuel connection by pressing lightly on the metal
plate 5 and pulling the connection apart.
– Remove the fuel hose 6 from the fuel pump.
Repair manual KTM LC8
6
5
7
– Unscrew the tank retaining screw and pull the tank ventilation off
the connector at the filling hole.
– Disconnect the connector for the horn 7.
– Disconnect the fuel sender and fuel pump connector 8.
– Carefully lift off the tank.
– To mount, proceed in the reverse order.
– To bleed the cooling system: see chapter 12
– To add engine oil: see chapter 12
8
3-35
Removing the engine - 990 Supermoto
– Jack up the motorcycle on the link fork using assembly stand
625.29.055.000.
– Open the seat lock with the ignition key and take off the seat.
1
– Unscrew the screws 1 on the left and right of the side cover and
take off the side cover.
– Drain the coolant out of the radiator and engine: see Chapter 12.
– Drain the engine oil out of the oil tank and engine: see Chapter 12.
1
– Close both fuel taps 2 and pull off the fuel hoses.
– Disconnect the fuel connection by pressing lightly on the metal
plate 3 and pulling the connection apart.
– Disconnect the connection 4 of the gasoline pump and tank gauge
sender.
– Unscrew the tank fixing screws and pull the tank breather off of the
connection at the filling hole.
– Remove the tank carefully.
2
4
3
–
–
–
–
5
6
Remove the side cover 5 on the left and right.
Expose the line of the side stand and disconnect it.
Remove the screws 6 and the nut 7.
Remove the side stand.
7
– Expose the lines of the lambda probes and disconnect the plug-in
connections 8.
8
8
– Loosen the exhaust clamps of the front and rear exhaust manifold.
– Unscrew the holder 9 of the front exhaust manifold from the
engine.
9
3-36
– Loosen the nuts 1 of the front exhaust manifold and take off the
front exhaust manifold.
– Loosen the nuts 2 of the rear exhaust manifold and take off the rear
exhaust manifold.
1
1
2
2
– Remove the retaining pin 3 by remove the lock on the retaining pin.
– Detach the return spring of the brake lever.
– Remove the screw 4 and take off the foot brake pedal.
– Remove the footrests on both sides.
4
3
Art.-No. 3.206.056-E
– With the help of another person, jack up the motorcycle at the rear.
– Mount the retaining pin insert 5 on the assembly stand.
– Raise the assembly stand at the rear and slide the retaining pins on
both sides into the footrest holder.
NOTE: If the retaining pins are difficult to slide into the footrest holder,
or cannot be slid in at all, loosen the counter nuts 6 and, after the
retaining pins have been slid into the footrest holder, retighten them.
– Push down the rear of the assembly stand to jack up the motorcycle.
6
Repair manual KTM LC8
5
– Disconnect the negative terminal of the battery.
– Remove the vent hose 7 and the hose 8 of the SLS valve on the
upper section of the air filter box (special pliers 600.29.57.100).
– Disconnect the plug-in connection 9 of the intake air temperature
sensor.
– Unscrew the screws of the upper section of the air filter box and
remove the upper section of the air filter box.
7
8
9
3-37
2
3
– Unscrew the screws 1 and take the intake snorkel 2 with the frame
off of the air filter box.
– Pull off the vent and EPC hoses and remove the top section of the
air filter box.
– Turn the intake trumpet 3 clockwise and take it off; remove the air
filter.
1
– Disconnect the plug-in connection 4 of the SLS valve 5 and take
the SLS valve off of the lower section of the air filter box.
4
5
– Disconnect the plug-in connection 6 of the generator.
– Take the manifold pressure sensors 7 on the left and right off of the
holder and disconnect the plug-in connections.
– Take the plug-in connection 8 of the throttle body off of the holder
and disconnect the plug-in connection 8.
– Pull the drain hose off of the lower section of the air filter box.
– Unscrew both side covers of the lower section of the air filter box.
6 7
7
8
– Remove the fuel line 9 (special pliers 600.29.57.100) and loosen
the hose clamps bk.
– Fold the throttle body up toward the front and secure it on the
handlebar using a wire or rubber band; the throttle body does not
need to be removed completely.
9
NOTE: The lower section of the air filter box must be raised slightly to
make room for plug-in connection of the throttle body.
– Take the lower section of the air filter box off of the intake pipe.
bk
NOTE: The intake channels should be closed off with a cloth to keep
parts from falling out.
– Disconnect the electrical plug-in connection of the horn.
– Disconnect the electrical connections of the fan motor and
temperature switch bl.
– Remove the water hoses from the radiator (special pliers
600.29.057.100)
– Remove the screws bm and take off the radiator.
bm
bl
NOTE: The fan and radiator shield do not need to be removed from the
radiator.
bm
3-38
– Detach the oil line between the oil tank and the valve cover from the
front of the oil tank (special pliers 600.29.57.100).
– Unscrew the oil lines from the oil terminal 1 and pull them out;
remove the O-rings.
2
1
– Loosen the retaining screws 2 at the oil tank and take off the oil
tank.
4
– Expose the line of the gear position sensor.
– Disconnect the plug-in connection 3 of the gear position sensor.
– Disconnect the plug-in connection 4 of the ignition pulse generator.
3
2
Art.-No. 3.206.056-E
– Loosen the screws 5 of the lateral supports and the nut 6 of the
bolt, pull out the bolt and take off the supports.
5
6
8
– Unscrew the clutch slave cylinder 7 and chainguard 8.
– Remove the chain roller and the chain securing guide.
– Pull the locking pin out of the push rod.
Repair manual KTM LC8
7
bk
bl
9
– Remove the adapter for the clutch slave cylinder 9 and the chain
securing guide bk.
– Take off the adapter for the hydraulic coupling bl.
– Pull the locking pin out of the push rod.
3-39
–
–
–
–
Loosen the chain adjuster.
Loosen the nut of the wheel spindle.
Push the wheel into the frontmost position.
Remove the chain 1 from the rear sprocket and place it over the
link fork.
– Take the chain off of the engine sprocket.
NOTE: To avoid damaging the link fork, place a cloth between the link
fork and the chain 1.
1
– Position component 600.29.055.100 on the engine with the trolley
jack, push the bolt 2 of the engine support through the front and
raise the engine slightly.
2
– Unscrew the ground cable connections 3 and the positive cable
from the starter.
3
3
– Disconnect the connectors of the oil pressure sensor 4, temperature
sensor 5 and the front 6 and rear ignition coils. Remove the cable
binders where necessary.
4
5
6
– Pull out the bolt 7 of the lower support (raising or lowering the
engine slightly if necessary).
– Loosen the nut of the swingarm pivot 8 and hammer out the
swingarm pivot with a suitable pipe.
– Using the trolley jack, pull the engine forward, lower it and move it
out to one side.
7
8
– Remove all hoses and cables from the engine.
3-40
Refitting the engine - 990 Supermoto
– Before mounting the engine, attach the water, SLS and vacuum
hoses (Öttiger clamps - special pliers 600.29.057.000 or springloaded band-type clamps - special pliers 600.29.057.100)
– Position the swing arm and fix with the swing arm pivot on the right
and a suitable pipe on the left..
– Lift the engine into the frame with the trolley jack, insert the sealing
washer in the rear exhaust flange and secure with copper paste if
necessary.
– Guide the chain along the side of the pinion and insert the swing
arm pivot 1, screw on the nut but do not tighten yet.
– Insert the bolt in the lower support (raise or lower the engine slightly
if necessary).
– Remove the trolley jack attachment 600.29.055.100 from the
engine.
1
– Plug the connector on the oil pressure switch 2, the temperature
sensor 3 and the front and rear ignition coil 4. Use cable clips to
fasten the wiring harnesses.
Art.-No. 3.206.056-E
2
3
4
– Screw the ground cable connections 5 and the positive cable onto
the starter.
Repair manual KTM LC8
5
5
– Place the chain over the pinion and rear sprocket.
– Tension the chain using the chain adjuster 6, see the owner's
manual.
– Tighten the nut on the wheel spindle to 90 Nm.
6
6
3-41
– Insert the locking pin in the pushrod.
– Mount the adapter for the hydraulic clutch 1.
– Mount the chain securing guide 2 and the adapter for the clutch
slave cylinder 3.
2
1
3
5
– Screw on the clutch slave cylinder 4 and the chainguard 5.
4
– Align the side supports and battery case against the engine, insert
the bolt 6 and mount the nut.
– Mount the bolts 7 (M10x23), lifting the engine slightly if necessary.
Tighten the nut and bolts to 45 Nm.
– Tighten the nut on the swing arm pivot to 130 Nm.
7
6
– Carefully install the oil line, mount the oil tank and tighten the
fixing bolts 8.
– Connect the return line to the oil tank and mount the spring-loaded
band-type clamp with the special pliers 600.29.057.100.
– Mount both oil lines on the oil terminal 9 with new O-rings, screw
in the screws (M6x20) with the holding plates and tighten with 10
Nm.
8
8
NOTE:
– To ensure that the oil pump can build up oil pressure more quickly,
the intake line (left) should be removed from the oil tank and
prefilled with engine oil.
– Check the hose section of the intake line for tearing - see Technical
Information.
bl
9
bk
– Create the plug-in connection bk of the gear position sensor and
secure the line with cable binders.
– Create the plug-in connection of the ignition pulse generator bl.
3-42
– Screw on the radiator together with the fan and the radiator shield
1, tighten the bolts to 10 Nm.
– Connect the water hoses on the radiator (special pliers
600.29.057.100)
– Create the electrical plug-in connection of the horn, fan motor and
temperature switch 2.
1
1
2
– Mount the lower air filter box on the intake ports.
!
5
REMOVE
CAUTION
!
THE CLOTH USED TO COVER THE INTAKE PORTS
– Place the throttle body into the lower section of the air filter box.
NOTE: The lower section of the air filter box must be raised slightly to
make room for the plug-in connection 3 of the throttle body.
– Connect the drain hose to the lower section of the air filter box.
– Connect the lower section of the air filter box to the intake flange.
– Attach the sleeves of the throttle body to the intake flange.
4
Art.-No. 3.206.056-E
NOTE: the clamps on the carburetor connection boots must be aligned
so that they can be tightened through the openings in the side covers.
– Insert the throttle body in the bellows and tighten the bellows
clamps 4.
– Connect the fuel hose 5 to the throttle body.
7 6
6
3
– Create the plug-in connection 3 of the throttle body and attach it to
the holder.
– Attach both side covers of the lower section of the air filter box and
screw them on tightly.
– Attach the manifold pressure sensors 6 to the holder and create the
plug-in connections.
– Create the plug-in connection 7 of the generator.
– Put the air filter in place, position the intake trumpet 8 and turn
counterclockwise.
– Mount the intake snorkel 9 with the frame on the air filter housing.
9
Repair manual KTM LC8
8
– Position the upper section of the air filter box, screw it in place and
connect the vent hose.
– Create the plug-in connection of the intake air temperature sensor
bk.
– Mount the vent hose bl and the hose bm of the SLS valve (special
pliers 600.29.57.100).
bl
bm
– Connect the negative terminal of the battery.
bk
3-43
– Take down the motorcycle with the help of a second person and take
the assembly stand 1 out of the footrest holder.
– Jack up the motorcycle on the link fork.
– Mount the footrests on both sides.
1
– Position the foot brake pedal and tighten the screw 2 with 25 Nm
(+ Loctite 243).
– Attach the return spring to the foot brake pedal.
– Mount the retaining pin 3 by installing the lock on retaining pin.
2
3
– Position the rear exhaust manifold and fix it with the nuts 4, but do
not tighten the nuts yet.
– Position the front exhaust manifold and fix it to the holder with the
screw 6.
– Tighten the nuts 5 of the front exhaust manifold and the nuts of the
rear exhaust manifold.
4
4
5
5
NOTE:
– in each case, one of the studs must be mounted with a sleeve that
acts as a spacer between the cylinder and the clamping plate.
– the exhaust nuts should be tightened evenly without warping the
clamping plate.
– Tighten the exhaust clamps of the front and rear exhaust manifolds.
– Tighten the screw 6 of the holder of the front exhaust manifold.
6
– Route the lines of the lambda probe, secure them with cable binders
and create the plug-in connections 7.
7
7
3-44
3
1
– Position the side stand.
– Tighten the screw 1 and the nut 2 with 45 Nm (+ Loctite 243).
– Create the plug-in connection of the side stand switch and secure
the cable with cable binders.
– Mount both side covers 3.
2
– Fill coolant into the radiator, compensating reservoir and engine: see
Chapter 12.
– Fill in engine oil: see Chapter 12.
– Position the tank on the motorcycle and screw it in place.
– Create the connection 4 of the gasoline pump and tank gauge
sender.
– Create the fuel connection 5 by connecting the two lines.
– Mount the fuel hoses and open the fuel taps 6.
6
5
4
– Position the side covers and screw them in place 7.
Repair manual KTM LC8
Art.-No. 3.206.056-E
– Mount the seat and take down the motorcycle.
– Before taking a test ride, check all hose connections for tightness.
– Check that all hoses, lines and cables are correctly seated.
7
4-1
DISASSEMBLING THE ENGINE
Repair manual KTM LC8
Art.-No. 3.206.056-E
INDEX
VALVE COVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
SPARK PLUG SHAFT INSERTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
SETTING CYLINDER REAR TO TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
CAMSHAFTS CYLINDER REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
CHAIN TENSIONER CYLINDER REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
TIMING CHAIN CYLINDER REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
DOUBLE TIMING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
CYLINDER HEAD REAR WITH CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
SETTING CYLINDER FRONT TO TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
CAMSHAFTS CYLINDER FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
OIL PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
CHAIN TENSIONER CYLINDER FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
TIMING CHAIN CYLINDER FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
CYLINDER HEAD FRONT WITH CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
OIL SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
CLUTCH COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9
PRIMARY PINION AND CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
GENERATOR COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11
ROTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11
FREEWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12
BALANCER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12
SHIFT MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12
ENGINE CASE HALF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14
OIL PUMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15
4
4-2
Clean the engine thoroughly on the outside prior to disassembling.
– Clamp the engine in the work stand using the special tool
600.29.002.000.
Valve covers
1
–
–
–
–
990 Super Duke R only: remove screw 1.
Pull out the spark plug connectors..
Unscrew the spark plugs using the special tool 600.29.073.000.
Remove the bolts 1 on the valve covers, remove both valve covers.
– Dismount the gaskets of the bolts, the valve covers and the spark
plug shafts 2.
2
2
Art.-No. 3.206.056-E
2
3
Spark plug shaft inserts
– Pull the spark plug shaft inserts out of the spark plug shafts (pry out
carefully with 2 screwdrivers if necessary), remove the O-rings 3 (2
pieces for each spark plug shaft) and discard.
Repair manual KTM LC8
4
Starter motor
– Remove both bolts 4 and pull the starter motor out of the case. The
starter motor is sealed off with an O-ring on the case side.
5
5
4-3
Setting cylinder rear to TDC
– Unscrew the plug 1 from the generator cover to be able to turn the
crankshaft.
1
– Turn the crankshaft in a counterclockwise direction until the rear
cylinder is in the TDC position. The marks 2 (points as of model
year 2007) must coincide with the flat outer surface of the cylinder
head at the camshaft gears.
NOTE: the camshaft gears are identical for both cylinders but have
marks for cylinders rear and front. Match the respective mark to the
respective cylinder, i.e. the crosses for cylinder rear and the circles for
cylinder front.
2
2
– Remove the case bolt and screw in the special tool 0113 080802
3 to block the crankshaft.
3
Camshafts cylinder rear
– Check and note down the valve clearance before you dismount the
camshafts.
Valve clearance (at 20ºC): intake 0.10 - 0.15 mm
exhaust 0.25 - 0.30 mm
– Loosen the bolts on the camshaft bearing bridge from the rear
cylinder and carefully remove the camshaft bearing bridge.
!
CAUTION
!
TIGHTENING THE BOLTS OF THE CAMSHAFT BEARING BRIDGE, MAKE SURE
THAT THE VALVES ARE NOT ACTUATED BY THE CAMSHAFT (SEE ILLUSTRATION),
OTHERWISE THE BEARING BRIDGE WILL BREAK.
WHEN
– Remove the camshafts from the cylinder head without tilting.
4-4
Chain tensioner cylinder rear
– Remove the bolt from the chain tensioner 1.
1
NOTE: measure the preload on the chain tensioner element before
dismounting:
– Apply the chain tensioner bolt to the chain tensioner element
without compressing the spring.
– Measure the distance between the sealing washer and the cylinder
head.
The measured value should be between 6 mm and 11 mm. If the value
is lower, the tensioning rail could be worn or the timing chain
excessively elongated. If it is higher, the engine was turned to TDC
against the running direction.
– Remove the sealing washer.
– Pull out the chain tensioner element 2.
Art.-No. 3.206.056-E
NOTE: the housing and the tensioning piston on the chain tensioner
element are compression molded. If they fall apart during disassembly,
the chain tensioner element must be replaced.
2
Timing chain cylinder rear
Repair manual KTM LC8
NOTE: Valid up to and including model year 2006
– Loosen the bearing bolt 3 on the double timing gear and pull out of
the cylinder head together with the needle bearing. The double
timing gear will slide down slightly, relieving the timing chain.
NOTE: Valid as of model year 2007
– Remove the screw of the bearing bolt 4 and carefully press out the
bearing bolt 4 with a screwdriver. The timing gear slips down easily
and the timing chain loosens.
3
4
A
5 6
7
– Remove the O-ring on the bearing bolt.
– Use a wire hook A which you can bend from a piece of welding wire
to lift the side of the chain 5 towards the inside from the chain
teeth 6 over the gear teeth 7 of the double timing gear. Hold the
double timing gear towards the outside by inserting your finger
through the hole for the bearing bolt.
4-5
Double timing gear
– Lift the double timing gear out of the cylinder head, letting the
chain fall into the slot.
1
2
Cylinder head rear with cylinder
– Remove the outer nut 1.
– Loosen the cylinder-head nuts crosswise.
600.29.083.000 is required for the inside nuts 2.
Special
nut
– Pull the cylinder head and cylinder up until the piston-pin retainer
can be lifted out of the groove on the generator side with a suitable
screwdriver.
NOTE: the piston-pin retainer can easily be removed if the piston is
held in place by the cylinder.
– Press the piston pins out of the piston by hand and remove the
cylinder together with the piston.
– Discard the cylinder-base gasket.
Setting cylinder front to TDC
Loosen the crankshaft locking bolt and continue to turn the engine
towards the front cylinder's TDC position, keeping the timing chain on
the rear cylinder slightly tensioned and holding the conrod in the
center of the opening in the case.
!
CAUTION
!
YOU DO NOT HOLD THE CHAIN, IT MAY GET JAMMED BETWEEN THE TIMING
GEAR OF THE BALANCER SHAFT AND THE TENSIONING RAIL.
IF THE CONROD IS NOT POSITIONED IN THE CENTER OF THE OPENING IN THE
CASE, THE CONROD BOTTOM WILL BLOCK ON THE BALANCER SHAFT AND
PREVENT THE CRANKSHAFT FROM TURNING.
– IF
–
– Turn the crankshaft until the front cylinder is in the TDC position.
The marks 3 (circles) must coincide with the flat outer surface of
the cylinder head at the camshaft gears.
3
3
– The same camshaft gears are used in both cylinders but they have
marks for cylinder rear and front. Use the camshaft gear marked
with a cross for cylinder rear and the camshaft gear marked with a
circle for cylinder front cylinder.
– Block the crankshaft again.
4-6
Camshafts cylinder front
– Check and note down the valve clearance before you dismount the
camshafts.
Valve clearance (at 20ºC): intake 0.10 - 0.15 mm
exhaust 0.25 - 0.30 mm
– Loosen the bolts on the camshaft bearing bridge from the front
cylinder and carefully remove the camshaft bearing bridge.
!
CAUTION
!
TIGHTENING THE BOLTS OF THE CAMSHAFT BEARING BRIDGE, MAKE SURE
THAT THE VALVES ARE NOT ACTUATED BY THE CAMSHAFT (SEE ILLUSTRATION),
OTHERWISE THE BEARING BRIDGE WILL BREAK.
WHEN
– Remove the camshafts from the cylinder head without tilting.
Oil pressure switch
– Loosen the oil pressure switch 1 and unscrew. Discard sealing
washer.
1
Chain tensioner cylinder front
Art.-No. 3.206.056-E
– Remove the bolt on the chain tensioner 2.
NOTE: measure the preload on the chain tensioner element before
dismounting:
– Apply the chain tensioner bolt to the chain tensioner element
without compressing the spring.
– Measure the distance between the sealing washer and the cylinder
head.
2
The measured value should be between 6 mm and 11 mm. If the value
is lower, the tensioning rail could be worn or the timing chain
excessively elongated. If it is higher, the engine was turned to TDC
against the running direction.
Repair manual KTM LC8
– Remove the sealing washer.
– Pull out the chain tensioner element 3.
NOTE: the housing and the tensioning piston on the chain tensioner
element are compression molded. If they fall apart during disassembly,
the chain tensionerelement must be replaced.
3
4-7
Timing chain cylinder front
1
NOTE: Valid up to and including model year 2006
– Loosen the bearing bolt 1 on the double timing gear and pull out of
the cylinder head together with the needle bearing. The double
timing gear will slide down slightly, relieving the timing chain.
NOTE: Valid as of model year 2007
– Remove the screw of the bearing bolt 2 and carefully press out the
bearing bolt 4 with a screwdriver. The timing gear slips down easily
and the timing chain loosens.
2
3
A
– Remove the O-ring on the bearing bolt.
– Use a wire hook A which you can bend from a piece of welding wire
to lift the side of the chain 3 towards the inside from the chain
teeth 4 over the gear teeth 5 of the double timing gear. Hold the
double timing gear towards the outside by inserting your finger
through the hole for the bearing bolt.
4
– Lift the double timing gear out of the cylinder head, letting the
chain fall into the slot.
5
6
7
Cylinder head front with cylinder
– Remove the outer nut 6.
– Loosen the cylinder-head nuts crosswise.
600.29.083.000 is required for the inside nuts 7.
Special
nut
– Pull the cylinder head and cylinder up until the piston-pin retainer
can be lifted out of the groove on the clutch side with a suitable
screwdriver.
NOTE: the piston-pin retainer can easily be removed if the piston is
held in place by the cylinder.
– Press the piston pins out of the piston by hand and remove the
cylinder together with the piston.
– Discard the cylinder-base gasket.
4-8
Water pump
– Remove the water pump cover 1, discard the O-ring gasket.
NOTE: also remove the 2 dowel pins used to keep the water pump
cover in a central position.
1
– Hold the water pump wheel with special tool 600.29.082.000,
remove the bolt 2 and pull the water pump wheel 3 off of the
shaft.
2
NOTE:
– The bolt and the water pump wheel only need to be removed if the
water pump will be serviced. They do not need to be removed if you
are only dismounting the clutch cover.
– If the water pump wheel cannot be removed because it is being held
by residual thread adhesive, the water pump shaft and the water
pump wheel can be pressed out from the inside later.
!
3
CAUTION
!
IF
YOU TRY TO LOOSEN THE BOLT ON THE WATER PUMP WITHOUT USING SPECIAL
TOOL 600.29.082.000, YOU MAY BREAK THE DRIVER ON THE BALANCER SHAFT
OR WATER PUMP SHAFT.
Oil screen
Art.-No. 3.206.056-E
– Remove the oil screen cover 4.
– Carefully pull the oil screen 5 out of the clutch cover with a pair of
pliers.
5
4
Clutch cover
6
– Remove the bolts and detach the inner clutch cover together with
the outer clutch cover. Be careful not to lose the dowel pins.
Repair manual KTM LC8
NOTE:
– The outer clutch over can remain on the inner clutch cover if you
also remove the bolt 6 on the outer clutch cover.
– If the case bolt for the blocking hole is still mounted, it must also be
removed.
– A vibration damper 7 is mounted in the outer clutch cover from the
2005 model; do not loosen the screw 8.
!
CAUTION
!
THE SCREW ON THE VIBRATION DAMPER IS LOOSENED, A NEW OUTER CLUTCH
COVER WITH A VIBRATION DAMPER OR THE OLD CLUTCH COVER WITHOUT THE
VIBRATION DAMPER MUST BE USED SINCE THE SELF-CUTTING SCREW 8 CANNOT BE
ADEQUATELY SECURED. IF YOU REMOUNT THE VIBRATION DAMPER WITH THE SCREW,
THE SCREW CAN BECOME LOOSE AND DAMAGE THE ENGINE.
IF
7
8
4-9
Clutch
– Remove the bolts on the clutch springs crosswise and lift off the
pressure cap.
– Pull out the clutch push rod.
– Insert a wire hook in the recess in the clutch disks and pull all of
the clutch disks out of the clutch hub.
NOTE: leave the spring washer and supporting ring in the clutch. They
will be detached together with the inner clutch hub, at which time they
can be easily removed.
A
– Slip on the holder for the inner clutch hub A 600.29.003.000,
counteract the inner clutch hub and loosen the nut (32 mm).
– Pull off the inner clutch hub together with the clutch pressure
booster and the underlying washer, which usually adheres to the
inner clutch hub.
NOTE: you do not need to dismount the primary pinion if you are only
replacing the outer clutch hub:
– Remove the engine locking bolt 0113 080802.
– Continue turning the crankshaft until the flat part of the pickup ring
1 coincides with the teeth on the outer clutch hub.
1
2
– Pull the needle bearing 2 out of the outer clutch hub with a
suitable screwdriver, carefully pushing the outer clutch hub back
and forth.
– Press the outer clutch hub away from the primary pinion and
remove.
NOTE: the gear for the oil pump drive is located on the back of the
outer clutch hub and can easily fall down.
4-10
Primary pinion and clutch
3
2
1
If you are completely dismounting the engine, the primary pinion must
be detached before you remove the clutch.
– Mount the special tool 0113 080802 (engine locking bolt) and hold
the crankshaft in the rear or front cylinder's TDC position.
– Unscrew the pickup 1.
– Loosen the nut 2 of the primary pinion (46 mm, LH thread) and
remove together with the washer.
– Loosen the nut 3 of the balancer shaft (30 mm) and remove
together with the washer.
– Pull the outer clutch hub away from the housing until the pickup
ring 4 can be removed. It is secured by a pin.
– Completely remove the outer clutch hub together with the needle
bearing.
NOTE:
– The gear for the oil pump drive is located on the back of the outer
clutch hub and can easily fall down.
– Remove the spacing washer inserted between the gear for the oil
pump drive and the bearing which may adhere to the bearing.
4
Art.-No. 3.206.056-E
Up to the 2004 model:
– Pull off the gear on the balancer shaft 5.
5
– From the 2005 model:
– Remove the spring washer 6.
– Use the special tool 600.29.050.000 to turn the tensioning wheel
7 in a counterclockwise direction until the tensioning wheel and
the drive wheel are retained by each other S.
Repair manual KTM LC8
– Remove the tensioning wheel 7, tension spring 8 and drive wheel
9 together.
S
NOTE:
– If the spreader components do not need to be serviced, the
tensioning wheel, tension spring and drive wheel do not need to be
taken apart.
– If the spreader components are removed and separated, they must
be preassembled before remounting (see Chapter 5).
– If you cannot remove the drive wheel from the balancer shaft, pull it
off using the extractors 590.29.021.044 and 600.29.058.000 evenly, do not tilt!
6
7
8
9
4-11
2
– Insert the pressure tool 600.29.031.000 1 in the crankshaft bore,
turn the balance weight up and pull the primary pinion 2 off the
crankshaft with the puller 600.29.033.000.
1
– Remove the balance weight 3 from the balancer shaft; carefully pry
the woodruff key out of the shaft groove with a screwdriver.
– Slip off the timing chain and pull the engine sprocket off of the
balancer shaft.
– Unscrew the chain tensioning rail 4.
4
NOTE:
– if you intend to reuse the timing chain, engine sprocket and chain
tensioning rail, mark the running direction and the cylinder
allocation.
– If you cannot remove the balance weight from the balancer shaft,
pull it off using the extractors 590.29.021.044 and
600.29.058.000.
3
Generator cover
5
6
– Loosen all of the bolts on the generator cover except the bolt on the
starter idler shaft 5 and remove the generator cover, being careful
not to lose the dowel pins. Discard the gasket.
NOTE: the rotor's magnetic retaining force will prevent the cover from
being removed easily.
– Bend up the lock washer, unscrew the nut 6 and remove the engine
sprocket together with the lock washer.
Rotor
7
– Remove the upper starter idler gear 7.
– Remove the rotor bolt 8 and the washer.
8
– Screw the pressure screw 9 600.29.009.010 (up to the 2004
model) or 600.29.009.110 (from the 2005 model) into the
crankshaft.
!
9
CAUTION
!
HOLE IN THE CRANKSHAFT HAS A FINE THREAD FROM THE 2005 MODEL. IF
YOU USE THE PRESSURE SCREW 600.29.009.010 YOU WILL DESTROY THE
THREAD.
THE
– Pull the rotor off of the crankshaft using the puller 600.29.009.000
bk; remove the pressure bolt and the engine locking bolt.
bk
4-12
Freewheel
– Remove the freewheel lock 1 and lift the freewheel 2 of the
crankshaft.
– Pull the lower starter idler gear 3 from the balancer shaft.
3
2
1
Balancer shaft
– Gently tap the balancer shaft off on the clutch side with a rubber
hammer.
!
MAKE
CAUTION
!
SURE THE TIMING CHAIN DOES NOT GET CAUGHT.
NOTE: a stop disk is located on the outside of the roller bearing on the
balancer shaft (on the clutch side) which should be removed before the
balancer shaft is dismounted.
– Remove the timing chain and unscrew the tensioning rail.
NOTE: if you intend to reuse the timing chain and chain tensioning
rail, mark the running direction and the cylinder allocation.
Art.-No. 3.206.056-E
Shift mechanism
– Push the shift rail 4 away from the shift locating drum and pull out
the shift shaft 5.
– Remove the bolt 6 from the shift locating drum.
5
4
Repair manual KTM LC8
8
7
6
– Press the locking lever 7 down to relieve the shift locating drum 8,
remove the shift locating drum.
– Loosen the bolt and remove the locking lever 9 (not required for
further engine removal).
4-13
Engine case half
– Remove the gear shift sensor 1 with the pin and spring. Unscrew
the oil filter cover 2, discarding the gasket on the oil filter cover
and the oil filter.
– Unscrew all HH bolts accessible from the generator side.
2
1
– Tilt the case horizontally with the generator side up.
– Lift the case half of the generator side while lightly tapping the drive
shaft with a rubber hammer. If necessary, tap the drive shaft
downwards.
!
CAUTION
DO
!
NOT USE A SCREWDRIVER OR SIMILAR TOOL TO PRY THE CASE HALVES APART
SINCE THIS MAY DAMAGE THE SEALING AREAS.
– Discard the case gasket.
– Remove the crankshaft from the case.
4-14
Transmission
1
– Remove the oil rail 1 for the transmission lubrication. It is secured
at the bottom to keep it from twisting.
NOTE: the oil rail is sealed with 2 O-rings from the 2005 model which
should be replaced.
– Pull out the shift rails 2 together with the upper shift rail springs.
2
2
3
3 5
– Tilt the shift forks 3 to the side; watch the shift rollers 4 while you
remove the shift drum 5.
– Remove the shift forks and the lower springs of the shift rails.
4
4
43
Art.-No. 3.206.056-E
– Bring the engine into a vertical position (mounting position) and
remove the lock ring 6 and washer from the countershaft.
6
– Simultaneously pull both transmission shafts out of the bearing
seats.
Repair manual KTM LC8
NOTE: also remove the spacing washer on the countershaft which often
adheres to the bearing.
4-15
Oil pumps
– Remove the lock ring 1 from the oil pump shaft; remove the
spacing washer 2 and oil pump gear 3.
– Pull the needle roller 4 out of the pump gear and remove the
washer underneath.
1
3
2
4
– Loosen the bolts on the outer oil pump 5 (pressure pump) and
remove the oil pump housing.
5
NOTE: the centering pins are usually retained in the oil pump housing;
if they are retained, pull them out with pliers.
– Remove the inner oil pump 6 (suction pump).
6
– Remove the suction pump's inner and outer rotor (7 and 8) from
the oil pump shaft.
– Pull the needle roller 9 out of the oil pump shaft.
7
8
9
– Pull the oil pump shaft and the two pressure pump rotors out of the
engine housing.
– Remove both rotors from the oil pump shaft and pull out the needle
roller.
5-1
SERVICING INDIVIDUAL COMPONENTS
Repair manual KTM LC8
Art.-No. 3.206.056-E
INDEX
ROLLER BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
MAIN BEARINGS - GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3
REPLACING BEARING SHELLS, OUTPUT END . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
REPLACING BEARING SHELLS, GENERATOR END . . . . . . . . . . . . . . . . . . . . . . . .5-4
REPLACING THE CONROD BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5
SELECTING THE BEARING SHELLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5
REPLACING THE SUPPORTING BEARINGS IN THE CLUTCH COVER . . . . . . . . . . . .5-6
OVERHAULING THE WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7
CHECKING THE SUCTION PUMP FOR WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
CHECKING THE PRESSURE PUMP FOR WEAR . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
BYPASS VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
DISASSEMBLING THE CYLINDER HEAD AND CHECKING
PARTS FOR WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9
CHECKING THE PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10
ASSEMBLY INSTRUCTIONS FOR PISTON RINGS . . . . . . . . . . . . . . . . . . . . . . . .5-10
CHECKING THE PISTON RING END GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10
MEASURING PISTONS + CYLINDERS, ESTABLISHING THE PISTON
MOUNTING CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10
PISTON AND CYLINDER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11
ASSEMBLING THE CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11
GENERATOR COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13
TORQUE LIMITER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13
VALVE GEAR – CHECKING PARTS FOR WEAR . . . . . . . . . . . . . . . . . . . . . . . . . .5-13
PREASSEMBLING THE SPREADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14
CLUTCH – CHECKING PARTS FOR WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15
SHIFT MECHANISM – CHECKING PARTS FOR WEAR . . . . . . . . . . . . . . . . . . . . .5-16
PREASSEMBLING THE SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16
GENERAL INFORMATION ON SERVICING THE TRANSMISSION . . . . . . . . . . . . . .5-17
ASSEMBLING THE MAIN SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-17
ASSEMBLING THE COUNTERSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18
CHECKING THE FREEWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-19
REPLACING THE FREEWHEEL HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-19
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-19
5
5-2
Replacing the roller bearing
1
A
1
– Remove all bearing locking bolts 1 from both case halves.
NOTE:
– Additional oil jets are installed from the 2005 model; they should
also be removed to prevent them from being bent.
– the output-end antifriction bearing on the countershaft mounted by
KTM does not have a sealing from the 2005 model. An antifriction
bearing with a one-sided sealing is provided for repair; to keep it
from blocking the lubrication, the open side must point towards the
inside (towards the center of the housing).
A
A
1
Art.-No. 3.206.056-E
1
2
– Remove all shaft seal rings and the dowel pins from the case halves.
Heat both case halves evenly in an oven at 150° C; the roller bearings
will fall out of the case by themselves. If any roller bearings should be
left in the case, tap the case lightly on a flat wooden surface.
NOTE: the shift shaft bearing 2 must be pressed out with the pressing
tool 600.29.043.030, although this bearing is usually highly resistant
to wear.
4
– Replace all of the roller bearings. The new roller bearings can be
inserted by hand until flush as soon as the case temperature has
reached approx. 150° C. The roller bearings should fit tightly after
cooling down. Use a mandrel to carefully press in any bearings that
are not flush with the surface.
3
Repair manual KTM LC8
NOTE: the shift shaft bearing 2 must be pressed in flush with the
pressing tool 600.29.043.030.
5
– Press in the shaft sealing ring 3 for the push rod until flush using
the special tool 600.29.043.010.
– Press in the shaft sealing ring for the countershaft 4 until flush
using the special tool 600.29.043.020.
– Press in the shaft sealing ring for the shift shaft 5 until flush using
the special tool 600.29.043.030.
– Apply Loctite 243 to all bearing locking bolts 1 and tighten to 6 Nm.
6
7
– Remove all of the oil jets, blow compressed air through the oil ducts
and screw the oil jets back on.
NOTE:
– Size "60" jets are used to lubricate the timing chains, size "90" jets
for the piston cooling.
– Starting with engine number 2-600-02549, a size "30" reducing
sleeve 6 is screwed into the outer bore 7 on the outside of the left
housing half to supply the clutch and the pushrod with oil. This jet
should be retrofitted in all engines of an earlier make.
5-3
Replacing the main bearings-general information
NOTE:
– The bearing shells for the friction bearings are pressed in and out in
a cold state.
– Mark the position of the bearing end gap 1 on the engine case with
a felt-tip pin to facilitate reassembly.
1
2
NOTE: the main bearing shells have retaining brackets to hold them in
position from the 2005 model; they must be removed before the main
bearing shells are pressed out and mounted again after the main
bearing shells are remounted; apply Loctite 243 to the screws and
tighten to 6 Nm.
– Press the main bearing shells out of both engine case halves from
the inside to the outside using the press mandrel 600.29.044.050 2.
Before you select the bearing shells you must measure the crankshaft.
– Measure the diameter of the two main bearing pins at 3 points that
are 120° apart using a micrometer gauge. This only applies to
crankshafts that you will continue to use.
Diameter of main bearing pin: 49.965 mm – 49.975 mm (yellow)
49.976 mm – 49.985 mm (blue)
49.986 mm – 49.995 mm (red)
NOTE:
– Use the bearing color indicated for the respective measurement.
– The crankshaft must be replaced if the measurement falls short of
the minimum diameter or if the crankshaft is worn.
– New crankshafts do not need to be measured. Use new bearings
according to the colored circles 3 marked on the crankshaft web of
the new crankshaft.
3
NOTE:
– there are 2 types of bearings for each bearing color – the grooved
bearing shell (with the lubricating groove and oil bore) is pressed
into the top of the case half of the generator end and the smooth
bearing shells (without lubricating groove) are pressed into the
bottom of the case half of the generator end and into the case half
of the output end - applicable for models up to the 2004 model.
– Bearing shells with grooves on the top and bottom (with lubricating
groove and lubrication bore) are mounted on the generator end of
the housing half from the 2005 model.
– A new crankshaft comes with 2 grooved bearing shells. They can
also be installed in engines preceding the 2004 model.
!
CAUTION
!
IF
YOU MOUNT A BEARING SHELL THAT IS SMOOTH ON THE BOTTOM ON THE
GENERATOR END OF THE ENGINE FROM THE 2005 MODEL, THE WATER JET TO
COOL THE PISTON WILL NOT BE SUPPLIED WITH LUBRICATING OIL AND WILL LEAD TO
DAMAGE.
– Measure the bearing bores with a micrometer to ensure that the
bearing shells are seated firmly in the engine case after being
pressed in.
Nominal dimension: 54.000 mm – 54.015 mm
NOTE: if the bearing bores are too big, the engine case must be
replaced.
Measure the inner diameter of the bearings after they are pressed in to
ensure that the bearing clearance is correct.
NOTE: the inner diameter of the bearings must be measured at a 90°
angle to the bearing end gap.
The diameter of the main bearing pin must be deducted from the inner
diameters of the bearings, the difference is the radial clearance of the
main bearing.
Setpoint value for the radial clearance of the main bearing:
0.025 mm – 0.055 mm
Wear limit: 0.080 mm
Example: Inner bearing diameter measured 50.020 mm
Main bearing pin measured 49.980 mm
50.020 – 49.980 = 0.040 mm radial clearance
5-4
Replacing bearing shells, output end
– Center the new bearing shells (both smooth) with the assembling
sleeve 600.29.044.050 1. The assembling sleeve is beveled on
one side so the bearing shells can be pushed in easily. The bearing
shells should protrude 1-2 mm on the other side of the assembling
sleeve to make it easier to position them in the engine case.
1
– Position the bearing shells on the output end of the case such that
the end gap on the bearing shells points to the marks 2 made when
disassembling.
2
Art.-No. 3.206.056-E
– Press in the bearings from the outside to the inside through the
assembling sleeve up to the stop using the press mandrel
600.29.044.050 3.
!
3
–
–
CAUTION
!
ALWAYS PRESS IN BEARING SHELLS FROM THE OUTSIDE TO THE INSIDE
OTHERWISE THEY WILL NOT BE POSITIONED CORRECTLY AND THE BEARING RADII
OF THE CRANKSHAFT WEBS WILL PRESS AGAINST THE BEARING SHELLS. THIS IS
WHY THE BEARING SHELLS ARE SEATED 2 MM BELOW THE EDGE OF THE
BEARING BORE.
THE ASSEMBLING SLEEVE SERVES AS A STOP. IT IS NOT REMOVED UNTIL THE
BEARING SHELLS ARE SEATED IN THE CORRECT POSITION.
Replacing bearing shells, generator end
– Center the new bearing shells (smooth on the bottom, grooved on
top up to the 2004 model, both grooved from the 2005 model) with
the assembling sleeve 600.29.044.050 – same procedure as for the
bearing shells, output end (see above).
– Position the bearing sleeves at the generator end of the case with
the bearing shell end gap pointing to the marks 4 made when
disassembling. Do not cover the oil bore.
– Press the bearings into the engine case half from the outside to the
inside through the assembling sleeve up to the stop using the
special tool 600.29.044.050.
Repair manual KTM LC8
!
–
–
–
–
4
CAUTION
!
ALWAYS PRESS IN BEARING SHELLS FROM THE OUTSIDE TO THE INSIDE OTHERWISE
THEY WILL NOT BE POSITIONED CORRECTLY AND THE BEARING RADII OF THE
CRANKSHAFT WEBS WILL PRESS AGAINST THE BEARING SHELLS. THIS IS WHY THE
BEARING SHELLS ARE SEATED 2 MM BELOW THE EDGE OF THE BEARING BORE.
THE ASSEMBLING SLEEVE SERVES AS A STOP. IT IS NOT REMOVED UNTIL THE
BEARING SHELLS ARE SEATED IN THE CORRECT POSITION.
IF THE BEARING SHELLS ARE INCORRECTLY ALIGNED OR IF SMOOTH BEARING
SHELLS ARE PRESSED IN ON TOP, THE OIL SUPPLY TO THE SPRAYING NOZZLES
TO COOL THE PISTONS AND LUBRICATE THE TIMING CHAIN WILL BE
INTERRUPTED, LEADING TO SERIOUS ENGINE DAMAGE.
IF A SMOOTH BEARING SHELL IS INSTALLED ON THE GENERATOR END IN ENGINES
STARTING WITH THE 2005 MODEL, THE WATER JET TO COOL THE PISTONS WILL
NOT BE SUPPLIED WITH LUBRICATING OIL AND WILL LEAD TO DAMAGE.
NOTE:
– After replacing all friction and roller bearings, dismount the spraying
nozzles and oil nozzles and clean the oil ducts with compressed air
to make sure they are not clogged.
– Coat the friction bearings with Molycote grease.
Apply Loctite 243 to the spraying nozzles and oil nozzles and tighten to 6 Nm.
5-5
Replacing the conrod bearings
– Clamp each conrod in a vise using protective jaws.
– Loosen the bolts 1 on the conrod bearing covers with the special
wrench socket 600.29.075.000 and remove the bearing covers.
1
NOTE: mark the conrod caps to ensure that each cap is mounted to the
same conrod when it is measured and assembled.
– Remove the conrod caps.
– Clean the crankshaft and blow compressed air through the
lubrication bores.
Selecting the bearing shells
Before you select the new bearing shells you must measure the conrod
journal.
– Measure the diameter of the conrod journal at 3 points that are
120° apart using a micrometer gauge.
Diameter of the conrod journal:
41.978 mm – 41.989 mm (yellow)
41.990 mm – 42.000 mm (blue)
42.001 mm – 42.011 mm (red)
NOTE:
– Use the bearing color indicated for the respective measurement.
– The crankshaft must be replaced if the measurement falls short of
the minimum diameter or if the crankshaft is worn.
– Clamp each conrod in a vise, insert new bearing shells, position the
crankshaft with a plastigauge measuring strip A (600.29.012.000)
on top and mount the conrod caps with the old bolts, as described
below.
!
–
–
CAUTION
!
INSERT THE PLASTIGAUGE MEASURING STRIPS AT A 90° ANGLE TO THE BEARING
END GAP.
DO NOT TURN THE CONRODS ON THE CONROD JOURNAL.
– Unclamp the conrods and compare the width of the plastigauge
measuring strip with the information on the packing. The width of
the plastiguage measuring strip is equivalent to the bearing
clearance.
A
Setpoint value of the conrod bearing clearance:
0.030 mm – 0.060 mm
Wear limit: 0.080 mm
– Clamp each conrod in a vise using protective jaws, apply a thin layer
of Molycote grease to the bearing shells, position the crankshaft and
mount the conrod caps with new bolts.
2
2
!
CAUTION
!
THE
BEARING SHELLS SHOULD BE MOUNTED IN AN OFFSET POSITION IN THE
CONROD TO ALLOW ROOM FOR THE CRANKSHAFT RADIUS 2. IF THE CONRODS ARE
MOUNTED BACKWARDS, THE BEARING SHELLS WILL EXERT PRESSURE ON THE
RADIUS AND BLOCK THE CONRODS.
– Tighten the conrod bearing bolts with the special wrench socket
600.29.075.000 to 25 Nm (1st stage). The tighten to 30 Nm (2nd
stage) and finally by another 60° (3rd stage).
3
NOTE: use a degree wheel 3 (600.29.010.000) to make sure the
conrod bearing bolts are tightened correctly.
5-6
Replacing the supporting bearings in the clutch cover
– Pull the bearing shells out of the clutch cover using the puller
151.12.017.000 and the internal extractor 600.29.018.000 1.
1
– Measure the diameter of the bearing pin at 3 points that are 120°
apart using a micrometer gauge.
Diameter of the supporting bearing pin: 27.985 mm – 28.000 mm
NOTE: The crankshaft must be replaced if the measurement falls short
of the minimum diameter or if the crankshaft is worn.
Art.-No. 3.206.056-E
– Center the new bearing shells with the assembling sleeve
600.29.046.028 2. The assembling sleeve is beveled on one side
so the bearing shells can be pushed in easily. The bearing shells
should protrude 1-2 mm on the other side of the assembling sleeve
to make it easier to position them in the clutch cover.
2
Repair manual KTM LC8
3
– Place the bearing shells on the clutch cover with the assembling
sleeve and press in the bearing shells to the stop using the press
mandrel 600.29.046.028 3.
5-7
Overhauling the water pump
– Remove the washer 1 from the water pump shaft and pry the shaft
sealing ring 2 out of the case.
NOTE: if the water pump wheel cannot be removed because it is being
held by residual thread adhesive, the water pump shaft and the water
pump wheel can be pressed out from the inside after the lock ring 4 is
removed.
2
1
4
– Remove the outer lock ring 3 from the water pump shaft using
suitable pliers.
– Press the water pump shaft out of the bearing from the outside to
the inside. The inner lock ring 4 does not need to be removed.
– Heat the case evenly in an oven at 150° C; the old bearing will fall
out of the bearing seat by itself and the new bearing can easily be
pressed into the bearing seat by hand. The bearing should fit flush
and tightly after it cools down. If not, press in with the pressing tool
600.29.043.060.
– Insert the water pump shaft in the new bearing from the inside to
the outside.
3
NOTE: the recess in the water pump shaft should point towards the
inside.
– Mount the lock ring 3.
5
– Place the protective sleeve 5 585.29.005.000 on the pump shaft
and press in a new shaft sealing ring 2 until flush using the
pressing tool 600.29.043.040. Mount the washer 1.
NOTE: To replace the water pump seal ring see Technical Information,
Chapter 1.
2
5-8
A
A
Checking the suction pump for wear
– Insert both suction pump rotors in the housing.
– Use a feeler gauge A to check the clearance between the inner and
outer rotor:
Setpoint value: 0.1 mm
Wear limit: 0.2 mm
– Use a feeler gauge A to check the clearance between the outer rotor
and the housing:
Setpoint value: 0.2 mm
Wear limit: 0.4 mm
– Use a feeler gauge A and a straight edge B to check the axial
clearance:
B
Setpoint value: 0.04 mm – 0.09 mm
Wear limit: 0.25 mm
A
Art.-No. 3.206.056-E
A
A
Checking the pressure pump for wear
– Insert both pressure pump rotors in the case.
– Use a feeler gauge A to check the clearance between the inner and
outer rotor:
Setpoint value: 0.1 mm
Wear limit: 0.2 mm
– Use a feeler gauge A to check the clearance between the outer rotor
and the case:
Setpoint value: 0.2 mm
Wear limit: 0.4 mm
– Use a feeler gauge and a straight edge to check the axial clearance:
Setpoint value: 0.04 mm – 0.09 mm
Wear limit: 0.25 mm
Bypass valve
1
– Remove the lock ring 1 on the bypass valve using suitable pliers
and take the individual bypass valve parts out of the housing.
Repair manual KTM LC8
NOTE: the spring is pretensioned.
– Check parts for visible wear and damage.
– Measure the length of the pressure spring:
Minimum length of pressure spring: 42.0 mm
– Clean parts, oil the pistons and insert in the bore. Position the
spring, place a washer on the spring and mount the lock ring in the
groove using suitable pliers.
NOTE: different pistons were installed starting with engine number
2-600-00773. Engines of an earlier make must be converted; see
Technical Information, Chapter 1.
5-9
Disassembling the cylinder head and checking parts for wear
NOTE: the illustration shows the font cylinder. The procedure for the
rear cylinder is identical.
1
– Pull all of the bucket tappets 1 out of the cylinder head.
NOTE:
– Note down the mounting position to ensure that the same bucket
tappet is inserted in the same bore during installation.
– The compensating washers 2 for the valve clearance (shims) usually
adhere to the bottom of the bucket tappets and should be set aside
together with the bucket tappets.
2
– Invert the cylinder and cylinder head and remove the three Allen
bolts 3 and nuts.
– Remove the cylinder and pistons from the cylinder head and discard
the cylinder head gasket.
– Unscrew the chain guide.
3
3
3
– Press the valve springs together using the valve assembling tool
(590.29.019.000 with the attachment 600.29.041.000 4) and
remove the valve spring key from the valve shaft. Relieve the springs
and remove from the cylinder head.
4
NOTE: note down the mounting position of the valves to ensure that
the valves are mounted in the same position during installation.
– Pull the valve shaft seal off the valve shaft with pliers and remove
the valve spring washer.
NOTE: a washer (14x30x2) is located under the spring retainers for the
exhaust valve springs to increase the spring preload.
– Repeat the above procedure for the other valves.
– Clean all parts.
Sealing area
Check the spark plug thread and valve seats for damage or cracks. Use
a straight edge A and a feeler gauge B to check the sealing area to
the cylinder for distortion. Max. distortion: 0.05 mm.
A
B
Valve seats
The valve seats may not be impacted. Width of sealing seat: intake
max. 1.8 mm; outlet max. 2.0 mm. Reseat the valves if necessary.
Valves
Check the valve disk for wear and runout. The valve disk runout should
not exceed 0.03 mm. The valve seat may not be impacted. The sealing
area should be in the middle of the valve seat. The valve shaft is hardchrome-plated. Wear usually occurs at the valve guide.
C
Valve guides
The valve guides are checked with the limit plug gauge C
590.29.026.006 (Ø 6.05 mm). If the limit plug gauge can easily be
pushed into the valve guide, the valve guide needs to be replaced at a
special workshop.
Valve springs
Check the valve springs for fractures or other wear. Measure the spring
length with a sliding caliper in an unloaded condition:
Minimum length of inner spring: 38.0 mm (950) or 37.0 (990)
Maximum length of outer spring: 41.3 mm (950) or 41.2 (990)
5-10
Checking the pistons
– Mark the position of the piston arrow in the cylinder to facilitate
reassembly and to ensure that the same piston is mounted in the
same cylinder again.
– Press the piston up out of the cylinder.
– Replace the piston if oil consumption is high or the piston skirt is
excessively grooved.
– If the piston is to be reinstalled:
1. Check the piston bearing surface for damage.
2. Piston ring grooves: the piston rings must move freely in the groove.
Use old piston rings or sandpaper (400 grit) to clean the piston ring
grooves.
3. Check the piston rings for damage and end gap.
4. The piston pins must move freely in the bolt hole when mounted.
Replace piston pins that are badly discolored or have visible running
marks. Place the piston pin in the conrod and check for clearance.
Maximum clearance in the conrod eye: 0.08 mm.
A
NOTE: the piston pin may not have any clearance when mounted and
should be easy to move when applying slight counterpressure.
Checking the piston ring end gap
– Insert the piston ring in the cylinder and align with the piston
(approx. 10 mm under the upper edge of the cylinder).
– Measure the end gap with a feeler gauge A.
Piston ring end gap: max. 0.50 mm
If the end gap is larger than indicated above, check the cylinder for
wear. If the cylinder wear is within the tolerance limits, replace the
piston ring.
Art.-No. 3.206.056-E
Assembly instructions for piston rings
– Mount the oil scraper ring in the lower piston ring groove with the
mark facing the piston head.
– Mount the compression ring in the middle piston ring groove with
the mark facing the piston head.
– Mount the compression ring in the upper piston ring groove with the
mark facing the piston head.
Measuring pistons and cylinders, establishing the piston
mounting clearance
– To establish cylinder wear, use a micrometer to measure the cylinder
in the middle of the bearing surface.
– Measure the X and Y axis of the cylinder diameter to establish any
ovality.
x
Repair manual KTM LC8
y
– Measure the piston at the piston skirt across the piston pin, 9 mm
from the lower edge.
950:
990:
Piston size I: 99.953 mm – 99.967 mm
Piston size II: 99.963 mm – 99.977 mm
Wear limit: 99.930 mm
Piston size I: 100.943 mm – 100.957 mm
Piston size II: 100.953 mm – 100.967 mm
Wear limit: 100.930 mm
– The piston mounting clearance is the difference between the
smallest cylinder diameter and the piston diameter.
Piston mounting clearance 950: 0.04 mm – 0.06 mm
Wear limit: 0.10 mm
Piston mounting clearance 990: 0.05 mm – 0.07 mm
Wear limit: 0.10 mm
5-11
Piston and cylinder identification
The cylinder size 1 is impressed in the bottom of the cylinder near the
chain tunnel; 1 is size I, 2 is size II.
1
The piston size 2 is impressed in the top of the piston; 1 is size I, 2 is
size II.
2
Assembling the cylinder head
– Slide the valve spring washers 3 over the valve guides and mount
new valve shaft seals 4.
– Lubricate the valve shafts and insert the valves in their original
position in the valve guides.
7
6
5
4
3
NOTE:
– A washer to increase the spring preload is located under the spring
retainers.
– A washer with a thickness of 1 mm was installed up to engine
number 2-600-00070.
– Two washers with a thickness of 1 mm were installed in the engines
with the engine number 2-600-00071 to 2-600-00124
– A washer with a thickness of 2 mm (14x30x2) was installed in
engine number 2-600-00125. It can also be used for earlier
engines.
– Mount the inner and outer valve springs 5 with the spring retainers
6 and compress the springs using the valve assembling tool
(590.29.019.000 with the attachment 600.29.041.000).
– Grease the valve spring keys 7 and position on the valve shafts.
Relieve the valve springs.
– Tap the valve spring retainers to set the keys.
5-12
– Place the lubricated piston on the cylinder and clamp the piston
rings together with the piston ring clamping band 600.29.015.000 1.
– Use a plastic hammer to tap lightly on the top of the piston ring
clamping band until it is flush with the cylinder.
1
– Use the hammer handle to carefully tap the piston into the cylinder,
making sure the piston rings do not get caught.
!
CAUTION
!
IF
THE PISTON RINGS ARE PROPERLY CLAMPED BY THE PISTON RING CLAMPING
BAND AND THE CLAMPING BAND IS FLUSH WITH THE CYLINDER, IT SHOULD BE EASY
TO PUSH THE PISTON INTO THE CYLINDER BY TAPPING LIGHTLY WITH THE HAMMER
HANDLE. APPLYING MORE FORCE WILL ONLY DAMAGE THE PISTON RINGS.
Art.-No. 3.206.056-E
– Invert the cylinder head, mount a new cylinder head gasket and put
the cylinder into position.
NOTE: the cylinder and the cylinder head are marked at the exhaust
flange 2. One or two circles are impressed on both parts
2
2
Repair manual KTM LC8
3
3
– Secure with Loctite 243 and tighten the three Allen bolts 3 to 18
Nm (1st stage) and 23 Nm (2nd stage).
– Mount the chain guide rail, apply Loctite 243 to the bolt and
tighten (15 Nm). Check the chain rail guide for mobility.
3
– Mount the bucket tappets 4 and the valve shims 5 in their original
positions in the cylinder head.
4
NOTE: if the valve clearance was incorrect when measured or if the
valves and valve seats were serviced or parts of the valve gear were
replaced, the thickness of the valve shims must be corrected.
5
5-13
Generator cover
5
4
3
1
1
– Loosen the three bolts 1 on the stator.
– Tilt the cable retaining bracket 2 away from the cable with long
nose pliers A (see small arrow) and pull out of the housing. Take
the cable duct out of the generator cover and remove the stator.
– Pry the shaft sealing ring on the balancer shaft 3 out of the
generator cover and discard.
– Remove the lock ring 4 and pull the idler with the disk and the
bearing from the bearing bolt.
– Heat the housing to 150° C. The bearing 5 will fall out of the
housing by itself.
– Press in a new bearing 5 until flush. Slide the new bearing on the
bearing bolt, slide on the idler and disk and mount the lock ring 4.
– Use the special tool 600.29.043.050 to press in the new shaft
sealing ring on the balancer shaft 3, open side first.
– Position the stator, press the cable duct in the generator cover.
– Push the retaining bracket in the recess of the housing and fit into
place. Apply Loctite 243 to the stator bolts and tighten to 10 Nm.
Torque limiter
NOTE: a torque limiter is used to avoid damage to the engine if the
engine "blows back" when started. Check the flange on the center gear
and the cam surfaces for wear.
Valve gear – checking parts for wear
Check the teeth of the balancer shaft 6 for wear.
Check the rollers and links of the timing chain 7 for wear, damage and
smooth operation.
2
A
Check the timing chain guides 8 for wear.
Check the timing chain tensioning rails 9 for wear.
Check the teeth on both double timing gears bk and the camshaft gears
bl for wear.
Check the camshafts and camshaft bearing positions for wear and
seizing marks.
bl
bk
8
bm
bn
NOTE: the spring preload cannot be checked directly; if the tension
spring is worn, the balancer shaft drive will become loud.
7
9
bo
bp
6
8
bl
7
bk
9
Check the spreader components for wear and damage, particularly
around the spreader wheel centering: spring washer bm, tensioning
wheel bn, tension spring bo and drive wheel bp.
5-14
Preassembling the spreader drive
NOTE:
– The tension spring bolts must be attached as illustrated.
– The other holes 1 are used to block the spreader drive.
1
1
– Attach the tension spring bolts 2 in the drive wheel 3 and press
the tension spring into the recess of the drive wheel.
3
2
Art.-No. 3.206.056-E
4
– Mount the tensioning wheel so that the tension spring bolts engage
in the right hole 4 and then press the two gears together.
NOTE: gently press together with your fingers.
Repair manual KTM LC8
– Mount the preassembled spreader drive on the lower part of the
pretensioning tool 600.29.050.000, making sure the pin on the
tool engages in the groove in the drive wheel.
– Screw on the nut and washers for the balancer shaft to prevent the
spreader drive from falling apart.
– Clamp the lower part 600.29.050.000 with the flat areas in a vise.
– Apply the pretensioning tool hook wrench 600.29.051.000 to the
tensioning wheel and turn against the spring until the pin can be
inserted in the hole.
NOTE: the preload is approximately one tooth gap.
5-15
3
1
4
5
9
6
8
2
7
Clutch – checking parts for wear
Check the thrust bearing 1 for wear.
Check the front end of the pushrod 2 for wear and blow compressed air through the holes.
NOTE: the pushrod is made of nitride steel from the 2005 model. If you are repairing an engine older than the 2004 model,
replace the old pushrod with the newer version.
Clutch springs 3 must have a minimum length of 29.0 mm (new 30.77 mm). If necessary, replace all 6 at the same time.
The clutch disks must be even.
10 steel lamella 4 – may not have any recesses.
11 lining disks 5, wear limit 2.65 mm
Inner clutch hub 6 – check the outer and inner teeth for wear.
Needle bearing 7 – check for wear.
Springs in the outer clutch hub 8
Springs dampen the drive train from the primary drive to the clutch. Check these springs in addition to performing the regular
wear tests. Try to turn the outer clutch hub when the engine is blocked – you should not feel any backlash.
NOTE: the outer clutch hub must have a supporting ring with a thickness of 1 mm - see Technical Information, Chapter 1.
Check the sides of the clutch pressure booster 9 for wear.
5-16
Shift mechanism – checking parts for wear
1
Shift forks 1
Check the leaf for wear.
Check the driving bolt 2 for the shift drum for wear.
Shift rolls 3
Check the shift rolls for hair cracks and pressure marks. It
should be easy to turn the shift rolls on the driving bolts 2
of the shift forks.
1
1
3
3
Shift drum 4
Check the shift grooves for wear.
Check both grooved ball bearings in the shift drum for
wear.
2
6
5
B
8
7
4
9
Art.-No. 3.206.056-E
bk
Shift rail 5
Check for wear at the points of contact.
Check the return surface B on the shift rail for wear
(replace if excessively grooved).
Guide bolts 6
Check for a tight fit and wear.
Guidance
Check play (play
max. 0.7 mm).
between
guide
bolts
and
slider
Preassembling the shift shaft
7
– Mount the shift rail on the shift shaft by engaging the guide bolt 6.
– Attach the spring 7 and slide on the plastic sleeve 8.
5
NOTE: the noses on the plastic sleeve will engage in the opening in the
shift rail and the shift shaft and hold the spring in place.
8
9
bk
Repair manual KTM LC8
– Mount the return spring 9 such that the offset A runs towards the
shift quadrant.
– Slide the disk bk onto the shift shaft.
A
5-17
General information on servicing the transmission
– Clamp the main shaft in the vise (use protective jaws) and remove
the gears.
– Clean and check all parts.
Use new lock rings whenever you repair the transmission.
Check the tooth profile on the transmission shafts and sliding gears for
wear.
Place the sliding gears on the transmission shafts and check whether
they run smoothly on the teeth.
Check the bearing positions on the transmission shafts.
Mount the idler gear with bearings on the transmission shaft and check
for clearance.
Check the needle bearings in the idler gears.
bk
9
8
7
6
5
4
3
2
1
Assembling the main shaft
– Clamp the main shaft in the vise (use protective jaws) with the gear
facing down.
– Mount the needle bearing 1 and slide the 5th gear idler 2 over the
needle bearing with the claws pointing up.
– Mount the stop disk 3 (28.3 x 35.75 x 1.5 mm) and the lock ring
4 with the sharp edge facing up.
– Mount the 3rd and 4th gear sliding gear 5 with 4th gear (larger
outer diameter) facing down.
– Mount the stop disk 6 (22.2 x 30,2 x 1.5 mm).
– Slip on the needle bearing 7 and slide the 6th gear idler 8 over the
needle bearing with the claws pointing down.
– Slip on the 2nd gear fixed gear 9 with the collar facing down and
mount the stop disk bk (20.2 x 28 x 1.5 mm).
Check all gear wheels for smooth operation.
5-18
General information on servicing the transmission
– Clamp the main shaft or countershaft in the vise (use protective
jaws) and remove the gears. Pull off the bearing ring.
– Clean and check all parts.
Use new lock rings whenever you repair the transmission.
Check the tooth profile on the transmission shafts and sliding gears for
wear.
Place the sliding gears on the transmission shafts and check whether
they run smoothly on the teeth.
Check the bearing positions on the transmission shafts.
Mount the idler gear with bearings on the transmission shaft and check
for clearance.
Check the needle bearings in the idler gears. Mount the bearing ring
using a suitable tube.
Assembling the countershaft
– Clamp the countershaft in the vise (use protective jaws) with the
collar facing down.
bs
br
Art.-No. 3.206.056-E
9
8
bq
bp 7
bo 6
bl
Repair manual KTM LC8
– Slide the 2nd gear idler 2 with the groove facing up over the needle
bearing.
– Mount the stop disk 3 (30.2 x 39 x 1.5 mm) and the lock ring 4
with the sharp edge facing up.
5
– Mount the 6th gear sliding gear 5 with the shift groove facing up.
– Mount the lock ring 6 with the sharp edge facing down and the stop
disk 7 (26.2 x 36 x 1.5 mm).
– Mount the needle bearing 8 and 9 and slide the 3rd gear idler bk
over the needle bearing with the collar facing up.
bn
bm
bk
– Oil the needle bearing 1 and mount.
4
3
1
2
– Slip on the 4th gear idler bl with the collar facing down.
– Mount the stop disk bm (26.2 x 36 x 1.5 mm) and lock ring bn with
the sharp edge facing up.
– Mount the 5th gear sliding gear bo with the shift groove facing down
and the stop disk bp (24.3 x 35.75 x 1.0 mm).
– Mount the 1st gear idler bq with the groove facing down, the needle
bearing br and the stop disk bs (20.2 x 34 x 1.0 mm).
Check all gear wheels for smooth operation.
5-19
Checking the freewheel
2
– Insert the freewheel gear 1 in the freewheel.
– You should be able to turn the freewheel gear in a counterclockwise
direction.
– The freewheel gear should block without backlash in a clockwise
direction.
– Check the reduction gear 2 and the needle bearings 3 for wear,
replace if necessary.
3
3
1
Replacing the freewheel hub
– Remove the 6 bolts, tap the side of the freewheel hub with a plastic
hammer and remove the freewheel hub.
4
– Hold the components of the freewheel 4 together.
– Check the segments in the freewheel for wear.
– Check the freewheel hub 5 at the freewheel running surface for
wear.
– Apply Loctite 648 to the flange areas on the rotor and the freewheel
hub.
– Mount the freewheel hub on the rotor.
– Apply Loctite 648 along the entire thread length of the screws and
tighten crosswise to 15 Nm - see Technical Information, Chapter 1.
5
!
ALWAYS USE NEW
LOCTITE 648.
BOLTS
CAUTION
(QUALITY GRADE 12.9)
!
AND COAT BOLT THREAD WITH
– Generously oil the freewheel and insert in the freewheel hub.
Starter
6
– Since the starter will show little wear after 10,000 starts and the
replacement of individual parts is uneconomical, these steps will not
be described in detail at this point.
– Replace the O-ring 6 on the starter flange.
6-1
ASSEMBLING THE ENGINE
Repair manual KTM LC8
Art.-No. 3.206.056-E
INDEX
OIL PUMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
AXIAL CLEARANCE OF THE MAIN SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4
CASE HALF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5
SHIFT MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6
ALIGNING THE RETURN SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6
BALANCER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7
FREEWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7
ROTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7
GENERATOR COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8
TIMING CHAIN AND BALANCING WEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8
PRIMARY PINION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9
OUTER CLUTCH HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9
CLUTCH DISKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10
CLUTCH COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11
OIL SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12
CYLINDER HEAD REAR WITH TIMING CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . .6-13
CHAIN TENSIONER CYLINDER REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-15
CAMSHAFTS CYLINDER REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-16
SETTING CYLINDER FRONT TO TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-17
CYLINDER HEAD FRONT WITH TIMING CHAIN . . . . . . . . . . . . . . . . . . . . . . . . .6-17
CHAIN TENSIONER CYLINDER FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-19
OIL PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-19
CAMSHAFTS CYLINDER FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-20
STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-21
SPARK PLUG SHAFT INSERTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-22
VALVE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-22
6
6-2
Clean all parts thoroughly before reassembling.
1
– Clamp the output-end engine case on the engine work stand and
move into a vertical position (installation position).
Oil pumps
NOTE: lubricate the oil pump rotors and the oil pump shaft prior to
installation.
– Slide the outer rotor of the pressure pump into the bore with the
mark 1 facing the engine case.
4
3
– Insert the needle roller 2 on the pressure pump in the oil pump
shaft and slide on the inner rotor 3 of the pressure pump. The mark
4 on the inner rotor of the pressure pump must point to the groove
5 in the oil pump shaft.
– Insert the oil pump shaft and inner rotor of the pressure pump into
the engine case.
NOTE: contrary to common practice, the two marks for the outer and
inner rotor of the pressure pump are not on the same side.
Art.-No. 3.206.056-E
2
5
– Mount the pressure pump case 6 and fix with the short bolt 7
(M6x20) (apply Loctite 243 to the bolt but do not tighten yet). Do
not forget the centering pins on the pressure pump housing.
6
7
Repair manual KTM LC8
bk
bl
8
– Insert the needle roller in the oil pump shaft and slide on the inner
rotor 8 of the suction pump. Mount the outer rotor 9 such that the
mark bk is visible on the outside.
NOTE: the marks for the outer and inner rotors (bk and bl) of the
suction pump are on the same side.
9
– Hold the outer rotor in place while you slide the suction pump
housing bm over the rotor. Do not forget the centering pins.
– Replace the O-ring and lubricate.
bm
6-3
– Apply Loctite 243 to the three remaining oil pump bolts (M6x40)
and screw in. Tighten bolts to 10 Nm.
4
1
2
– Slide on the disk, insert the needle roller 1 and mount the oil pump
gear 2 with the collar facing the rear.
– Slide on the spacer washer 3 and mount the lock ring 4 on the oil
pump shaft.
– Check the oil pump for smooth operation by turning the oil pump
gear.
3
Axial clearance of the main shaft
– Slide the main shaft in den bearing seat and mount the 2nd housing
half with a new gasket.
– Screw both housing halves together, tighten the screws to 10 Nm
(see page 6-5).
– Position the test gauge holder on the engine case and measure the
axial clearance of the mainshaft.
Axial clearance: 0.01 - 0.13 mm
!
CAUTION
!
YOU ARE USING A CONVENTIONAL DIAL GAUGE SUPPORT, IT MUST BE
SCREWED ONTO THE ENGINE CASE; IF YOU ARE USING A MAGNETIC SUPPORT, IT
MUST BE ATTACHED TO A STEEL PLATE SCREWED ONTO THE ENGINE CASE (SEE
PHOTO).
ALWAYS MOVE THE MAIN SHAFT BY HAND, DO NOT USE ANY TOOLS.
CAREFULLY MEASURE THE AXIAL CLEARANCE; IF THE CLEARANCE IS TOO SMALL,
THE BEARINGS WILL PRELOAD AND THIS CAN LEAD TO ENGINE DAMAGE.
– IF
–
–
– Correct the axial clearance if the measured value does not
correspond to the setpoint value.
– To correct, remove the main shaft and add or remove compensating
disks on the generator side.
NOTE:
– If the axial clearance is too large, use a thicker compensating
washer.
– If the axial clearance is too small, use a thinner compensating
washer.
– Always mount the compensating washer on the generator side.
– Finally, check the axial clearance again.
6-4
Transmission
– Simultaneously push both transmission shafts into the bearing
seats.
NOTE: pay attention to the spacing washer on the countershaft.
– Slide the washer on the counter shaft and mount the lock ring 1.
– Move the engine into a horizontal position.
Art.-No. 3.206.056-E
1
2
2 4
3
3
– Insert the lower gearshift rail springs in the bores with the tapered
ends down.
– Position the shift forks 2 in the shift grooves and tilt aside, paying
attention to the shift rollers 3 – fix with grease if necessary. Mount
the shift drum 4 and allow the shift forks to engage in the shift
drum.
NOTE: since 3 different shift forks are used they cannot be confused
with each other.
2
3
– Mount the gearshift rails 5, paying attention to the lower gearshift
rail springs. Insert the upper gearshift rail springs in the gearshift
rails with the tapered ends up.
6
NOTE: the longer gearshift rail is used for the countershaft shift forks.
Repair manual KTM LC8
– Insert the oil rail for transmission lubrication 6 in the bore and turn
to engage the locking pin.
5
5
NOTE: the oil rail is sealed with 2 O-rings from the 2005 model which
should be replaced.
6-5
– Insert the crankshaft in the friction bearing.
NOTE:
– The crankshaft end with the thread for the primary pinion bolt
connection must point down.
– The conrod for the rear cylinder 1 must face up. Both conrods
should be in the position shown in the illustration.
1
– Mount the case dowel pins and put a new case gasket in place.
NOTE: additional housing dowels are used for items 19 and 21 (see
photo below) starting with the 2005 model.
Case half
– Slide the protective sleeve 600.29.005.000 over the countershaft.
– Slip on the generator-end case half. Tap lightly on the countershaft
with a rubber hammer if necessary.
!
DO
M6x65/75 (19)
M6x65/70 (21)
M6x65 (18)
M6x65/75 (20)
M6x65 (17)
– Screw in all HH case bolts (see illustration for bolt
lengths) and tighten to 10 Nm.
M6x40 (5)
M6x40 (6)
M6x90 (4)
M6x90 (3)
NOTE:
– the bolts should be tightened in the order shown
in the illustration (numbers in parentheses).
– Screws item 19 and 20 were changed from
M6x65 to M6x75 and screw item 21 to M6x70
starting with model year 2005.
– Move the case into a horizontal position with the
generator side facing up.
M6x40 (7)
M6x75 (12)
!
NOT TRY TO DRAW THE TWO CASE HALVES TOGETHER WITH THE CASE BOLTS.
M6x90 (2)
M6x65 (16)
CAUTION
M6x90 (1)
M6x60 (15)
M6x75 (14)
M6x40 (8)
M6x60 (13)
M6x60 (11)
M6x60 (10)
M6x60 (9)
– Position the pin and spring in the shifting drum. Mount the gear
sensor 2 with 2 M5x10 bolts. Tighten bolts to 4 Nm.
– Slide in a new oil filter and mount the oil filter cover 3 with a new
gasket. Tighten M5x16 bolts to 6 Nm.
3
2
6-6
Shift mechanism
2
– Mount the locking lever 1 with the spring. Apply Loctite 243 to the
M5x20 bolt and tighten to 6 Nm.
– Press the locking lever down and mount the shift locating drum 2.
NOTE: the flat parts of the shift locating drum are off center.
1
– Apply Loctite 243 to the M6x30 bolt 3 and tighten to 10 Nm.
– Slide the shift shaft 4 in the bearings, push the shift rail 5 away
from the shift locating drum and press the shift shaft towards the
case to the stop; let go of the shift rail.
4
3
5
Aligning the return spring
Art.-No. 3.206.056-E
– Engage second or third gear.
– Check the backlash of the shift rail and the clearance of the shift
bolt.
– The backlash of the shift rail is the distance the rail travels until the
shift shaft begins to move. You should be able to feel the pressure of
the return spring. Relative to the basic position, this backlash A
should be equal towards the top and towards the bottom.
– The backlash can be corrected by aligning the return spring.
Repair manual KTM LC8
6
B
– To align, dismount the shift shaft and bend the return spring as
needed at the bends B using a pair of pliers. Remount the shift
shaft. When the shift shaft is installed, the return spring must rest
against the shift bolt 6 and the dolly of the shift mechanism
support.
– Bend the return spring again if necessary.
6-7
– Screw on the generator-end timing chain tensioning rail 1. Apply
Loctite 243 to the bolt and tighten to 20 Nm.
!
CAUTION
!
SURE NO LOCTITE THREAD ADHESIVE IS ON THE PIVOT AREA OF THE BOLT.
THIS COULD CAUSE THE TIMING CHAIN TENSIONING RAIL TO BLOCK AND BREAK.
MAKE
Balancer shaft
– Heat the generator-end bearing of the balancer shaft evenly with a
heat gun (up to model 2004).
1
NOTE: a roller bearing without an inner ring is used instead of the ball
bearing starting with the 2005 model; these bearings no longer need to
be warmed.
– Fit the timing chain on the generator end (pay attention to the
running direction if the chain has already been used) and slide into
the balancer shaft 2. The timing chain must be placed over the rear
sprocket.
– Check the balancer shaft for smooth operation.
1
2
Freewheel
– Slip the freewheel 3 on the crankshaft and attach the locking
device 4 with 2 M6x16 bolts. Apply Loctite 243 to the bolts and
tighten to 10 Nm.
– Attach the lower starter idler gear 5 to the balancer shaft with the
collar on the inside.
5
3
4
Rotor
– Hold the freewheel with your finger while mounting the rotor, turning
it in a counterclockwise direction.
7
6
– Mount the rotor bolt 6 with disk, apply Loctite 243 to the bolt and
tighten to 180 Nm (M16) or 150 Nm (M16x1.5).
NOTE:
– to prevent the crankshaft from turning, block it with the engine lock
bolt.
– Check the force fit of the rotor on engines that do not have a
woodruff key fixture - see Technical Information, Chapter 1.
– Mount the upper starter idler gear 7 on the journal.
6-8
Generator cover
– Mount dowel pins on the engine case and put a new gasket in place.
Position the generator cover and tighten the generator cover bolts to
10 Nm (see illustration for bolt lengths).
M6x30
M6x30 (A)
M6x30 (A)
M6x35
NOTE: the bolts marked with an A must be mounted with new copper
sealing washers (6x10x1); the bolt marked with a B is used to attach a
cable clip.
M6x30
M6x35
M6x30
M6x30
M6x30
M6x35 (B)
– Mount the engine sprocket with the lock washer and tighten the nut
1 to 100 Nm, bend over the lock washer.
Art.-No. 3.206.056-E
1
Timing chain and balancing weight
– Screw the output-end timing chain tensioning rail 2. Apply Loctite
243 to the bolt and tighten to 20 Nm.
2
!
4
3
Repair manual KTM LC8
CAUTION
!
SURE NO LOCTITE THREAD ADHESIVE IS ON THE PIVOT AREA OF THE BOLT.
THIS COULD CAUSE THE TIMING CHAIN TENSIONING RAIL TO BLOCK AND BREAK.
MAKE
– Insert the woodruff key for the chain sprocket in the shaft groove
and push the chain sprocket onto the balancer shaft. Fit the timing
chain (pay attention to the running direction if the chain has already
been used).
– Insert the woodruff key for the balancing weight in the shaft groove
and mount the balancing weight 3 with the aperture 4 towards the
front.
6-9
Primary pinion
– Mount the woodruff key for the primary pinion in the shaft groove (if
dismounted).
– Mount the primary pinion 1 with the longer collar towards the rear.
The bore for the pickup ring must face towards the outside.
1
4
2
– Mount the gear wheel of the balancer shaft 2 with the collar facing
the back (up to the 2004 model).
– From the 2005 model: slide on the preassembled spreader drive,
making sure the drive wheel and tensioning wheel do not fall apart;
pull out the pin.
!
CAUTION
!
TURN
THE BALANCER SHAFT UNTIL THE MARKS ON GEARS FOR THE CRANKSHAFT
3 AND BALANCER SHAFT 4 COINCIDE AS SHOWN IN THE ILLUSTRATION. MAKE
SURE THE TIMING CHAINS DO NOT GET CAUGHT.
3
NOTE: when the marks coincide the first cylinder of the engine is in
the TDC position.
– Slide a 30.3 x 50 x 2 mm spacer washer 5 and a needle bearing 6
on the clutch shaft.
– Mount the gear for the oil pump drive on the back of the outer
clutch hub. The gear is secured by 3 needle rollers.
5
6
Outer clutch hub
– When slipping the outer clutch hub onto the shaft, leave enough
room for the pickup ring 7 which is held in place by a pin.
!
CAUTION
!
– THE PIN ON THE PICKUP RING MUST ENGAGE IN THE HOLE OF THE PRIMARY PINION.
– THE PICKUP RING IN CARBURATOR AND INJECTION MODELS ARE
DIFFERENTIATED BY THE POSITION OF THE "TOOTH GAP"; THEY CANNOT BE
INTERCHANGED.
– After mounting the ring gear on the crankshaft, push the outer
clutch hub up to the stop, moving the oil pump wheel back and
forth to make the procedure easier.
– Mount a 33.2 x 46 x 2 disk and nut 8 (46 mm) on the primary
pinion (LH thread). Apply Loctite 243 to the nut and tighten to
130 Nm.
– Mount a 20.2 x 33 x 1.5 mm disk and nut 9 on the balancer shaft.
Apply Loctite 243 to the nut and tighten to 150 Nm (up to the
2004 model).
7
9
– Mount the washer 20.2x34x1 mm and the spring washer
30.5x46.5x0.6-1.5, apply Loctite 243 to the nut 9 (A/F 30 mm) on
the balancer shaft and mount, tighten the nut to 120 Nm (from the
2005 model).
!
8
bk
CAUTION
!
THE GEAR WHEEL AND BALANCER SHAFT ARE PRESTRESSED STARTING WITH THE
2005 MODEL; THE NUT ON THE BALANCER SHAFT MAY ONLY BE TIGHTENED TO
120 NM OTHERWISE THE SPREADER DRIVE WILL BE DAMAGED.
– Screw on the pickup bk. Apply Loctite 243 to the bolts (M6x16) and
tighten to 10 Nm. Press the cable duct into the recess in the case.
NOTE: the gap between the pickup and the pickup ring must be between
0.6 and 1.0 mm (950) or between 0.4 and 0.6 mm (990).
6-10
– Slide the 25 x 48 x 6.5 mm disk and inner clutch hub together with
the clutch pressure booster onto the main shaft teeth.
NOTE: the two clutch pressure booster parts are marked with
coinciding circles.
– Attach the holder for the inner clutch hub A 600.29.003.000.
Mount the 22 x 37 x 3 mm disk. Apply Loctite 243 to the nut (32
mm) and tighten to 130 Nm. Remove support.
– Turn the inner clutch hub to check for smooth operation.
B
A
2
Art.-No. 3.206.056-E
Clutch disks
4
3
Repair manual KTM LC8
– First mount the supporting plate 1 and then the
spring washer 2 with the open side facing
outwards (see illustration).
– Starting with the lining disk 3 with the largest
inner diameter, alternately insert 11 lining disks
and 10 clutch disks.
B
2
1
NOTE:
– Thoroughly oil all disks.
– The clutch lining on the first and last clutch disks
have a different color since these two disks run on
aluminum on one side.
– The first clutch disk has a larger inner diameter to
hold the support and lining disk.
– The clutch disks are punched out. The sharp
edges on all of the disks must point in the same
direction. The round recesses (for demounting)
must be in the same meshing.
– The last lining disk must be turned one meshing
further.
– Push the clutch pushrod into the transmission main shaft.
– The marks B on the pressure cap and inner clutch hub must
coincide when the pressure cap is mounted.
– Mount the pressure springs with disks and bolts (M6x16). Tighten
the bolts crosswise to 10 Nm.
6-11
Clutch cover
– A vibration damper 1 is mounted in the outer clutch cover from the
2005 model, screw 2 may not be loosened.
!
CAUTION
!
THE SCREW ON THE VIBRATION DAMPER IS LOOSENED, A NEW OUTER CLUTCH
OVER WITH A VIBRATION DAMPER OR THE OLD CLUTCH OVER WITHOUT THE
VIBRATION DAMPER MUST BE USED SINCE THE SELF-CUTTING SCREW 2 CANNOT BE
ADEQUATELY SECURED. IF YOU REMOUNT THE VIBRATION DAMPER WITH THE SCREW,
THE SCREW CAN BECOME LOOSE AND DAMAGE THE ENGINE.
IF
1
2
– Mount the dowel pins on the engine case and put
a new clutch cover gasket in place.
M6x30
NOTE: remove the locking bolt to make it easier to
mount the clutch cover.
M6x85
M6x35
M6x30
M6x30
M6x30
M6x30
M6x30
M6x30
M6x30
– Turn the water pump shaft 3 until the recess fits over the driver 4
of the balancer shaft when the clutch cover is mounted.
3
4
– Mount the inner clutch cover together with the outer clutch cover,
inserting the bolts as illustrated. Tighten to 10 Nm.
– Screw the locking bolt back in.
6-12
Oil screen
– Insert the oil screen 1 in the opening in the case.
1
NOTE: the oil screen has a TOP marking 2 which must point up.
– Mount the oil screen cover; tighten the two M6x35/M6x40 bolts to
10 Nm.
2
Water pump
Art.-No. 3.206.056-E
– Mount the water pump wheel 3 and disk on the shaft. Hold with
the holding spanner 600.29.082.000, secure the bolt 4 M6x15
with Loctite 243 and tighten to 10 Nm.
4
3
Repair manual KTM LC8
– Mount the dowel pins and replace the O-ring gasket.
– Mount the water pump cover 5 with 4 M6x60 bolts. Tighten to
10 Nm.
5
6-13
Cylinder head rear with timing chain
– Remove the M10x161 stud bolts, strength class 10.9, and replace
with stud bolts in class 12.9.
1
NOTE: you can tell the two strength classes apart by their thread
length. Stud bolts in class 12.9 have a thread length of 26 mm; stud
bolts in any other length must be replaced.
– Mount a new base gasket.
NOTE: make sure the crankshaft is blocked in the cylinder rear TDC
position.
– Fit the timing chain and chain tensioning rail in the cylinder.
NOTE:
– The chain guide is mounted on the exhaust side of cylinder rear.
– The timing chain should be drawn up and held in the chain tunnel
with a thin welding wire 1 or a rubber band.
– Push the cylinder head and cylinder over the stud bolts until the
piston pin can be pressed into the piston by hand from the output
end. Insert a new piston pin retainer with a screwdriver into the
piston groove.
!
CAUTION
!
– DO
–
–
NOT PULL THE PISTON OUT OF THE CYLINDER UP TO THE OIL SCRAPER RING
SINCE THE PISTON RING WILL BE DAMAGED BY THE LOWER EDGE OF THE
CYLINDER.
THE OPENING TOWARDS THE CRANKSHAFT SHOULD BE COVERED WITH A CLOTH
TO PREVENT THE PISTON PIN RETAINER FROM FALLING OUT OF THE ENGINE
CASE.
THE PISTON PIN RETAINER 2 MUST BE IN THE POSITION SHOWN IN THE
ILLUSTRATION.
2
Push the cylinder head and cylinder down. Oil the cylinder head
nuts and mount with the washer - see Technical Information.
The cylinder head nuts are tightened in 2 stages.
5
3
4
1st stage:
– Tighten the cylinder head nuts crosswise. Use the special nut
600.29.083.000 for the internal nuts 3 and the special wrench
600.29.081.000 for the outer nut 4.
!
CAUTION
!
– THE TIGHTENING TORQUE FOR THE 1ST STAGE IS 25 NM. SINCE THE SPECIAL
WRENCH 600.29.081.000 IS USED FOR NUT 4, IT MUST BE TIGHTENED TO
23 NM.
– THE TORQUE WRENCH USED MUST BE USED IN LINE WITH THE SPECIAL WRENCH
600.29.081.000 (SEE ILLUSTRATION).
5
– Tighten the two outer nuts 5 to 8 Nm.
2nd stage:
– Tighten the cylinder head nuts crosswise.
!
–
CAUTION
!
TIGHTENING TORQUE FOR THE 2ND STAGE IS 38 NM. SINCE THE SPECIAL
WRENCH 600.29.081.000 IS USED FOR NUT 4, IT MUST BE TIGHTENED TO
34 NM.
THE TORQUE WRENCH USED MUST BE USED IN LINE WITH THE SPECIAL WRENCH
600.29.081.000 (SEE ILLUSTRATION).
– THE
6-14
– Push the double timing gear down into the chain tunnel draw the
timing chain along the side on the inside.
A
2
– Use the wire hook A to lift the side of the chain on the inside over
the gear teeth 1 onto the chain teeth 2 of the double timing gear.
Hold the double timing gear towards the outside by inserting your
finger through the hole in the bearing bolt.
Repair manual KTM LC8
Art.-No. 3.206.056-E
1
– Mount and grease a new O-ring on the bearing bolt 3 of the double
timing gear.
– Lift the double timing gear, insert the bearing bolt on the double
timing gear and the needle bearing into the cylinder head and
tighten to 30 Nm.
3
6-15
Chain tensioner cylinder rear
– Insert the chain tensioner element 1 in the cylinder head bore.
NOTE: the housing and tensioning piston of the chain tensioner are
compression molded. If the two parts cannot be separated, the chain
tensioner must be replaced.
1
– Apply the chain tensioner bolt and new sealing washer to the chain
tensioner element without compressing the spring.
– Measure the distance 2 between the sealing washer and the
cylinder head.
2
The measured value has to be between 6 mm and 11 mm. If the value
is lower, the tensioning rail could be worn or the timing chain
excessively elongated. If it is higher, the engine was turned to TDC
against the running direction.
– Mount the chain tensioner bolt 3 with a new sealing washer and
tighten to 20 Nm.
3
6-16
Camshafts cylinder rear
– Insert the two camshafts marked "in re" (rear intake camshaft) and
"ex re" (rear exhaust camshaft) into the bearings without tilting. The
marks on the camshaft gears must coincide with the flat outer
surface of the cylinder head (see illustrations).
Art.-No. 3.206.056-E
1
NOTE:
– The same camshaft gears are used in both cylinders but they have
marks for cylinder rear and front. Use the camshaft gear marked
with a cross 1 (points as of 2007) and for cylinder rear and the
camshaft gear marked with a circle for cylinder front.
– The cams 2 of both camshafts on the cylinder rear will point
towards the inside in the TDC position.
– The camshaft bearing bridges 3 and the cylinder heads 4 have
coinciding marks to ensure that the same camshaft bearing bridge is
mounted on the same cylinder head.
1
2
– Place plastigauge measuring strips 5 (600.29.012.000) on the
camshaft bearing positions.
– Carefully mount the camshaft bearing bridge and tighten the bolts in
the camshaft bearing bridge to 10 Nm (M8) in the first stage.
– Tighten to 18 Nm (M8) and 10 Nm (M6) in the second stage.
3
Repair manual KTM LC8
4
!
CAUTION
!
TIGHTENING THE BOLTS OF THE CAMSHAFT BEARING BRIDGE, MAKE SURE
THAT THE VALVES ARE NOT ACTUATED BY THE CAMSHAFT (SEE ILLUSTRATION),
OTHERWISE THE BEARING BRIDGE WILL BREAK.
WHEN
NOTE: do not turn the camshafts.
– Remove the camshaft bearing bridge again and compare the width
of the plastigauge measuring strip 6 with the information on the
packing. The width of the plastiguage measuring strip is equivalent
to the bearing clearance.
Camshaft bearing clearance: 0.020 mm – 0.061 mm
Wear limit: 0.09 mm
5
6
– Carefully mount the camshaft bearing bridge and tighten the bolts in
the camshaft bearing bridge to 10 Nm (M8) in the first stage.
– Tighten to 18 Nm (M8) and 10 Nm (M6) in the second stage.
6-17
Setting cylinder front to TDC
– Loosen the crankshaft locking bolt and turn the engine
counterclockwise 1 rotation and then 75° towards the front
cylinder's TDC position, keeping the timing chain on the cylinder
rear slightly tensioned and holding the conrod in the center of the
opening in the case.
!
CAUTION
!
CRANKSHAFT MUST BE TURNED 1 ROTATION AND 75° IN A
COUNTERCLOCKWISE DIRECTION, OTHERWISE THE IGNITION INTERVAL WILL NOT
BE CORRECT AND THE MOTOR WILL NOT RUN.
IF YOU DO NOT HOLD THE CHAIN, IT MAY GET JAMMED BETWEEN THE TIMING
CHAIN ON THE CRANKSHAFT AND THE TENSIONING RAIL.
IF THE CONROD IS NOT POSITIONED IN THE CENTER OF THE OPENING IN THE
CASE, THE CONROD BOTTOM WILL BLOCK ON THE BALANCER SHAFT AND
PREVENT THE CRANKSHAFT FROM TURNING.
– THE
–
–
– Screw the crankshaft locking bolt back in.
75º
Cylinder head front with cylinder and timing chain
– Remove the M10x161 stud bolts, strength class 10.9, and replace
with stud bolts in class 12.9.
1
NOTE: you can tell the two strength classes apart by their thread
length. Stud bolts in class 12.9 have a thread length of 26 mm; stud
bolts in any other length must be replaced.
– Mount a new base gasket.
NOTE: make sure the crankshaft is blocked in the cylinder front TDC
position.
– Fit the timing chain and chain tensioning rail in the cylinder. Tilt the
chain tensioning rail 1 towards the chain to allow it to engage in
the chain tunnel of the engine case.
NOTE:
– The chain guide is mounted on the intake side of cylinder front .
– The timing chain should be drawn up and held in the chain tunnel
with a thin welding wire or a rubber band.
– Push the cylinder head and cylinder over the stud bolts until the
piston pin can be pressed into the piston by hand from the output
end. Insert a new piston pin retainer with a screwdriver into the
piston groove.
!
– DO
–
–
2
CAUTION
!
NOT PULL THE PISTON OUT OF THE CYLINDER UP TO THE OIL SCRAPER RING
SINCE THE PISTON RING WILL BE DAMAGED BY THE LOWER EDGE OF THE
CYLINDER.
THE OPENING TOWARDS THE CRANKSHAFT SHOULD BE COVERED WITH A CLOTH
TO PREVENT THE PISTON PIN RETAINER FROM FALLING OUT OF THE ENGINE
CASE.
THE PISTON PIN RETAINER 2 MUST BE IN THE POSITION SHOWN IN THE
ILLUSTRATION.
6-18
2
– Push the cylinder head and cylinder down. Oil the cylinder head
nuts and mount with the washer - see Technical Information.
The cylinder head nuts are tightened in 2 stages.
1st stage:
– Tighten the cylinder head nuts crosswise. Use the special nut
600.29.083.000 for the internal nuts 1 and the special wrench
600.29.081.000 for the outer nut 3.
1
!
3
2
CAUTION
!
– THE TIGHTENING TORQUE FOR THE 1ST STAGE IS 25 NM. SINCE THE SPECIAL
WRENCH 600.29.081.000 IS USED FOR NUT 3, IT MUST BE TIGHTENED TO
23 NM.
– THE TORQUE WRENCH USED MUST BE USED IN LINE WITH THE SPECIAL WRENCH
600.29.081.000 (SEE ILLUSTRATION).
– Tighten the two outer nuts 2 to 8 Nm.
2nd stage:
– Tighten the cylinder head nuts crosswise.
!
CAUTION
!
TIGHTENING TORQUE FOR THE 2ND STAGE IS 38 NM. SINCE THE SPECIAL
WRENCH 600.29.081.000 IS USED FOR NUT 3, IT MUST BE TIGHTENED TO
34 NM.
THE TORQUE WRENCH USED MUST BE USED IN LINE WITH THE SPECIAL WRENCH
600.29.081.000 (SEE ILLUSTRATION).
– THE
–
Art.-No. 3.206.056-E
– Push the double timing gear down into the chain tunnel draw the
timing chain along the side on the inside.
A
5
4
6
Repair manual KTM LC8
– Use the wire hook A to lift the side of the chain on the inside over
the gear teeth 4 onto the chain teeth 5 of the double timing gear.
Hold the double timing gear towards the outside by inserting your
finger through the hole in the bearing bolt.
– Mount and grease a new O-ring on the bearing bolt 6 of the double
timing gear.
– Lift the double timing gear, insert the bearing bolt on the double
timing gear and the needle bearing into the cylinder head and
tighten to 30 Nm.
6-19
Chain tensioner cylinder front
– Insert the chain tensioning element 1 in the cylinder head bore.
NOTE: the housing and tensioning piston of the chain tensioner are
compression molded. If the two parts cannot be separated, the chain
tensioner must be replaced.
1
– Apply the chain tensioner bolt and new sealing washer to the chain
tensioner element without compressing the spring.
– Measure the distance 2 between the sealing washer and the
cylinder head.
2
The measured value should be between 6 mm and 11 mm. If the value
is lower, the tensioning rail could be worn or the timing chain
excessively elongated. If it is higher, the engine was turned to TDC
against the running direction.
– Mount the chain tensioner bolt 3 and tighten to 20 Nm.
3
Oil pressure switch
– Mount the oil pressure switch 4 with a new sealing washer and
tighten to 10 Nm.
4
6-20
Camshafts cylinder front
– Insert the two camshafts marked "in fr" (front intake camshaft) and
"ex fr" (front exhaust camshaft) into the bearings without tilting. The
marks on the camshaft gears must coincide with the cylinder head
surface (see illustrations).
Art.-No. 3.206.056-E
1
NOTE:
– The same camshaft gears are used in both cylinders but they have
marks for cylinder rear and front. Use the camshaft gear marked
with a cross for cylinder rear and the camshaft gear marked with a
circle 1 for cylinder front.
– The cams 2 of both camshafts on the cylinder front will point
towards the outside in the TDC position.
– The camshaft bearing bridges 3 and the cylinder heads 4 have
coinciding marks to ensure that the same camshaft bearing bridge is
mounted on the same cylinder head.
1
2
– Place plastigauge measuring strips 5 (600.29.012.000) on the
camshaft bearing positions.
– Carefully mount the camshaft bearing bridge and tighten the bolts in
the camshaft bearing bridge to 10 Nm (M8) in the first stage.
– Tighten to 18 Nm (M8) and 10 Nm (M6) in the second stage.
3
Repair manual KTM LC8
4
!
CAUTION
!
TIGHTENING THE BOLTS OF THE CAMSHAFT BEARING BRIDGE, MAKE SURE
THAT THE VALVES ARE NOT ACTUATED BY THE CAMSHAFT (SEE ILLUSTRATION),
OTHERWISE THE BEARING BRIDGE WILL BREAK.
WHEN
NOTE: do not turn the camshafts.
– Remove the camshaft bearing bridge again and compare the width
of the plastigauge measuring strip 6 with the information on the
packing. The width of the plastiguage measuring strip is equivalent
to the bearing clearance.
5
6
Camshaft bearing clearance: 0.020 mm – 0.061 mm
Wear limit: 0.09 mm
– Carefully mount the camshaft bearing bridge and tighten the bolts in
the camshaft bearing bridge to 10 Nm (M8) in the first stage.
– Tighten to 18 Nm (M8) and 10 Nm (M6) in the second stage.
6-21
NOTE:
– Check the position of the camshafts on cylinder front in the TDC
position of cylinder rear.
The cams on the exhaust camshaft 1 point towards the inside and
push open the exhaust valves, the cams on the intake camshaft 2
also point towards the inside, the bucket tappets are not actuated.
If the camshafts are in a different position, check the timing and
reset.
– Check valve clearance (see Chapter 12)
2
1
– Remove the crankshaft blocking tool 3. Insert the case bolt
(M8x60) with a new sealing washer and tighten to 10 Nm.
– Screw the plug 4 into the generator cover.
3
4
Starter motor
– Insert the starter motor into the opening in the case with a new
O-ring (greased). Insert both bolts 5 (M6x25) and tighten to
10 Nm.
5
5
6-22
Spark plug shaft inserts
– Mount new O-rings 1 on the spark plug shafts and grease. Push the
spark plug shaft inserts all the way in.
1
– Mount the valve cover gaskets 2 and spark plug shaft gaskets 3.
3
2
Art.-No. 3.206.056-E
Valve cover
– Mount the valve cover. Insert bolts 4 with the sealing washers and
tighten to 10 Nm.
4
4
4
– Screw in the spark plugs with special tool 600.29.073.000 and
tighten to 12 Nm (950, M10) or 20 Nm (990, M12x1.5).
– Connect the spark plug connectors.
– 990 Super Duke R only: mount and tighten screw 5.
Repair manual KTM LC8
5
7-1
ELECTRICAL
Repair manual KTM LC8
Art.-No. 3.206.056-E
INDEX
CHECKING FOR LOSS OF CURRENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3
DISMOUNTING THE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3
CHARGING THE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3
JUMP START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.3
CHECKING THE CHARGING VOLTAGE/ RECTIFIER REGULATOR . . . . . . . . . . . . . . .7-3
CHECKING THE GENERATOR COILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3
ELECTRIC STARTER SYSTEM 950 ADVENTURE . . . . . . . . . . . . . . . . . . . . . . . . .7-4
ELECTRIC STARTER SYSTEM 990 SUPER DUKE/R . . . . . . . . . . . . . . . . . . . . . . .7-5
ELECTRIC STARTER SYSTEM 950 SUPERMOTO/950 SUPER ENDURO . . . . . . . . .7-6
ELECTRIC STARTER SYSTEM 990 ADVENTURE -2007 . . . . . . . . . . . . . . . . . . . .7-7
ELECTRIC STARTER SYSTEM 990 ADVENTURE 2007- . . . . . . . . . . . . . . . . . . . .7-8
ELECTRIC STARTER SYSTEM 990 SUPERMOTO . . . . . . . . . . . . . . . . . . . . . . . . .7-9
CHECKING THE AUXILIARY STARTER RELAY . . . . . . . . . . . . . . . . . . . . . . . . . .7-10
FUNCTIONAL CHECK OF THE AUXILIARY STARTER RELAY . . . . . . . . . . . . . . . . .7-11
CHECKING THE DIODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12
CHECKING THE STARTER RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-13
CHECKING THE STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-13
CHECKING THE CLUTCH SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-14
CHECKING THE TIP SWITCH AND THE EMERGENCY OFF SWITCH . . . . . . . . . . .7-15
TROUBLESHOOTING IN THE STARTER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . .7-15
IGNITION SYSTEM, ECU 950 ADVENTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-16
IGNITION SYSTEM, ECU 950 SUPERMOTO . . . . . . . . . . . . . . . . . . . . . . . . . . .7-17
IGNITION SYSTEM, ECU 950 SUPER ENDURO . . . . . . . . . . . . . . . . . . . . . . . . .7-18
CHECKING THE ECU 950 ADVENTURE/950 SUPERMOTO/SUPER ENDURO . . . . .7-19
CHECKING THE PULSE GENERATOR 950 ADVENTURE/SUPERMOTO/SUPER ENDURO . .7-19
CHECKING THE FUEL PUMP RELAY 950 ADVENTURE/SUPERMOTO/SUPER ENDURO . .7-20
CHECKING THE IGNITION COILS (CARBURETTOR MODELS ONLY) . . . . . . . . . . . .7-20
TROUBLESHOOTING IN THE IGNITION SYSTEM 950 ADVENTURE/
SUPERMOTO/SUPER ENDURO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-21
THE EPC SYSTEM 950 ADVENTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-22
THE EPC SYSTEM 950 SUPERMOTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-23
THE EPC SYSTEM 950 SUPER ENDURO . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-24
7
7-2
ELECTRICAL
Repair manual KTM LC8
Art.-No. 3.206.056-E
INDEX
CHECKING THE SOLENOID VALVE FOR THE EPC 950 ADVENTURE/950 SUPERMOTO . .7-25
CHECKING THE GEAR SENSOR 950 ADVENTURE/950 SUPERMOTO . . . . . . . . . .7-25
CARBURETOR HEATER 950 ADVENTURE/950 SUPERMOTO/950 SUPERMOTO . .7-26
INJECTION/IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-27
ESTABLISHING THE INJECTION PERIOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-27
CORRECTION SENSORS AND INPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-27
SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-28
BASIC DESCRIPTION OF THE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-29
WIRING DIAGRAM 990 SUPER DUKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-30
WIRING DIAGRAM 990 SUPER DUKE R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-31
WIRING DIAGRAM 990 ADVENTURE -2007 . . . . . . . . . . . . . . . . . . . . . . . . . . .7-32
WIRING DIAGRAM 990 ADVENTURE 2007- . . . . . . . . . . . . . . . . . . . . . . . . . . .7-33
WIRING DIAGRAM 990 SUPERMOTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-34
BLOCK DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-35
DESCRIPTION OF THE ELECTRIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-35
DESCRIPTION OF THE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-37
SAFETY AGAINST FAILURE/EMERGENCY OPERATION . . . . . . . . . . . . . . . . . . . .7-43
COMPONENT TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-44
ERROR CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-55
ABBREVIATIONS, LIMIT VALUES 990 SUPER DUKE . . . . . . . . . . . . . . . . . . . . .7-56
ABBREVIATIONS, LIMIT VALUES 990 ADVENTURE / 990 SUPERMOTO . . . . . . .7-57
ALARM SYSTEM 990 SUPER DUKE/R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-58
ORDER FOR ADDITIONAL HAND-HELD TRANSMITTERS . . . . . . . . . . . . . . . . . . .7-59
ADAPTING THE HAND-HELD TRANSMITTER . . . . . . . . . . . . . . . . . . . . . . . . . . .7-59
STARTING WITH THE EMERGENCY CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-60
ABS-SYSTEM 990 ADVENTURE
CHECKING THE FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-61
CHECKING THE ABS FAULT MEMORY USING THE KTM DIAGNOSTICS TOOL . . . .7-61
CHECKING THE ABS SENSOR WITH THE KTM DIAGNOSTICS TOOL . . . . . . . . . . .7-61
7
7-3
Checking for loss of current
Check for loss of current before you check the rectifier regulator.
– Switch off the ignition and disconnect the ground wire from the
battery.
– Connect an ammeter between the ground wire and the negative pole
on the battery.
Set point value: max. 2 mA
– If the value is higher, look for the current consumers.
For example:
– a defective regulator/rectifier
– a defective multifunctional digital speedometer
– Creepage current in the socket connectors or in the ignition lock
NOTE: you will need to set the clock on the multifunctional digital
speedometer after the battery is connected.
Dismounting/replacing the battery
see Chapter 3
0,00
Charging the battery
see Owner's Manual
Jump start
see Owner's Manual
Checking the charging voltage / rectifier regulator
Art.-No. 3.206.056-E
NOTE: the following figures only apply to fully charged batteries.
– Connect a voltmeter to both battery terminals.
– Start the engine and switch on the low beam.
– Rev the engine up to 5000 rpm and read the voltage.
Set point value: 14.0 – 15.0 V
If the measured value deviates significantly from the set point value:
– Check the socket connectors from the stator to the regulator rectifier
and from the regulator rectifier to the cable tree.
– Check the generator coils
– Replace the regulator rectifier
Checking the generator coils
– Disconnect the socket connector 1 and measure the 3 cables
(yellow) to the generator back to back for resistance.
1
Set point value: max 1,0 Ω bei 20º C
Repair manual KTM LC8
– Check all three cables for short circuit to ground.
– Check both connectors for damage.
7-4
30
30
3
1
2
7
3th
3fuse
C_BB/9
C_AB/9
N
orange 1
8
10 A
3
1
2
C_AI1/2
yellow 0.5
7
1
diode
bm
2
3
31
C_AT2/2
C_AM3/3
A
page 7/9
1
C_AL
C_AR/2
brown 0.5
brown 0.5
1
pink 0.5
green-black 0.5
diode
brown 0.5
bl
starter motor
yellow 0.5
bn
M
2
C_AI/2
B
page 4/9
sidestand switch
8 clutch switch
brown 0.5
4
pink 0.5
C_AF/4
2
C_BF1/1
red 0.5
yellow 0.5
C_BA1/1
31
red 4
6
1
5
battery
black-orange 0.5
orange 0.5
start auxillary relay
1
red 0.5
30
orange 0.5
3
C_AR/3
C_AM2/3
C_AE/4
4
neutral switch (N) / 2nd gear / 3th gear
2
2nd
bk
red 4
start-relay
ignition switch
4
9
start/stop switch
31
Electric starter system 950 Adventure
NOTE: the starter system is equipped with a safety feature.
You will only be able to start under the following conditions:
– If the gnition lock is in the ON position
– If the emergency OFF switch is in the ON position
– If the transmission is shifted to neutral or the clutch is pulled
How the starter system operates:
Battery voltage travels from the battery 1 through the ignition lock 2, fuse 3 and the emergency OFF switch 4 to the coil of
the auxiliary starter relay 5 .
The ground supply to the coil of the auxiliary starter relay takes place if at least one of the following conditions are met:
– Transmission is shifted to neutral (neutral switch 6 is closed, current can flow through diode 7 and the neutral switch
against the ground)
– Clutch is pulled (clutch switch 8 is closed, the current can flow through the clutch switch against the ground)
NOTE: if these conditions are met, the load contact from the coil is closed (nonrecurring "click “).
When the tip switch 9 is actuated, battery voltage flows through the closed load contact of the auxiliary start relay 5 to the coil
of the start relay bk and from there against the ground. This causes the load contact on the start relay to close and battery
voltage to flow via the start relay contact to the starter engine bl .
The diode bm is one of the electric starter system's important safety features which prevents the starter engine from being
actuated although a gear is engaged and the clutch is not pulled. The diode does not allow current to flow when the side stand is
folded down, in other words, the auxiliary starter relay will not have a ground connection via the side stand switch.
If the clutch is released with the engine running and a gear engaged although the side stand is folded down (driving off with the
side stand folded down) the ECU will not have a ground connection through the pink cable, the voltage will increase to
over 2.5 volts and the ECU will break the ignition, immediately causing the engine to stall.
An alarm system (accessory) can be connected to the BA/BF bn connectors. The two connectors must be connected together if no
alarm system is installed.
7-5
re-wh
C o nnector for
optional
alarm system
18
18
17
17
U
8
8
7
7
9
re-wh
4
br
re-wh
re-wh
M
3
G
8
9
6
6
5
5
bl
4
4
bl
3
3
2
2
1
1
1
2
7
diode
start auxillary relay
4
8
C_AI1/2
C_AI2/2
1
2
2
ye-wh
1
2
A
3
p a ge 6
1
re-wh
diode
bn
1
generator
6
3
ignition 9
gn-bl
10
fuse
10 A
C_BB/9
C_AB/9
ye-wh
re-wh
3
C_BI/2
2
C_AU/2
C_AE1/4
30
A
start relay
starter motor
C_DK/18
11
10
bl
bm
C_DJ/18
11
regulator-rectifier
gn
re-wh
12
ye
gn
1
1
13
ye-wh
1
o r a nge 1
15
C_AF2/4
battery
13
12
4
5
16
2
14
or-bl
16
15
14
start/stop switch
re-bl
bk
re-bl
Dummy plug
30
ignition switch
30
2
3
C_AL1/2
C_AM2/3
C_AT1/2
C_AR2/3
9
2 nd
3 th
N
7
clutch switch
neutral switch (N) / 2nd gear / 3rd gear
Art.-No. 3.206.056-E
31
Electric starter system 990 Super Duke/R
NOTE: The starting system is equipped with security features.
The motorcycle can only be started under the following conditions:
–
–
–
–
Ignition lock in the ON position
Emergency-off switch in the ON position
Transmission in the idle position or the clutch pulled
Alarm system deactivated (if installed)
990 Super Duke starting system - mode of operation:
Battery voltage flows from the battery 1 via the ignition lock 2, fuse 3 and the emergency-off switch 4 to the tip switch 5.
The coil of the auxiliary start relay 6 is supplied with ground if at least one of the following conditions are met:
– Transmission in the idle position (neutral switch 7 closed, current can flow via the diode 8 and the neutral switch to chassis)
– clutch pulled (clutch switch 9 closed, current can flow via the clutch switch to chassis)
Repair manual KTM LC8
By pressing the tip switch 5, battery voltage will flow to the coil of the auxiliary start relay 6 (via the bridge connector bk or the
alarm system - if installed; for accessories, see alarm system) which picks up the load contact, as well as to the coil of the start
relay bl via the closed load contact and from there to chassis. This causes the contact on the start relay to close and battery
voltage to flow via the contact on the start relay to the starter engine bm.
The diode bn is one of the starting system's important safety components. It prevents the starter engine from being actuated even
if a gear is engaged and the clutch is not pulled.
If the clutch is released with the engine running and a gear engaged although the side stand is folded down (driving off with the
side stand folded down) the ECU will interrupt the ignition and injection and immediately cause the engine to stall.
7-6
re-wh
Dummy plug
battery
30
A
C_AF3/4
start relay
1
re-wh
2
re-wh
3
re-bu
4
br
3
18
17
17
16
16
15
15
14
13
C_DK/18
18
12
C_DJ/18
U
red-white 1
regulator-rectifier
bk
Connector for
optional
alarm system
8
3
2
13
12
11
10
10
9
9
8
8
7
7
C_BB/9
C_AB/9
8
6
6
5
5
9
4
4
bl
3
3
bl
2
2
1
1
C_BC/6
1
2
C_AC/6
7
5
4
diode
bn
diode
diode
6
9
C_AF/4
A
A
A
A
A
A
8
re-ye
re-wh
ye-bl
bl-wh
ye
orange 0.5
2
C_AI1/2
bm
1
1
2
pink 0.5
J-page3/8
yellow 0.5
2
green-black 0.5
3
1
1
ye-bu
or-bl
red 0.5
4
f us e bo x
A
2
10 10 10 10 1 0
1 0 15 1 0
A
orange-white 0.5
1
1
C_AI2/2
C_AI/2
1
2
C_AL3/2
C _AM1/3
C_AT3/2
C_AR1/3
5
D-pa ge 4/8
G- pag e 6 /8
F-pag e6/8
3
7
2
4
1
brown 0.5
C-page 5/8
bo
C_AF2/4
H-p age 6/8
B-page 5/8
red-white 1
light system relay
A-page3/8
I-page6/8
3
re-bl
red-blue 0.5
brown 0.5
16
start auxillary relay 4
or
re-wh
or
re-wh
or
re-wh
or
bl
re-wh
starter motor
M
generator
ignition switch
14
11
G
30
start/stop switch
orange-white 0.5
red-white 1
red-white 1
red-white 1
red-white 1
30
2nd
3th
N
clutch switch
E-page3/8
neutral switch (N) / 2nd gear / 3rd gear
31
Electric starter system 950 Supermoto/R, 950 Super Enduro
NOTE:
– The electric starter system is equipped with a safety feature.
– The 950 Super Enduro model does not have an alarm system, dummy plug or emergency off switch.
You will only be able to start under the following conditions:
– If the ignition switch is in the ON position
– If the emergency OFF switch is in the ON position
– If the transmission is shifted to neutral or the clutch is pulled
How the electric starter system operates:
Battery voltage travels from the battery through the fuse 1, the ignition switch 2 and the emergency OFF switch 3 (950
Supermoto only) to the coil of the auxiliary starter relay 4.
The ground supply to the coil of the auxiliary starter relay takes place if at least one of the following conditions are met:
– Transmission is shifted to neutral (neutral switch 5 is closed, current can flow through diode 6 and the neutral switch
against the ground)
– Clutch is pulled (clutch switch 7 is closed, the current can flow through the clutch switch against the ground)
NOTE: if these conditions are met, the load contact from the coil is closed (nonrecurring "click ").
When the tip switch 8 is actuated, battery voltage flows through the control unit of the alarm system (if installed, otherwise
through the dummy switch 9 - 950 Supermoto only), the closed load contact of the auxiliary start relay 4 to the coil of the
start relay bk and from there against the ground. This causes the load contact on the start relay to close and battery voltage to
flow via the start relay contact to the starter engine bl .
If a gear is engaged when the engine is running and the clutch is released although the side stand is folded down (driving off
with the side stand folded down), the ECU will no longer have contact to the ground via the diode bm and the pink cable, the
voltage will increase to over 2.5 volts and the ECU will interrupt the ignition, immediately causing the engine to stall.
The diode bn is a freewheeling diode that is used to reduce peak voltages and thus protect the electronic components.
The light system relay bo is used to stop the power supply to the light system, relieving the battery.
7-7
30
red-white 1
red-white 1
red-white 1
red-white 1
re-wh
start/stop switch
4
re-wh
3
re-bu
4
br
3
G
generator
2
C_ AC/6
7
4
5
diode
diode
bk
6
R-page3/9
C_AI1/2
10
10 10
fus e box
A
A
A
A
A
A
re-wh
re-gn
bl-wh
ye-bu
2
green-black 0.5
3
1
I-page6/9
2
C_ AL 3/2
1
ye
bl-ye
8
A
1
yellow-white 0.5
2
C_AT3/2
re-ye
A
4
5
10
C_AF/4
10
C_AI1/2
1
red 0.5
1
9
15 10
re-bl
red-blue 0.5
brown 0.5
16
10
s t a r t a ux i l l ar y r e l ay
re-wh
gn
re-wh
gn
1
re-wh
9
gn
gn
2
re-wh
starter motor
M
8
C_ BC/6
1
red -black 0.5
30
A
re-wh
2
2
3
8
1
ignition switch
C_BB/9
C_AB/9
battery
U
red-white 1
regulator-rectifier
start relay
30
I-page3/9
light system relay
C-page 5/9
D-page 5/9
G-page7/9
F-page7/9
7
2
4
1
brown 0.5
B-page 6/9
C_AF2/4
H-page7/9
red-white 1
3
J-page3/9
A-page3/9
clutch switch
E-page3/9
Art.-No. 3.206.056-E
31
Electric starter system 990 Adventure -2007
NOTE: The electric starter system is equipped with a safety feature.
You will only be able to start under the following conditions:
– If the ignition switch is in the ON position
– If the emergency OFF switch is in the ON position
– If the transmission is shifted to neutral or the clutch is pulled
How the electric starter system operates:
Battery voltage travels from the battery through the fuse 1, the ignition switch 2 and the emergency OFF switch 3 to the tip
switch 4. By pressing the tip switch, the coil and load contact of the auxiliary start relay 5 are supplied with battery voltage.
The ground supply to the coil of the auxiliary starter relay 6 takes place if at least one of the following conditions is met:
– Transmission is shifted to neutral (neutral switch is closed, current can flow through the diode [6] and the neutral switch
against the ground);
– Clutch is pulled (clutch switch 7 is closed, the current can flow through the clutch switch against the ground).
Repair manual KTM LC8
When the coil of the auxiliary starter relay closes the load contact, battery voltage will flow to the starter relay 8, causing the
contact on the starter relay to close and the starter engine 9 to turn.
The diode bk is one of the electric starter system's important safety features. It prevents the starter engine from being actuated
although a gear is engaged and the clutch is not pulled.
If the clutch is released with the engine running and a gear engaged although the side stand is folded down (driving off with the
side stand folded down) the ECU will interrupt the ignition and injection, immediately causing the engine to stall.
7-8
30
red-white 1
red-white 1
red-white 1
red-white 1
start/stop switch
4
red-white 1
U
re-wh
3
re-bu
4
br
3
G
generator
2
7
C_AC/6
4
5
5
10 10 10 10 10
4
C_AF/4
10 15 10
fuse box
A
A
A
A
A
A
A
3
re-wh
re-gn
bl-wh
ye-bu
1
ye
bl-ye
8
SAR-page3/9
2
re-ye
A
red 0.5
re-wh
1
9
re-bl
red-blue 0.5
16
brown 0.5
start auxillary relay
re-wh
gn
re-wh
1
gn
gn
7
gn
R-page3/9
re-wh
starter motor
M
6
C_BC/6
1
red -black 0.5
30
A
re-wh
2
2
3
8
1
ignition switch
C_BB/9
C_AB/9
battery
C_BI/2
C_AU/2
regulator-rectifier
start relay
30
re-wh
light system relay
B-page 6/9
C-page 5/9
D-page 5/9
G-page7/9
F-page7/9
2
C_AF2/4
H-page7/9
red-white 1
3
J-page3/9
A-page3/9
4
1
E-page3/9
31
Starting system 990 Adventure 2007NOTE: The starting system is equipped with security features.
The motorcycle can only be started under the following conditions:
– Ignition lock in the ON position
– Emergency-off switch in the ON position
– Transmission in the idle position or the clutch pulled
How the electric starter system operates:
The battery voltage flows from the battery to the fuse 1, ignition switch 2, emergency OFF switch 3, and finally to the tip
switch 4. By pressing the tip switch, the coil and load contact of the auxiliary start relay 5 are supplied with battery voltage.
The coil of the auxiliary start relay 6 is supplied with ground if at least one of the following conditions are met:
– Transmission in the idle position (neutral switch 7 closed, current can flow via the diode 8 and the neutral switch to chassis)
– clutch pulled (clutch switch 9 closed, current can flow via the clutch switch to chassis)
When the coil of the start auxiliary relay closes the load contact, the battery voltage flows to the starter relay 6, the contact of
the starter relay is closed and the starter motor 7 turns.
The diode bn is one of the starting system's important safety components. It prevents the starter engine from being actuated even
if a gear is engaged and the clutch is not pulled.
If the clutch is released with the engine running and a gear engaged although the side stand is folded down (driving off with the
side stand folded down) the ECU will interrupt the ignition and injection and immediately cause the engine to stall.
Components not named here, such as the neutral switch, clutch switch, etc., can be found in the wiring diagram of the engine
electronics in Chapter 13.
7-9
start/stop switch
diode
Immobilizer
4
5
6
7
8
48
1
28,29
/2.B2
10A
2
10A
2
-M1
M
8
1
gn
battery
-G1
30
A
regulator-rectifier
gn
C_AF/4
4
3
2
1
gn
2
58
1
59
2
U
re-wh
re-wh
-N1
30
CAN-L
ALA-A2
10A
/3.B2
/3.B2
/2.A2
175,143 -X12-P1
CAN-H
-F1 -F5 -F6
start relay
55
21
23
22
157
159
155
158
1
1
7
-K1
C_BI/2
3
156
153
-X12 splice
154
4
137
3
2
2
45,46
42
2
60,61
1
61,135,136,175,143
2
1
136
1
1
C_AI/2
52
C_DV/2
6
135
4
153
2
29,137
5
C_BK/4
C_BR/4
154
3
51,52
1
C_EL/2
starter
motor
-X1 splice
C_DO/8
C_BC/6
C_AC/6
C_AU/2
C_DN/8
40
-A2
57
3
-V1
56
5
-S2
56,57
2
58,59
antenna
immobilizer
ignition switch
-S1
-A1-X5
/2.C1
3
G
generator
5,13,20,38,50,54,55,63,65,197
-X2 splice
ACC
/3.B2
5,13,20,38,76,197,159
GND-X14
fuel-A2
fue-P1
Art.-No. 3.206.056-E
6
5
7
8
9
10 11 12 13 14
C_EF/14
-A1
C_EG/14
60
alarm system dummy plug
Connector for
optional
alarm system
STR-A3
/3.A5
1
3
4
42,43
2
41
4
43
3
40
1
53
2
45
30
4
54
49
1
48
2
50
3
/2.C1
/2.B5
/3.B2
51
1
47
47
2
77
46
4
76
44
Antenna
6
66
4
31
3
9
2
7
1
65
64
2
28
/3.E6
/3.E6
/3.B2
lig-X19
64
66 ALA-A1
63
7 flaR-X200
for optional alarm system
9 flaL-X200
/2.E5
2
1
3
1
C_BS/2
C_BV/2
C_EB/4
C_EB/4
C_EB/4
3
C_EB/4
4
C_AM/3
C_AR/3
-K2
-S3
seat
surveillance
fuel pump relay
M
fuel
pump
-K4
-K3
-M2
light relay
power relay
-K5
start auxillary
relay
Starting system 990 Supermoto
NOTE: The starting system is equipped with security features.
The motorcycle can only be started under the following conditions:
– Ignition lock in the ON position
– Emergency-off switch in the ON position
– Transmission in the idle position or the clutch pulled
How the electric starter system operates:
The battery voltage flows from the battery to the fuse 1, ignition switch 2, emergency OFF switch 3, and finally to the coil of
the start auxiliary relay 4.
The coil of the auxiliary start relay is supplied with ground if at least one of the following conditions are met:
– Transmission in the idle position (neutral switch closed, current can flow via the diode and the neutral switch to chassis)
– clutch pulled (clutch switch closed, current can flow via the clutch switch to chassis)
Repair manual KTM LC8
NOTE: If these conditions are met, the load contact is closed by the coil ("clicks" once).
When the tip switch 5 is actuated, battery voltage flows to the control unit of the alarm system (if present, otherwise via the
dummy connector 6), to the closed load contact of the start auxiliary relay 4, to the coil of the starter relay 7, and from there
to ground. The load contact of the starter relay is closed and battery voltage flows via the contact of the starter relay to the starter
motor 8.
If the clutch is released with the engine running and a gear engaged although the side stand is folded down (driving off with the
side stand folded down) the ECU will interrupt the ignition and injection and immediately cause the engine to stall.
The diode is a free wheeling diode; it is used to protect electronic components by reducing voltage peaks.
The light relay 9 is used to interrupt the power supply to the lighting system during the start procedure to relieve the battery.
Components not named here, such as the neutral switch, clutch switch, etc., can be found in the wiring diagram of the engine
electronics in Chapter 13.
7-10
Checking the auxiliary starter relay
– Dismount the auxiliary starter relay 1 (950 Adventure).
1
NOTE: orange, yellow, red and white/red cable colors.
– Dismount the auxiliary starter relay 1 (990 Adventure -2007).
NOTE: red/black (2x), yellow/white, red/blue cable colors.
– Dismount the auxiliary starter relay 1 (990 Adventure 2007-).
NOTE: red/black (2x), yellow/white, green/orange und red/blue
– Dismount the auxiliary starter relay 2 (990 Super Duke/R).
2
NOTE: red/black (2x), yellow/white, red/white cable colors
– Dismount the auxiliary starter relay 3 (950 Supermoto/R, 990
Supermoto).
NOTE: orange, yellow, red and white/red cable colors.
3
A
B
– Connect the auxiliary starter relay (see drawing) to a 12 V battery,
making sure you hear the relay switch (nonrecurring "click").
NOTE: the 12 V battery must be connected to the two terminals to
which the orange and yellow cable colors (950 Adventure/950
Supermoto) or red/black and yellow/white (990 Adventure/Super Duke)
are connected when the plug is connected.
– Use an ohmmeter to measure the continuity between terminals A
and B.
Reading: max 1 Ω OK
Reading: ∞ Ω defective
7-11
Functional check of the auxiliary starter relay (950 Adventure)
– Pull the auxiliary starter relay out of the bracket.
– Connect an ohmmeter or continuity tester to the cable of the
auxiliary starter relay (red and red/white cables).
– Perform the tests in the specified order. The auxiliary starter relay
must switch under the following 2 conditions:
– Slowly pull the clutch lever with the gear engaged. The auxiliary
starter relay should switch at half of the lever travel (ignition and
kill switch on).
If not, check the clutch switch. Observe the idle indicator lamp, it
may not light up. If it does, check the diode.
– Switch the transmission to neutral with the clutch released. The
auxiliary starter relay should switch on and switch off when the gear
is engaged. If not, check the diode and neutral switch
NOTE: You will hear a faint click when the auxiliary starter relay
switches. The ohmmeter or the continuity tester will display the
continuity when the auxiliary starter relay is switched on.
Functional check of the auxiliary start relay (990 Adventure/
990 Super Duke/R)
Art.-No. 3.206.056-E
–
Pull the auxiliary start relay out of the holder.
– Connect the voltmeter to the red/blue (990 Adventure) or red/white
(990 Super Duke/R) cable of the auxiliary start relay and measure
the voltage to chassis.
– Perform the tests in the specified order. The auxiliary start relay
must switch under the following conditions (the voltmeter will
display the on-board voltage):
– Slowly pull the clutch lever with a gear engaged and the tip switch
pressed. The auxiliary start relay switch will switch around half the
distance of the lever travel(ignition and emergency-off switch on!).
NOTE: if the starting system is working, the starter engine will start up
and start the engine.
If not, check the clutch switch. Watch the idle control lamp, it should
not light up. If it does, check the diode.
– Shift the transmission to neutral without pulling the clutch. The
auxiliary start relay should switch on and off again if the gear is
engaged. If not, check the diode and the neutral switch.
Functional check of the auxiliary start relay (950 Supermoto/R,
990 Supermoto)
Repair manual KTM LC8
– Pull the auxiliary start relay out of the holder.
– Connect the voltmeter to the red/blue cable of the auxiliary start
relay and measure the voltage to chassis.
– Perform the tests in the specified order. The auxiliary start relay
must switch under the following conditions (the voltmeter will
display the on-board voltage):
– Slowly pull the clutch lever with a gear engaged and the tip switch
pressed. The auxiliary start relay switch will switch around half the
distance of the lever travel(ignition and emergency-off switch on!).
NOTE: if the starting system is working, the starter engine will start up
and start the engine.
If not, check the clutch switch. Watch the idle control lamp, it should
not light up. If it does, check the diode.
– Shift the transmission to neutral without pulling the clutch. The
auxiliary start relay should switch on and off again if the gear is
engaged. If not, check the diode and the neutral switch.
7-12
Checking the diodes
NOTE: Diodes only conduct the current in one direction. They block in
the other direction.
1
Diodes can have 2 defects:
– the diode has no continuity.
– the diode has continuity in both directions.
Various malfunctions can occur, depending on the type of defect.
Each diode 1 (950/990 Adventure), 2 (990 Super Duke/R) and 3
(950 Supermoto/R, 990 Supermoto) is plugged into a bipolar
connector (connector AI)
1
Functional check:
– Connect a suitable ohmmeter to the diode and check the diode for
continuity.
– Connect the ohmmeter in the other direction and check if the diode
is blocked.
2
3
7-13
Checking the starter relay
– Disconnect the negative pole from the battery and dismount the
start relay.
– Connect the starter relay to a 12 V battery, making sure you hear the
relay switch (nonrecurring "click").
1
NOTE: the 12 V battery must be connected to the terminals to which
the connectors with following cable colors
.
950 Adventure: white/red 1 and brown 2
990 Adventure: red/blue 1 and brown 2
990 Super Duke: white red 3 and brown 4
950 Supermoto: red/blue 5 and brown 6
2
3
– Check the continuity between the two screw terminals with an
ohmmeter.
Reading: max. 1 Ω OK
Reading: ∞ Ω defective
4
Art.-No. 3.206.056-E
– Remove the fuse for the start relay and check for continuity.
6
5
Repair manual KTM LC8
Checking the starter motor
– Switch off the ignition.
– Disconnect the negative pole of the battery and remove the electric
starter motor.
– Clamp starter motor in a vise.
– Connect the negative pole of a 12 V battery to the housing of the
E starter motor and briefly connect the positive pole of the battery to
connection of the electric starter motor (use thick cables).
– The starter must turn as soon as the circuit is closed.
– If this is not the case, replace the starter.
7-14
Checking the clutch switch
– Disconnect the clutch switch connector from the cable tree.
– Connect an ohmmeter to the bipolar connector AT2 1 (950
Adventure) or AT1 1 (990 Adventure) or AT1 2 (990 Super
Duke/R) or AT3 3 (950 Supermoto/R, 990 Supermoto) of the clutch
switch and slowly pull the clutch lever.
– The switch should close around 2/3 of the lever travel.
1
2
3
Reading: max. 1 Ω when the clutch lever is pulled
Reading: ∞ Ω when the clutch lever is not pulled
7-15
Checking the tip switch and emergency OFF switch
1
– Disconnect the four-terminal connector BB 1 (950/990 Adventure),
2 (990 Super Duke/R) or 3 (950 Supermoto/R, 990 Supermoto)
on the tip switch / emergency OFF switch from the cable tree.
– Check both switches with an ohmmeter.
Tip switch: between pin 1 and pin 8
Reading: max. 1 Ω when the tip switch is actuated
Reading: ∞ Ω when the tip switch is not actuated
Emergency OFF switch: between pin 2 and pin 7
Reading: max. 1 Ω when the emergency OFF switch is switched on
Reading: ∞ Ω when the emergency OFF switch is switched off
– Afterwards check all lines for short circuit to ground.
Art.-No. 3.206.056-E
2
3
Repair manual KTM LC8
start/stop switch
C_BB/9
Pin 8
Pin 1
Pin 2
Pin 7
Troubleshooting in the starter system
If you actuate the tip switch but the starter engine does not run, check
the following points:
– Is the ignition lock in the ON position?
– Is the emergency OFF switch in the ON position?
– Does the idle indicator lamp light up when the ignition is switched
on?
– Can you start the engine when the clutch is pulled?
– Is the battery charged?
– Has the main fuse blown?
– Has the fuse for the electric starter system and ignition blown?
– Check the auxiliary starter relay
– Check the starter relay
– Check the E-starter engine
7-16
30
3
orange 1
pick up
5
2
9
throttle position sensor
1
2
7
orange 0.5
C_AR1/2
C_AT/2
C_AL1/2
black-orange 0.5
2
orange 0.5
C_AM/3
3 2
1
yellow-black 1
C_BB/9
C_AB/9
7
1
B
page 2/9
blue 0.5
10
yellow 0.5
1
black 0.5
8
blue-grey 0.5
6
13
pink 0.5
4
1
C
page 7/9
blue-white 0.5
7
black-brown 0.5
4
yellow-brown 0.5
11
grey 0.5
19
violet-white 0.5
25
C_AO/26
2
C_AF1/4
16
3
black-blue 0.5
U
yellow-white 0.5
brown-white 0.5
26
red-green 0.5
orange 0.5
1 2
2
C_AS1/2
orange 1
brown 0.5
C_AW/2
C_AW1/2
EPC 1 EPC 2
31
1
C_AS/2
1
6
C_AR/3
C_AM2/3
1
bk
C_BA/1
ignition coil
2 1 2
C_BF/1
1
2nd
front
8
2
1
18
3th
N
octane selector
fuel pump
31
E
C
yellow-blue 0.5
3
brown 0.5
4
20
2
2
1
C_AT/2
M
brown 0.5
30
fuel pump relay
battery
1
orange 1
fuse
5A
fuse
10 A
brown 0.5
start/stop switch
ignition switch
30
rear
neutral switch (N) / 2nd gear / 3th gear
31
Ignition system, ECU 950 Adventure
NOTE: this is a digital battery ignition system with the current supplied by the battery.
Battery voltage from the battery 1 flows to the ECU (control unit) 4 through the switched on ignition lock 2 and the switched
on emergency OFF switch 3.
The pulse generator 5 reports the crankshaft position to the ECU 4. The ECU uses this signal to calculate the ignition point for
each cylinder.
Battery voltage is supplied to both ignition coils 6 via the emergency OFF switch, the ground is switched by the ECU.
The coil on the fuel pump relay 7 obtains battery voltage from the ECU. After the ignition is switched on, the fuel pump relay
switches on for a few seconds and switches off again. If you start with the engine running, the fuel pump relay will stay on.
The fuel pump 8 obtains battery voltage from the battery through the switched on ignition lock 2 , via the fuse and the contact
on the fuel pump relay.
The throttle potentiometer (TPS) 9 reports the position of the carburetor throttle valves to the ECU via the yellow cable (on
connector AM or AR). The TPS is supplied with 5 volts of supply voltage (blue cable on connector AM or AR) by the ECU. The
black cable (on connector AM or AR) supplies the ground.
NOTE: See page 8-11 for the adjustment of the TPS.
The ECU receives a ground signal via the connected octane selector bk (connector BA and BF) and uses the stored ignition curve
for fuel with a minimum octane number of 95 (ROZ 95). If the octane selector is disconnected (connectors BA and BF pulled
apart) the engine can be operated with fuel with a minimum quality of ROZ 80.
7-17
30
30
start/stop switch
A-page2/8
7
5
sidestand switch
1
E-page2/8
throttle position sensor
9
red 0.5
C_AT/2
C_AR/3
C_AL/2
C _A M /3
2
1 2
1
C _AM 2 /3
C_AR2/3
3
1
3
7
2
fuel pump relay
3
4
4
5
5
6
6
7
7
8
8
9
9
10
10
11
11
12
12
13
13
14
14
4
yellow 0.5
4
black 0.5
C
1
blue-gr e y 0.5
8
pink 0.5
U
18
black-brown 0.5
16
yellow-brown 0.5
10
grey 0.5
2
violet-white 0.5
3
brown-white 0.5
20
re d -g ree n 0 .5
7
brown 0.5
2
2
18
1
orange 1
2 1
C_ A W /2
2
C_ A W 1 /2
2
1
C_AS/2
6
C_ AM 1 / 3
C_AR1/3
2nd
f r o nt
3th
N
C_AL2/2
M
8
rear
EPC 1 EPC 2
31
Art.-No. 3.206.056-E
1
C_AS1/2
1
C_AT2/2
2
1
17
K-page6/8
1
J-page2/8
ignition coil
C_DJ/18
18
blue 0.5
E
16
C_DK/18
17
19
11
15
16
yellow-white 0.5
brown 0.5
15
2
26
black-blue 0.5
3
3
yellow-blue 0.5
C_AF1/4
2
4
yellow-orange 0.5
fuel pump
2
or 0.5
13
25
brown 0.5
1
C_AO/26
alarm system dummy plug
1
3
yellow-orange 0.5
Connector for
optional
alarm system
yellow-black 1
2
pick up
brown 0.5
ignition switch
C_BB/9
C_AB/9
1
orange-black 0.5
2
neutral switch (N) / 2nd gear / 3rd gear
31
Ignition system, ECU 950 Supermoto
NOTE: this is a digital battery ignition system with the current supplied by the battery.
Battery voltage from the battery flows to the ECU (control unit) 4 through the switched on ignition switch 1, the switched on
emergency OFF switch 2 and the alarm system control unit (if installed, otherwise through the dummy plug 3).
The pulse generator 5 reports the crankshaft position to the ECU. The ECU uses this signal to calculate the ignition point for
each cylinder. Battery voltage is supplied to both ignition coils 6 via the emergency OFF switch, the ground is switched by the
ECU.
The coil on the fuel pump relay 7 obtains battery voltage from the ECU. After the ignition is switched on, the fuel pump relay
switches on for a few seconds and switches off again. If you start with the engine running, the fuel pump relay will stay on.
The fuel pump 8 obtains battery voltage from the battery through the fuse and the contact on the fuel pump relay (continuous
positive polarity).
The throttle potentiometer (TPS) 9 reports the position of the carburetor throttle valves to the ECU via the yellow cable (on
connector AM or AR). The TPS is supplied with 5 volts of supply voltage (blue cable on connector AM or AR) by the ECU. The
black cable (on connector AM or AR) supplies the ground.
Repair manual KTM LC8
NOTE: See Chapter 8 for the adjustment of the TPS.
7-18
30
30
A-page2/8
start bottom
4
orange-black 0.5
o-page5/8
engi n e s t op r el ay
E-page2/8
C_ BR/4
3
2 1
8
1
throttle position sensor
sidestand switch
C_ AF4/4
3
3
red 0.5
2
4
1
C_AT/2
C_ AL /2
2
yellow-white 0.5
19
bl ue 0.5
6
3
C_AM2/3
3
C_ AR2/3
1
2
3
2
4
C_AF1/4
26
11
y e l l ow 0.5
4
b l ac k 0 .5
2 C
1
blue-grey 0.5
8
pi nk 0.5
18
black-brown 0.5
1
16
yellow-brown 0.5
10
grey 0.5
2
violet-white 0.5
3
brown-white 0.5
20
red-green 0.5
7
brown 0.5
black-blue 0.5
J-page2/8
1
orange 1
2 1
brown 0.5
C _ AW/ 2
2
C _ AW1 / 2
1
C_ AS/2
ignition coil
C_ AS1/2
1
2
5
C_AM1/3
C_ AR1/3
2nd
front
7
2
1
2
3th
N
fuel pump
C_AO/26
fuel pump relay
C_AM/3
1 2
yellow-blue 0.5
E
U
C_ AR/3
1
yellow-orange 0.5
brown 0.5
13
25
yellow-black 1
C_BK1 /4
2
1
C_AT2/2
C_ AL 2/2
M
brown 0.5
ignition switch
black
pick up
rear
EPC 1 EPC 2
31
neutral switch (N) / 2nd gear / 3rd gear
31
Ignition system, ECU 950 Super Enduro
NOTE: this is a digital battery ignition system with the current supplied by the battery.
Battery voltage from the battery flows through the switched on ignition switch 1 to the ECU (control unit) 2.
The pulse generator 3 reports the crankshaft position to the ECU. The ECU uses this signal to calculate the ignition point for
each cylinder.
The ignition switch supplies the coil of the engine stop relay 4 with current, the ground is supplied by the emergency off switch,
i.e. the load contact closes when the emergency off switch is actuated. The engine stop relay is connected in parallel to the
pulse generator, which it short circuits when the emergency off switch is actuated, immediately causing the engine to stall.
Battery voltage is supplied to both ignition coils 5 via the ignition switch, the ground is switched by the ECU.
The coil on the fuel pump relay 6 obtains battery voltage from the ECU. After the ignition is switched on, the fuel pump relay
switches on for a few seconds and switches off again. If you start with the engine running, the fuel pump relay will stay on.
The fuel pump 7 obtains battery voltage from the battery through the fuse (continuous positive polarity) and the contact on the
fuel pump relay.
The throttle potentiometer (TPS) 8 reports the position of the carburetor throttle valves to the ECU via the yellow cable (on
connector AM or AR). The TPS is supplied with 5 volts of supply voltage (blue cable on connector AM or AR) by the ECU. The
black cable (on connector AM or AR) supplies the ground.
NOTE: see Chapter 8 for the adjustment of the TPS.
7-19
ECU 950 Adventure/Supermoto/Super Enduro
Check the cables and socket connectors on the ECU 1 (950
Adventure) and 2 (950 Supermoto/Super Enduro).
A functional check of the ECU can only be performed on an ignition
test stand.
1
– Check the ignition coil control: remove the ignition coil connector
and apply the measuring tips of the peak voltage adapter to the pins
of the connector AS (see checking the ignition coils).
– Actuate the tip switch and let the starter engine run for a few
seconds
Multimeter reading: 12 volts
!
CAUTION
!
TEST THE ECU WITH A CONVENTIONAL MEASURING DEVICE. THIS MAY
DESTROY HIGHLY SENSITIVE ELECTRONIC COMPONENTS.
NEVER
2
Checking the pulse generator 950 Adventure/950 Supermoto
Art.-No. 3.206.056-E
– Disconnect the connectors AL and AT and apply the measuring tips
of the peak voltage adapter to the connector AT 3 (yellow/blue and
yellow/white cable colors).
– Actuate the tip switch and run the starter engine for a few seconds.
Digital multimeter reading: 4.0 volts +/- 0.5 volts
NOTE: make sure the battery is fully charged.
3
– If the measured value deviates from the set point value, measure the
resistance of the pulse generator:
190 - 300 Ω at 20°C
NOTE: if the resistance figure is correct but the signal voltage deviates,
check the distance between the pulse generator and the pulse
generator wheel (see Chapter 6).
Repair manual KTM LC8
3
7-20
Checking the fuel pump relay 950 Adventure/950 Supermoto
– Dismount the fuel pump relay 1 (950 Adventure) and 2 (950
Supermoto).
NOTE: black/blue, blue/gray, yellow/black and brown cable colors
1
– Connect the fuel pump relay to a 12 V battery as shown, making
sure you hear the relay switch (nonrecurring "click").
NOTE: the 12 V battery must be connected to the two terminals to
which the blue/gray and brown cable colors are connected when the
plug is connected.
– Use an ohmmeter to measure the continuity between the terminals
A and B.
2
Reading: max. 1 Ω OK
Reading: ∞ Ω defective
A
B
Checking the ignition coils 950 Adventure/Supermoto/Super Enduro
3
– Disconnect and remove the ignition coil 3.
– Use an ohmmeter to obtain the following measurements:
Resistance of the primary coil (measured between the terminals):
1.0 – 1.6 Ω at 20°C
Resistance of the secondary coil (measured between one terminal and
the spark plug connector: 9.4 – 17.6 KΩ at 20°C
NOTE:
– Repeat the measurement for the other ignition coil.
– Replace the respective ignition coil if the measurement deviates
significantly from the set point value.
7-21
Troubleshooting in the ignition system 950 Adventure/950 Supermoto
Before checking the ignition, make sure:
– the ignition lock is in the ON position
– the emergency OFF switch is in the ON position (does not apply to the 950 Super Enduro)
– the battery is charged
– the main fuse is OK
– the fuse for the electric starter system and ignition is OK
Check whether there is an ignition spark upon starting:
– Pull of the ignition coil and remove the spark plug.
– Hold the spark plug and the ignition coil against the ground (engine case).
– A strong spark should be visible when the starter is actuated. If not, try a new ignition coil or new spark plug.
If no spark is visible during the first test, perform the following tests:
– Is battery voltage being applied to the ECU (orange cable color at connector AO) and to the ignition coils (orange cable colors
to both connectors AS)?
– Check the ignition control. Are the coils being controlled?
– If not, check the ignition lock, emergency OFF switch and the corresponding parts on the cable tree and the fuse for the
ignition and electric starter system, for the 950 Super Enduro, also check the emergency off switch and the engine stop relay
(relay should not attract).
If
–
–
–
the ignition is being supplied with voltage but no spark is visible, check:
the ground from the ECU
the cable from the ECU to the ignition coil
the pulse generator
Repair manual KTM LC8
Art.-No. 3.206.056-E
NOTE: the ECU cannot be tested with simple devices. It can only be tested on an ignition test stand.
7-22
30
30
3
ignition switch
2
pick up
throttle position sensor
fuse
10 A
1
2
7
orange 0.5
C_AL1/2
2
orange 0.5
C_AM/3
3 2
1
1
blue 0.5
10
yellow 0.5
1
black 0.5
8
blue-grey 0.5
6
13
pink 0.5
4
1
C
page 7/9
blue-white 0.5
7
black-brown 0.5
4
yellow-brown 0.5
11
grey 0.5
19
violet-white 0.5
25
C_AO/26
2
C_AF1/4
16
3
black-blue 0.5
U
yellow-white 0.5
brown-white 0.5
26
red-green 0.5
2
orange 0.5
1 2
2
C_AS1/2
brown 0.5
C_AW/2
31
1
C_AW1/2
EPC 1 EPC 2
5
C_AS/2
1
C_BA/1
ignition coil
2 1 2
orange 1
C_AR/3
C_AM2/3
1
C_BF/1
1
2nd
front
rear
1
C_AT/2
2
1
18
3th
N
6
octane selector
fuel pump
31
E
C
yellow-blue 0.5
3
B
page 2/9
brown 0.5
4
20
2
M
brown 0.5
30
fuel pump relay
battery
1
C_AR1/2
C_AT/2
black-orange 0.5
fuse
5A
yellow-black 1
C_BB/9
C_AB/9
orange 1
7
brown 0.5
start/stop switch
orange 1
neutral switch (N) / 2nd gear / 3th gear
31
The EPC system 950 Adventure
Mode of operation:
Battery voltage from the battery 1 is conducted to the ECU (control unit) 4 through the switched on ignition lock 2 and the
switched on emergency OFF switch 3.
The EPC valves 5 are supplied with battery voltage via the emergency OFF switch, the ground (red/green cable) is switched by
the ECU.
The ECU receives a ground from the gear sensor 6 via the grey (2nd gear) or via the violet/brown (3rd gear) cable if one of the
two gears is engaged.
If the throttle grip is opened all the way (which the ECU recognizes via the TPS 7) at a certain speed (or a certain number of
revolutions) in 2nd or 3rd gear, the ECU activates the ground control of the EPC valves.
Subsequently, the EPC valves will open an air connection to the carburetor diaphragm covers. A controlled amount of fresh air
can be sucked into the space above the diaphragm, reducing the vacuum over the carburetor diaphragm.
This causes the carburetor slides to open more slowly resulting in a lower air-gap area to be sucked in through the engine. The
engine performance and noise are significantly reduced.
NOTE: if the EPC valves are disconnected, this will not influence the other systems.
7-23
30
30
start/stop switch
A-page2/8
7
sidestand switch
1
E-page2/8
throttle position sensor
7
red 0.5
C_AT/2
C_AR/3
C_AL/2
C _A M /3
2
1 2
1
C _AM 2 /3
yellow-black 1
2
pick up
C_AR2/3
3
1
3
2
fuel pump relay
3
3
4
4
5
5
6
6
7
7
8
8
9
9
10
10
11
11
12
12
13
13
14
14
yellow 0.5
4
black 0.5
C
1
blue-gr e y 0.5
8
pink 0.5
U
18
black-brown 0.5
16
yellow-brown 0.5
grey 0.5
2
violet-white 0.5
3
brown-white 0.5
20
re d -g ree n 0 .5
7
brown 0.5
2
1
C_AS1/2
18
1
orange 1
2
1
17
31
1
J-page2/8
10
K-page6/8
Art.-No. 3.206.056-E
4
2 1
C_ A W /2
2
C_ A W 1 /2
5
2
1
C_AS/2
ignition coil
C_DJ/18
18
blue 0.5
E
16
C_DK/18
17
19
11
15
16
yellow-white 0.5
brown 0.5
15
4
2
26
black-blue 0.5
2
3
yellow-blue 0.5
C_AF1/4
2
or 0.5
yellow-orange 0.5
2nd
f r o nt
6
2
3th
1
C_AT2/2
C_ AM 1 / 3
C_AR1/3
N
fuel pump
1
C_AO/26
1
13
25
brown 0.5
3
yellow-orange 0.5
alarm system dummy plug
Connector for
optional
alarm system
C_AL2/2
M
brown 0.5
ignition switch
C_BB/9
C_AB/9
1
orange-black 0.5
2
rear
EPC 1 EPC 2
neutral switch (N) / 2nd gear / 3rd gear
31
The EPC system 950 Supermoto/R
Mode of operation:
Battery voltage from the battery flows to the ECU (control unit) 4 through the switched on ignition switch 1, the switched on
emergency OFF switch 2 and the alarm system control unit (if installed, otherwise through the dummy plug 3).
The EPC valves 5 are supplied with battery current via the emergency OFF switch, the ground (red/green cable) is switched by
the ECU.
The ECU receives a ground from the gear sensor 6 via the grey (2nd gear) or via the violet/brown (3rd gear) cable if one of the
two gears is engaged.
If the throttle grip is opened all the way (which the ECU recognizes via the TPS 7) at a certain speed (or a certain number of
revolutions) in 2nd or 3rd gear, the ECU activates the ground control of the EPC valves.
Subsequently, the EPC valves will open an air connection to the carburetor diaphragm covers. A controlled amount of fresh air
can be sucked into the space above the diaphragm, reducing the vacuum over the carburetor diaphragm.
This causes the carburetor slides to open more slowly resulting in a lower air-gap area to be sucked in through the engine. The
engine performance and noise are significantly reduced.
Repair manual KTM LC8
NOTE: if the EPC valves are disconnected, this will not influence the other systems.
7-24
30
30
A-page2/8
start bottom
o-page5/8
orange-black 0.5
engi n e s t op r el ay
E-page2/8
C_BK1 /4
C_ BR/4
3
2 1
5
1
throttle position sensor
sidestand switch
C_ AF4/4
3
2
4
1
yellow-black 1
red 0.5
C_AT/2
C_ AL /2
2
13
25
yellow-blue 0.5
26
yellow-white 0.5
19
bl ue 0.5
11
E
y e l l ow 0.5
4
b l ac k 0 .5
2 C
1
blue-grey 0.5
8
pi nk 0.5
18
black-brown 0.5
3
C_AM2/3
3
C_ AR2/3
2
3
2
4
C_AF1/4
1
1
yellow-brown 0.5
grey 0.5
2
violet-white 0.5
3
brown-white 0.5
20
red-green 0.5
7
brown 0.5
2
1
C_ AS1/2
orange 1
2 1
brown 0.5
C _ AW/ 2
2
C _ AW1 / 2
3
1
C_ AS/2
C_AM1/3
C_ AR1/3
4
ignition coil
1
2
2nd
front
1
C_AT2/2
2
1
2
3th
N
fuel pump
16
black-blue 0.5
J-page2/8
10
31
fuel pump relay
C_AM/3
1 2
brown 0.5
C_AO/26
U
C_ AR/3
1
yellow-orange 0.5
C_ AL 2/2
M
brown 0.5
ignition switch
black
pick up
rear
EPC 1 EPC 2
neutral switch (N) / 2nd gear / 3rd gear
31
EPC system 950 Super Enduro
Mode of operation:
Battery voltage from the battery is conducted through the switched on ignition switch 1 to the ECU (control unit) 2.
The EPC valves 3 are supplied with battery voltage via the ignition switch, the ground (red/green cable) is switched by the ECU.
The ECU receives a ground from the gear sensor 4 via the gray (2nd gear) or via the violet/brown (3rd gear) cable if one of the
two gears is engaged.
If the throttle grip is opened all the way (which the ECU recognizes via the TPS 5) at a certain speed (or a certain number of
revolutions) in 2nd or 3rd gear, the ECU activates the ground control of the EPC valves.
Subsequently, the EPC valves will open an air connection to the carburetor diaphragm covers. A controlled amount of fresh air
can be sucked into the space above the diaphragm, reducing the vacuum over the carburetor diaphragm. This causes the
carburetor slides to open more slowly resulting in a lower air-gap area to be sucked in through the engine. The engine
performance and noise are significantly reduced.
NOTE: if the EPC valves are disconnected, this will not influence the other systems.
7-25
Checking the solenoid valve for the EPC 950 Adventure, 950
Supermoto/R, 950 Super Enduro
– To check, disconnect connector AW 1 from the solenoid valve.
– Connect a 12-V battery with the two terminals on the solenoid valve.
1
– You should hear a click in the solenoid valve (the diaphragm
opening) when the circuit is closed.
– If you don't hear a click, the solenoid valve needs to be replaced.
– Repeat the procedure for the second valve 2.
!
CAUTION
!
THE RETAINING CLIP FOR THE FRONT EPC VALVE IS BENT, THE EPC VALVE WILL BE
ABLE TO TOUCH THE FRAME. THE ENGINE VIBRATIONS CAN CAUSE IT TO OPEN
SLIGHTLY, RESULTING IN A LACK OF POWER FOR THE ENTIRE SPEED RANGE.
IF
2
Art.-No. 3.206.056-E
Checking the gear sensor 950 Adventure, 950 Supermoto/R,
950 Super Enduro
3
–
Use a digital multimeter to measure the voltage between the
blue/green cable (neutral) and the ground on connector AM/AR 3 (950
Adventure) and 4 (950 Supermoto/Super Enduro) with the cables
connected.
Multimeter reading: 0 - 2.5 volts with the transmission in neutral
Multimeter reading: over 2.6 volts with a gear engaged
– Measure the voltage between the gray cable (2nd gear) and the
ground.
Multimeter reading: 0 - 2.5 volts with the transmission in 2nd gear
Multimeter reading: over 2.6 volts with the transmission not in 2nd gear
– Measure the voltage between the yellow/brown cable (3rd gear) and
the ground.
Repair manual KTM LC8
4
Multimeter reading: 0 - 2.5 volts with the transmission in 3rd gear
Multimeter reading: over 2.6 volts with the transmission not in 3rd gear
3
1 2
2
C_BF1/1
start auxillary relay
re-wh 3
re
1
4
or
2
C_AF/4
ye
re-wh
or
ye-re
diode
diode
rear
brake switch
re
br
ye-bl
C_BH/6
C_AP/6
4 5
6
C_AK2/2
ye-re
3
C_AI/2
2 1
gn-bl
C_AI1/2
2
pi
C_AH1/2
2
1
ye
1
gn-wh
re-wh
1
ye-bu
re-wh
2
re
re-wh
3
or
or
or
ye-re
A
A
bl-bu
f u se box
ye
2
Q
re-wh
ye-re
A
bl-wh
ye-bl
10 15 10
A
y e - bu
2
10 10 10 10 10
A
ye
A
b l - or
AL/2
A
AT2/2
A
1
C_AT1/2
br-re
C_AL2/2
ACC1
always ON
br
ignition switch
fuel level sensor
C_BA1/1
2
3
ye-bl
ch switch
C_AF1/4
b u - gr
rn
2
re-wh
4
br
4
ACC2
switched
1
re-wh
C_AE/4
f ue l p um p r e l a y
re-wh
3
ye
6
wh
ye-br
9
bl-or
2 7
re-wh
C_AU1/2
C_BI1/2
M
C_AT/2
30
A
M
1
or
1
f u e l pum p
1
4
battery
br
2
C_AH4/2
C_AB/9
8
start relay
starter motor
carb body
carb heater 2
1
bl-bu
wh
re-ye
ye-wh
0
bl
bl-wh
bl-bu
1
C_BB/9
re
G
or
r ela y
or
2
carb heater 1
light switch
start/stop switch
temperature switch
7-26
g n - gr
Adventure carburetor heater 950 Adventure, 950 Supermoto/R,
950 Super Enduro
1
Mode of operation: to prevent the carburetor from icing at low outdoor
temperatures and high humidities, both carburetors are heated by one
heating element 1 each. The air temperature must be below 3-9ºC and
the ignition on for the heaters to operate.
Current flows via the ignition switch 2 and a 10-ampere fuse 3 to the
temperature switch 4 under the headlight mask. From there it
continues to both heating elements 1 at a temperature of less than 39ºC.
Checking the heating elements
Use a digital multimeter to measure the resistance of the heating
elements.
Set-point value: 5 - 10 Ω at 20ºC
NOTE: if the resistance is higher, replace the heating element.
Checking the temperature switch
Disconnect the connector 4 and use a digital multimeter to measure
the resistance of the temperature switch (between the 2 yellow cables).
4
Set-point value: less than 1 Ω at temperatures of less than 3ºC
Set-point value: 8 Ω at temperatures of more than 16ºC
NOTE:
– If the resistance is ∞ Ω under 3ºC, replace the temperature switch.
– The temperature switch will switch on between 3ºC and 9ºC and off
between 10ºC and 16ºC.
– if no error was found and the carburetor heater still won't work,
check the ground supply to the carburetor by using a digital
multimeter to check the resistance between the carburetor and the
negative pole on the battery. The measured resistance should be less
than 1 Ω.
7-27
INJECTION/IGNITION SYSTEM
Establishing the injection period (injection volume)
Generally, the injection volume, i.e. the quantity of injected fuel, is dependent on the fuel pressure and the time the injection
valve is open. Since the fuel pressure regulator keeps the fuel pressure constant, the quantity of fuel injected is controlled by the
time the injection valve is open.
The basic injection rate is determined by the engine speed and manifold air pressure or throttle valve position; the opening
period is directly dependent on the engine load (manifold air pressure/throttle valve signal); fuel is injected every 720° crank
angle (every other rotation).
Additional sensors establish the operating conditions and driving conditions (e.g.: coolant and air temperature, ambient air
pressure, battery voltage, etc.); the basic injection rate is corrected based on the signals received from these sensors.
Control unit (ECU)
Manifold air pressure sensors/
throttle valve sensor
Basic injection rate
Pulse generator
Correction
Corrective sensors/inputs
Art.-No. 3.206.056-E
Actual injection rate
Injection valves
CORRECTION SENSORS AND INPUTS
SENSOR/INPUTS
INFORMATION
Coolant temperature sensor
The injection time must be prolonged and the idle speed increased for a
cold start and during the warming-up phase (required for starting
enrichment and a steady warming-up).
Throttle valve sensor
The quantity injected is dependent on the TPS position in the upper
Repair manual KTM LC8
load/speed range, it also influences the ignition.
Air temperature sensor
The injection time is prolonged at a lower intake air temperature and
reduced at a high temperature.
Ambient air pressure sensor
The injection time is reduced at a low ambient air pressure (e.g.: uphill
driving) and prolonged at a high ambient air pressure (the oxygen level
of the intake air drops as the altitude increases).
Lambda probes
The oxygen level in the emission (rich-mixture combustion results in
less residual oxygen, lean combustion in more residual oxygen).
Battery voltage
The injection time is prolonged at a low battery voltage.
7-28
SYSTEM DIAGRAM
CLUTCH: Clutch switch
CRK: Pulse generator
ECU: Control unit
EXAI: Secondary air valve
FLPR: Fuel pump relay
FUEL PUMP: Fuel pump
GP2: 2nd gear switch
GP3: 3rd gear switch
HEGO: Lambda probes
IGN: Ignition coils
IGP: Battery
INJ: Injection valves
ISC: Idle control motor
K-LINE: Diagnostics connector
MIL: Error lamp
MR: Main relay
NLSW: Neutral switch
PA: Ambient air pressure sensor
PM: Manifold air pressure sensors
PRESSURE REGULATOR: Pressure
regulator
PVC: Carbon canister purge valve (USA)
ROLL: Roll angle sensor
SSTAND: Side stand switch
TA: Air temperature sensor
TAC: Control motor for 2nd throttle valve
TACHO: Tachometer
TAP2: Sensor for 2nd throttle valve
TH: Throttle valve sensor
TW: Coolant temperature sensor
FUEL PUMP
PRESSURE REGULATOR
FLPR
IGP
MR
MIL
TACHO
ECU
PVC
K-LINE
TA
PA
ISC
EXAI
TAP2
TH
INJ2
INJ1
TAC
PM2
PM1
IG
N1
N2
IG
TW
HEGO2
CRK
HEGO1
ROLL
SSTAND
NLSW
GP2
GP3
CLUTCH
7-29
BASIC DESCRIPTION OF THE SYSTEM
Fuel system:
Fuel is drawn in by the fuel pump via the fuel screen and pumped through the fuel filter to the pressure regulator. All of these
components are located in the tank.
Since the fuel pump's flow rate and flow pressure are considerably higher than required by the injection system, a constant
pressure of 343 kPa (3.5 bar) is selected by means of the pressure regulator. The excess fuel returns to the fuel tank
unpressurized.
The pressurized fuel flows from the pressure regulator to the injection valves and is injected into the induction manifold when
the injection valves are opened (induction manifold or indirect injection).
The system does not require an external return line since the pressure regulator is installed in the tank.
Injection:
The injection nozzles are controlled by the control unit based on the pressure conditions in the induction manifold (manifold air
pressure sensors) and the rotational speed (pulse generator), taking the corrective injection periods into account (see above) this applies to the lower load/speed range. The opening of the injection nozzles is calculated according to the speed and throttle
valve signals at higher loads or speeds.
The injection is sequential, i.e. each injection nozzle is individually controlled and the fuel injected into the intake port of the
respective cylinder.
Ignition:
The ignition is also controlled by the ECU using a conventional transistor ignition system. Both the ignition timing and the
closing angle are calculated according to a stored map.
The ignition timing is established based on the following information: rotational speed, position of the throttle valve, the coolant
temperature and the operating condition (idle/not in idle). The ignition timing is also reduced if the two octane selector
connectors are not connected (when using low-octane fuel).
Idle control:
Art.-No. 3.206.056-E
The control unit controls the idle speed depending on the cooling liquid temperature by opening the throttle valve wider or less
wide with the idle speed control motor.
Trailing throttle fuel cutoff:
If the driver closes the throttle valve with the engine running at operating temperature at a speed of at least 5000 rpm (overrun
condition, i.e. the motorcycle is driving the engine), the control unit will interrupt the control of the injection valves until the
minimum speed drops below 5000 rpm. Purpose: to save fuel and improve exhaust emissions.
Speed limitation:
To avoid damage to the engine, the control of the injection nozzles is cut off at speeds exceeding 9600 rpm and the ignition
coils cut off at speeds exceeding 10100 rpm.
Secondary air control:
Fresh air is introduced into the exhaust through a valve during the warm-up stage to improve the emission quality and to reduce
the catalytic converter light-off time. Afterburning takes place.
Lambda control:
Repair manual KTM LC8
A lambda probe (one probe per cylinder) is used to find the ideal fuel/air ratio for the best possible combustion (at a mixture
ratio of 1 kg fuel and 14.7 kg air). The catalytic converter installed in the exhaust can operate at maximum efficiency (at a
maximum conversion rate).
The goal is to obtain the maximum lambda 1 air ratio, i.e. to make the air volume actually drawn in by the engine equivalent to
the air volume theoretically required (to burn the quantity of injected fuel).
If the quantity of drawn-in air is smaller (i.e. air deficiency), the mixture is rich (lambda less than 1).
If the quantity of drawn-in air is greater (i.e. excess air), the mixture is lean (lambda greater than 1).
Electronic power control (EPC):
Under certain operating conditions, the second throttle is controlled in accordance with the throttle valve position and speed.
Error detection/elimination:
An "FI" error lamp is installed in the multifunctional digital speedometer that lights up for 2 seconds after "Ignition on" (function
indicator) and goes out if the control unit fails to detect any errors.
The error lamp will stay on during operation if an error is detected; if the vehicle is standing (gear in neutral) the error lamp will
start to blink according to the respective error code.
The registered error codes can be read out through the diagnostics connector using the KTM diagnostics tool and deleted after
the error has been eliminated.
31
4
5
s en so r
rollover
C_AP2/6
bl
ye-re
bu
6
re-gn
or
wh-bl
br
3
L
L
rear
t°
p
C_BZ1/3
3
2
2
1
1
2
3
p
C_BZ/3
1
1
2
C_CM/2
t°
1
pu
3
p
C_BZ2/3
2
bl
2
or
br
or-wh
g n -re
1
3
C_AR3/3
C_AM3/3
2
P i c k up
C_AT/2
C_AL/2
1
3
4
2
1
15
fuse
10 A
7
sidestand switch
main relay
ye-wh
manifold pressure sensor rear
atmospheric pressure sensor
990 Super Duke 05
lambda sensor´s
f r ont
t°
C_CE/4
2
C_CE1/4
4 1
wh-or
C_CA/4
3
bl
C_CA1/4
4 1 2
bl
C_AX/2
ye-bl
gn-gr
bu
ye
re-br
or
t°
bl
bl
2
water temperature sensor
manifold pressure sensor front
1
bu
re
bl
bl
C_AL1/2
bu-bl
air temperature sensor
bu
C_AF/4
bl
C_AT1/2
ye-bu
re-wh
2
C_AI/2
1
7 13 14 3 24 23 11 12 4
C_AO/26
2 10 9 22 6 20 25 26 19 15 18 17
1
diode
1
2
3
C_AM2/3
ye-re
br
or
C_AR2/3
4
1
6
I
page 6/9
C_BB/9
1
8
ECU
2
33 15 13 23 11 3
bl
bl
or
C_CO/34
7 21 12 4 22 5
7
2
ye-or
diagnostic
c o nn e c to r
C_AB/9
6 29 26
H
6/8
G
6 /8
C
6/8
gr
ye-br
gn-bl
C_BH1/6
9 14 16 34
or
ignition switch
pi
N
3th
2nd
C_AP1/6
start/stop switch
ignition coil
bu
3rd gear
or-bl
or
f r ont
rear
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
fuse
10 A
14
10
8
4
5
11
bl-wh 9
o r 13
b l - gr
pi
bu-wh 3
gn-wh 7
b l - b r 15
wh-re 12
wh
gn
b l - o r 16
bu
ye
2
exhaust
air valve
C_CK/2
1
2
or
ye-wh 6
bl
9
1
re-wh
C_CP/16
C_CQ/16
bl
wh
610.41.012.000
3
f r ont
1
rear
C_CL/2
2
1
C_CL1/2
2
bu-bl
or
pu
ye
bu
re
gr
gr
wh
gn
pu
bu
2
C_AM/3
5
4
TPS
2
2 1
C_CA2/4
C_CE2/4
fuel pumprelay
3
2
C_AM4/3
C_AR4/3
2
M
fuel pump
4
1 3
C_AE/4
1
B
6/8
Q
f u e l pum p unit
3/8
ISC
stepper motor
s e c on d
throttle stepper motor
3
4
C_AR1/3
1
3
3
2
C_AM1/3
C_AF1/4
1
13
fuse
10 A
2nd TPS
C_AR/3
1
g n - re
airbox harness
1
C_AS/2
2
1
C_AS1/2
2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
or
Connector for
optional
alarm system
wh-br
C_DK/18
or
ignition switch
alarm system dummy plug
re-bl
or-wh
br
gr
bu-bl
wh
clutch switch
E
gn
pu
re-wh
or-wh
bu
bl
ye-bu
ye-wh
pu
bu-bl
gn-gr
re-br
re-gn
ye-re
ye
ye-wh
ye-bl
re
br
ye-or
ye
pi
gn-bl
ye-br
gr
ye-re
C
C_DJ/18
wh-pu
bu
or
bu-gr
br
br
bu-wh
wh
bu-br
or
bu
injector´s
or
bl
bu-bl
ye-bl
wh
ye
2nd gear neutral switch
wh-or
wh-bl
re-bl
bl-or
gn
wh
wh-re
bl-br
gn-wh
bu-wh
pi
bl-gr
bl-wh
wh-pu
wh-br
U
gn-re
or
bu-gr
pu
bu-bl
bu
bl
re
gr
br-re
30
31
30
7-30
WIRING DIAGRAM 990 SUPER DUKE
fuel level sensor
1
225
2
-B2
6
4
C_AP/6
5
3
4
164,165
-X7 splice
133,139,50,141
/1.E8
-B15
hego sensor
front
t°
1
t°
-B16
1
p
C_DP/3
2
164
-B4
atmospheric
pressure
sensor
3
/3.B2
137
1
p
C_DP/3
2
C_AR/2
-X101
205,209,210
205,206
1
p
C_DP/3
2
-B18
GND-P1
168,204
manifold
pressure
sensor rear
-B17
3
2
49
3
/1.D2
/3.B2
2
pick up
C_AT/2
C_AL/2
1
1
/3.B6
2 3 4 5 6
C_AO/26
ECU
-L3
/3.D4
GND-S5
-A2
-A2-P1
GND-H4
214,215,33
49,176,177,178
156,157,158
-X13 splice
-X17 splice
206,223
-X2 splice
GND-X2 4
1
C_AM/2
53,55,56,207,208,211,212,213
manifold
pressure
sensor front
3
/1.C7
-X8 splice
2
990 Superduke R 2008
hego sensor
rear
L
2
C_CE/4
3
C_CA/4
4
C_CE/4
1
C_CA/4
2
GND-X8
142,146,147,150,152,155,159,162,225
-X6 splice
132,133,134,135,136,137
-X15 splice
120,121,122,124,125,123
117,120,119,118
L
rollover
sensor -B7
50
-X16 splice
air temp.
sensor
t°
C_CM/2
145
159
-X11 splice
138
fue-P1
140
160
-X10 splice
165
156
134
161
115,116
149
-A1-X10
154
/1.D7
152
155
150
117
147
212
153
175
148
201
121
3
151
/3.B2
1
136
174
C_AR/3
132
tem-P1
139
211
122
2
167
1
168
C_AT/2
175
173
171
154
172
149
170
2
1
7
6
5
4
3
2 3 4 5 6
C_CO/34
1
8
214
/3.B2
/3.A8
178 Neu-P1
GND-X3
195
135
187
167
188
170
183
146
181
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
2.11
2.12
2.13
2.14
2.15
2.16
-A2-P1
313,314,315
319
312
310
308
305
304
300
306
303
320
316
311
309
307
1
C_CL/2
2
TAC-P1
1
ignition coil
front
C_EP/3
C_EO/3
3
/3.B2
2
1
C_CL/2
/3.B2
2
-Y4
3
2
1
M
1
-L5
MIL-P1
/3.B2
1
C_DU/2
1
2
M
-M6
C_CE/4
C_CA/4
2nd throttle
stepper motor
3
4
3
2
1
C_CK/2
611.11.175.000
610.41.012.000
main harness -
3 P.
Page:2
-Y1
-Y2
purge valve
exhaust air
valve
2
2
-M5
C_AE/4
1
C_AM/3
C_AR/3
2nd throttle
position sensor
ISC
stepper motor
3
-B14
4
ignition coil
rear
C_EP/3
C_EO/3
3
injection
rear
2
-L6
-Y3
300,301,302
1
C_AR/3
C_AM/3
main throttle
position sensor
316,317,318
-B13
injection
front
2
313
-X310 splice
-X309 splice
/3.F2
-X308 splice
193
125
194
186
189
185
184
CLU-A2
179,180,181
-X18 splice
7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34
215
E C U
7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
169
C_AL/2
174
200
126
157
STR-A3
145
3
141
176
2
179
1
158
C_EC/3
186
C_DO/8
187
C_DN/8
184
222
185
N
189
3th
191
2nd
188
C_AM/3
192
R
196
-A3 Starter Interlock Unit
190
180
/1.E7
140
-S11
148
169
151
-B11
138
-B3
163
6
194
4
193
1
195
C_AP/6
199
-X50
197
t°
198
-B9 t°
153
gear position
switch
142
C_CP/16
-X307
C_CQ/16
sidestand
sensor
160
9 87 65 4 3 2 1
16 15 14 13 12 11 10
173
162
309
fuel level
sensor
163
317
315
C_BH/6
171
301
diagnostic
connector
172
306
199
fuel-A2
182
320
177
/1.E4
183
314
196
304
water temp.
sensor
123
305
197
308
Art.-No. 3.206.056-E
118
303
302
311
318
312
198
307
119
310
124
319
190
Repair manual KTM LC8
7-31
SCHALTPLAN 990 SUPER DUKE R
114
air temp.
sensor
t°
C_CM/2
1
2
113
-B3
1
3
4
6
-X54
C_CZ/3
C_CY/3
2
-B5
t°
2
1
t°
-B6
-X4 splice
2
1
p
C_DP/3
-B7
1
3
2
1
p
C_DP/3
-X101
-B8
manifold
pressure
sensor front
3
1
2
2
1
p
C_DP/3
125
GND-P1
2
/3.B2
198,5,13 GND-X14
-X53
-B9
75
manifold
pressure
sensor rear
3
2.1
C_BJ/1
C_AY/1
1
89,179,186,126
pick up
C_AT/2
C_AL/2
1
-X8 splice
184
74
2 3 4 5 6
152
C_AO/26
1
118
ECU
-L3
-A4
/3.D6
-X6 splice 86,189,190
73,76,198,197,159
3
-X7 splice
19
125
122
96
87
7
6
5
4
3
2
1
1
2 3 4 5 6
C_CO/34
Neu-P1
192
17,157
/3.B2
97
110
104
106
108
102
100
98
-X301 splice
7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34
215
211
207
219
206
218
205
199
204
212
209
202
210
203
208
1
C_CL/2
176
ignition
coil
front
1
-L1
TAC-P1
MIL-P1
2
1
C_CL/2
injection
rear
2
ignition
coil
rear
-L2
1
/3.B2
/3.B2
C_AS/2
2
-Y3
215,216,217
1
C_AR/3
C_AM/3
1
M
-M4
1
or 1
2
2
C_CK/2
1
main harness 626.11.076.000
210
1
M
-M5
C_CE/4
C_CA/4
2
211
3 P.
Page:2
2nd throttle
stepper motor
3
4
3
-Y1
-Y2
purge valve
exhaust air
valve
2
2
C_AE/4
3
1
C_AM/3
C_AR/3
2nd throttle
position sensor
ISC
stepper motor
4
-B13
C_DU/2
-Y4
3
main throttle
position sensor
212,213,214
-B12
injection
front
2
180
C_AS/2
2
199,200,201
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
2.11
2.12
2.13
2.14
2.15
2.16
/3.F1
-X302 splice
-X303 splice
111
109
107
105
103
101
99
142 CLU-A2
-X11 splice
-X10 splice 191
-X9 splice
179
158,16
8
E C U
7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
124
C_AR/2
185
C_AM/2
126
1,3,14,53,68,70,93,104,127,185,155
-X5 splice
2
39
C_AR/3
83
186
C_AM/3
119
atmospheric
pressure
sensor
3
140
990 Supermoto 2008
hego sensor
rear
L
3
C_CE/4
4
C_CE/4
1
C_CA/4
2
C_CA/4
hego sensor
front
L
rollover
sensor -B4
C_AP/6
5
4
2.3 2.2 2.1
3
-X3 splice
/3.B2
-X305 splice
18,228
129
228
GND-X14 76,5,13,20,38,197,159
53,155
16
-X304 splice
15,227
17
158
CAN-L
/1.B5
128
115
-A1-X5
94
157
127
18
130
CAN-H
114
C_DN/8
187
/1.B4
121
90
15
tem-P1
80,91,95,97,113,116,120,129,138,150,184
/1.E8
80
152
20
93
/1.B7
81
151
194
120
91
14
150
193
83,90,109,117,119,139,151,183
139
73
74,75
117
3
116
2
138
124
38
39
118
1
123
C_DO/8
188
C_EC/3
92
N
107
3th
101
84
140
227
96
195
84,121,188
130
85
STR-A3 41
81
86
/1.E8
92
2nd
189
2
102
C_AT/2
190
-A3 Starter Interlock Unit
176
1
183
-S4
103
-B2
180
-X51
105
6
67
5
94
19
95
4
191
3
192
2
106
1
110
C_AP/6
82
85,142,187
111
-X50
88
t°
69
-B1 t°
123
218
gear position
switch
122
203
sidestand
sensor
2
-X300
C_CQ/16
87
fuel-A2
44
9 87 65 4 3 2 1
16 15 14 13 12 11 10
128
C_CP/16
70
88
98
202
89
100
108
/1.E5
99
200
82
219
CAN-BUS
connector
68
205
213
201
69
204
3
216
2
206
214
207
1
208
217
209
diagnostic
connector
67
water temp.
sensor
7-32
WIRING DIAGRAM 990 SUPERMOTO
4
ye-re
5
bu
31
sensor
rollover
C_AP2 /6
bl
6
re-gn
or
wh-bl
ye
L
L
rear
lambda sensor´s
f ront
t°
t°
C_CE/4
3
C_CE1 /4
2
2
3
1
3
2
p
C_DP1 /3
1
octane selector
br
1
2
C_CM/2
t°
3
p
C_DP/3
1
2
bl
atmospheric pressure sensor
990 Adventure
p
C_DP2 /3
ye-bl
gn-gr
bu
2
bl
bl
1
C_AX/2
t°
water temperature sensor
manifold pressure sensor front
br
4 1
wh-or
C_CA/4
3
bl
C_CA1 /4
4 1 2
bl
re
I-page 2/9
bu
air temperature sensor
bu
2
bu-bl
br
br-pu
re-br
or
bl
bl
br-bl
2
ye-bu
21
1
3
C_AR3 /3
C_AM3/3
2
Pick up
C_AT/2
C_ AL /2
1
or
br
or-wh
gn-re
sidestand sensor
3
4
2
1
bl
1
ye-wh
C_AF/4
bu
pi
C_ AL 1/ 2
C_BF/1
manifold pressure sensor rear
C_BA/1
pu
power relay
C_AI/2
2
1
7 13 14 3 2 4 2 3 11 12
4
2 10 9 2 2
C_AO/ 26
6 2 0 2 5 2 6 19 15 18 17
1
or
EFI
2
8
1
2
3
9 14 16 3 4
P
6/8
O
6/8
K
6/8
gr
ye-br
gn-bl
bu-gr
br
br
bu-wh
wh
bu-br
C_AR2/3
C_AM2/3
lbu
br
or
6
4
1
N
3th
2nd
C_AP1/6
C_AT1/2
Q-page7/ 9
3 3 15 13 2 3 11 3
C_BH1/6
7 21 12 4 2 2
3rd gear
neutral switch
diagnostic
connector
5
6 29 26
C_CO/ 34
1
f ront
C_ AS1/ 2
2
J-page2/9
1
2
1
or-bl
C_CW/2
14
8
5
ye-or 9
or 13
bl-gr
ye-gn 11
bu-pi 3
gn-wh 7
br-gr 15
wh-re 12
bu-or 4
gn
or-gn 16
bu
2
exhaust
air valve
C_ CK/2
1
6
2
pu-re 10
re-bl
bl
C_CQ/16
610.41.012.000
airbox harness
rear
C_AS/2
2
lbu
gr
R-page3/9
wh-pu
diode
or
E-page2/9
1
bl
wh
3
f ront
1
rear
C_ CL /2
2
1
C_ CL 1/ 2
2
bu-bl
or
pu
ye
bu
re
gr
gr
wh
gn
pu
bu
gn-re
2
C_AM/3
C_AR/3
2nd TPS
4
2
C_AR1 /3
1
4
2 1
C_CA2 /4
C_CE2 /4
fuel pumprelay
2
Q
4 1 3
C_ AE/4
3/9
ISC
stepper m ot or
second
throt tl e st epper m ot or
3
3
3
2
TPS
C_AM1/3
C_AF1 /4
1
3
2
C_AM4/3
C_AR4 /3
M
f uel pump
fuel pump unit
wh
clutch switch
E
or
br
bu-bl
gr
30
or-wh
bu
bl
ye-bu
ye-wh
pu
bu-bl
gn-gr
re-br
re-gn
ye-re
pu-re
re-bl
ye-bl
re
br-pu
or
ye
pi
gn-bl
ye-br
gr
lbu
C
wh-br
bu
C_CX/2
or
wh
ye
bu
or
bl
or-wh
bu
A-page2/9
bu-gr
ye-bl
pu
bu-bl
bl
re
gr
2nd gear
wh-or
wh-bl
or-bl
or-gn
gn
bu-or
wh-re
br-gr
gn-wh
bu-pi
ye-gn
bl-gr
ye-or
wh-pu
wh-br
U
gn-re
or
bu-bl
injector´s
gn
pu
Art.-No. 3.206.056-E
30
31
fuel level sensor
Repair manual KTM LC8
7-33
WIRING DIAGRAM 990 ADVENTURE -2007
C_CP/16
ignition coil
5
6
4
bl
31
sensor
rollover
C_AP2/6
ye-re
bu
1
br
br
2
C_AL1/2
C_AT1/2
ye
wh-bl
bl
3
L
L
rear
lambda sensor´s
front
t°
t°
C_CE/4
2
C_CE1/4
4 1
wh-or
C_CA/4
3
bl
C_CA1/4
4 1 2
re-gn
or
2
1
ye-bl
gn-gr
3
bu
1
atmospheric pressure sensor
2
3
p
C_DP1/3
1
octane selector
br
1
2
C_CM/2
t°
2
3
p
C_DP/3
1
br-bl
2
C_DF/2
PVC
1
990 Adventure (S)
2007-2008
p
C_DP2/3
2
bl
bl
C_AX/2
water temperature sensor
manifold pressure sensor front
t°
bu
2
or
br
1
3
C_AR3/3
C_AM3/3
2
Pick up
C_AT/2
C_AL/2
1
gn-re
or-wh
sidestand sensor
3
4
2
1
bl
clutch switch
bu-bl
br
br-pu
re-br
or
re
bl
C_AF/4
pi
ye-bu
bu
I-page 7/9
C_BF/1
bu
air temperature sensor
C_BA/1
or
bl
re-bl
ye-wh
bl
power relay
R-page3/9
21 1
7 13 14 3 24 23 11 12 4
2 10 9 22
E
C_AO/26
6 20 25 26 19 15 18 17 8
1
or-bl
2
EFI
1
C_AR2/3
lbu
br
or
C_AM2/3
P
6/8
O
6/8
K
6/8
gr
ye-br 2
gn-bl 3
4
1
6
ASP-page7/9
SAR-page2/9
N
3th
C_AI/2
or-wh
br-bl
bu
bl
ye-bu
ye-wh
pu
bu-bl
gn-gr
re-br
re-gn
ye-re
pu-re
re-bl
ye-bl
re
br-pu
or
ye
pi
gn-bl
ye-br
gr
lbu
pi-bu
C
pu
manifold pressure sensor rear
Q-page7/9
2
8
9 14 16 34
33 15 13 23 11
3
C_BH1/6
diagnostic
connector
6 29 26
C_CO/34
7 21 12 4 22 5
or-gn
1 5
2
7
6
8
4
front
C_AS1/2
1
3
C_DN/8
C_DO/8
Starter Interlock Unit
2
ignition coil
2nd
C_AP1/6
ye
or
gn-bl
1
6
2
8
5
gr
lbu
C_AR/3
1
exhaust
air valve
610.41.012.000
front
C_CL1/2
2
bu-bl
or
pu
ye
bu
re
gr
gr
wh
gn
pu
bu
gn-re
2
C_CX/2
3
2nd TPS
C_AM/3
1
bl
wh
2
1
2
ye-or 9
or 13
bl-gr
ye-gn 11
bu-pi 3
gn-wh 7
br-gr 15
wh-re 12
bu-or 4
gn
or-gn 16
14
pu-re 10
bu
C_CK/2
1
bl
re-bl
J-page2/9
airbox harness
rear
C_AS/2
2
or
pi
br-bu
wh-pu
pi-bu
br
or-bl
diode
C_CQ/16
bu
wh-br
bu
E-page2/9
C_CP/16
or
2
4
1
rear
C_CL/2
TPS
4
2 1
fuel pumprelay
3
2
C_AM4/3
C_AR4/3
M
fuel pump
2
4 1 3
C_AE/4
Q
fuel pump unit
3/9
ISC
stepper motor
second
throttle stepper motor
C_CE2/4
C_CA2/4
3
2
C_AR1/3
1
3
3
2
C_AM1/3
C_AF1/4
1
bu
C_CW/2
or
ye-bl
wh
ye
bl
or
or-wh
A-page2/9
bu-gr
pu
bu-bl
bu
bl
re
gr
neutral switch
2nd gear
3rd gear
bu-gr
br
br
bu-wh
wh
bu-br
re-bl
bu-br
wh-or
wh-bl
or-bl
or-gn
gn
bu-or
wh-re
br-gr
gn-wh
bu-pi
ye-gn
bl-gr
ye-or
wh-pu
wh-br
U
gn-re
bu-bl
injector´s
wh
br
gr
bu-bl
gn
pu
30
31
fuel level sensor
30
7-34
WIRING DIAGRAM 990 ADVENTURE 2007-
7-35
BLOCK DIAGRAM
A
Kill Switch
Ignition Switch
B
Battery
Power Relay
Regulator /
RECTA
A.C
Generator.
Start button
Starter
Relay1
C
A
Starter
Relay2
IGP
Sidestand Switch
MAP Sensor
#2(FRONT)
HEGO Sensor #1(REAR)
HEGO Sensor #2(FRONT)
Art.-No. 3.206.056-E
Atmospheric press. sensor
MAP Sensor
#1(REAR)
SSTAND(A/D)
INJ#1
Fuel Injector
#1(REAR)
INJ#2
Fuel Injector
#2(FRONT)
IG#1
Ignition
#1(REAR)
IG#2
Ignition
#2(FRONT)
PM#2
HG#1
HGHT#1
HG#2
HGHT#2
PA
PM#1
Throttle Position Sensor
TH
Inlet Air
Temp. Sensor
TA
PVC
Starter
Motor
Purge Valve
EXAI
Exhaust Air Injection
B
Fuel Pump Relay
Water Temp. Sensor
TW
FLPR
Fuel Pump
Rollover sensor
ROLL
2nd Throttle
Position Sensor
VCC
TAP
SG
2nd Throttle
Actuator Control
(stepper)
ISC AP
ISC AN
ISC BP
ISC BN
TAC AP
TAC AN
TAC BP
TAC BN
Meter Assembly
TACHO
Crank Sensor
Repair manual KTM LC8
Gear Position Switch3
Gear Position Switch2
Neutral Switch
Idle Speed
Control
(stepper)
CRKP
CRKM
Tachometer
MIL
Meter-Line
(K-LINE2)
GP#3
MIL
Meter Communication
GP#2
NLSW
C
Clutch Switch
CLUTCH
K-LINE
LG
LG
PG#1
PG#2
Diagnostic
Tool
NEUTRAL
indicator
M
7-36
DESCRIPTION OF THE ELECTRIC SYSTEM
Fuel pump relay:
A positive charge travels to the start/stop switch via the ignition switch and a fuse (10 amperes), then via the diode to the relay
coil (positive side). The ground for the relay coil is switched for several seconds by the control unit with the ignition on during
the starting process. The control is maintained as long as the engine is running. If the engine fails to start, Stalls or is switched
off, the control unit will immediately break the ground connection, also in case of a crash (roll sensor).
The positive charge for the load contact on the fuel pump relay travels via the ignition switch and the fuse (10 amperes), the
other side of the load contact leads to the fuel pump and from the fuel pump to the ground.
Main relay:
The positive charge travels to the start/stop switch via the ignition switch and a fuse (10 amperes), then via the diode to the relay
coil (positive side). The 2nd side of the relay coil is directly connected to the ground.
The positive charge for the load contact on the fuel pump relay travels via the ignition switch and the fuse (10 amperes); the
other side of the load contact supplies the following components with on-board voltage (orange cable/or): control unit, heater for
both lambda probes, both ignition coils, the secondary air valve and both injection nozzles.
Sensors:
All of the sensors (except the pulse generator) and both lambda probes are connected to the control unit ground by a black cable
(bl).
All of the sensors that have a 3-pole connector are supplied with control unit positive (5 volts) via a blue cable (bu).
Sensor information is transmitted to the control unit via the 2nd cable (temperature sensors) or via the 3rd cable (3-pole
sensors).
The lambda probe signal is transmitted via the red/green cable (re/gn; front cylinder) and red/brown (re/br; rear cylinder), the
control unit actuates the lambda probe heater through the ground circuit via the white/black (wh/bl; front cylinder) and
white/orange (wh/or; rear cylinder); the positive charge for the lambda probe heater comes from the main relay.
The pulse generator is an inductive sensor and directly connected to the control unit by 2 poles.
Actuators:
The ignition coils, injection nozzles and the valves for the secondary air system are ground-controlled, i.e. the respective
component is actuated as soon as the control unit transmits the ground.
The two stepping motors for the idle and the 2nd throttle valve each have 2 coils that are activated by the control unit until the
desired position is reached; the throttle valve sensors emit a feedback signal for the position.
Additional control unit outputs:
Tachometer, cooling liquid temperature and "FI" error lamp
7-37
DESCRIPTION OF THE COMPONENTS
Fuel pump
2
1
The vane-type pump mounted in the fuel tank is driven by an electric
motor 1 whose rotor is rinsed and simultaneously cooled and
lubricated with fuel.
A back-pressure valve is installed in the outlet opening which closes
when the ignition is switched off, stopping the pump in order to
maintain the residual fuel pressure; this prevents vapor bubbles from
forming in the fuel system.
The fuel pump is also equipped with a pressure relief valve to avoid
damage to the fuel pump if the pressure regulator 2 is defective.
Pressure regulator
The pressure regulator 2 mounted in the fuel tank operates like a
pressure relief valve that opens upon exceeding a certain system
pressure (343 kPa, 3.5 bar) and closes if this pressure is not achieved.
A valve is mounted on the spring-loaded diaphragm which closes when
the fuel pump stops. When the fuel pump starts up, the pressure in the
system rises until the spring over the diaphragm can be pressed
together; the diaphragm lifts the valve out of its seat, allowing fuel to
flow back into the tank, the system pressure decreases again. When the
pressure drops, the spring on the valve can close again and the control
process starts over again.
Art.-No. 3.206.056-E
Injection valves
The injection valves consist of a magnetic coil, a spring-loaded plunger,
a needle valve and a filter.
When the control unit triggers the injection valves, a magnetic field is
created in the magnetic coil, attracting the plunger against spring force
and thus lifting the needle valve from its seat. The fuel escapes
through 8 injection jets and forms 2 conical jets.
After injection, the control unit cuts off the circuit, the magnetic field
breaks down and the spring can close the needle valve again.
The filter prevents the tiny holes from becoming clogged with dirt.
The injection valves are mounted in the throttle valve body.
Coolant temperature sensor
The coolant temperature sensor consists of a thermal resistor that
changes its electric resistance depending on the temperature.
The sensor is an NTC (Negative Temperature Coefficient) sensor, i.e.
the resistance of the sensor drops if the temperature rises (but never
reaches zero resistance) and rises if the temperature drops (but never
reaches infinite resistance).
Repair manual KTM LC8
The coolant sensor is positioned on the left side of the engine.
Air temperature sensor
The mode of action is the same as for the coolant temperature sensor.
The air temperature sensor is located in the air filter box.
7-38
Manifold air pressure sensor
The manifold air pressure sensors are mounted on the frame and
connected to the intake port under the throttle valve with equally long
vacuum hoses. Reducing jets with a 1 mm air hole are connected to
the intake port.
NOTE: If the vacuum hoses are damaged, they must be replaced with
new, original KTM hoses.
!
CAUTION
!
– ALWAYS
–
–
REPLACE THE VACUUM HOSES ON THE INTAKE MANIFOLD IF THEY WERE
PULLED OFF.
DO NOT USE SILICONE SPRAY WHEN MOUNTING THE VACUUM HOSES. IT CAN
DAMAGE THE MANIFOLD AIR PRESSURE SENSORS.
DO NOT EXCHANGE THE CONNECTIONS ON THE INTAKE MANIFOLD WITH THE
CONNECTIONS ON THE CARBURATOR MODELS OTHERWISE THE INJECTION SYSTEM
IS LIKELY TO MALFUNCTION.
The intake pressure sensors convert the applied vacuum into an
electric signal for the control unit.
Each of the two intake pressure sensors is supplied with a 5-volt
operating voltage and a ground from the control unit.
The output signal increases with the pressure; i.e. the intake pressure
sensor emits a low voltage signal when the throttle valve is closed and
the pressure in the induction manifold is low (high vacuum due to the
engine's suction effect).
When the throttle valve is completely open, the induction manifold
pressure is practically equivalent to the ambient air pressure and the
voltage signal has a high value.
The sensors must be mounted vertically and the hoses leading to the
sensor inclining (due to condensate formation).
Ambient air pressure sensor
The mode of action is similar to the manifold air pressure sensor.
Information is relayed to the control unit indicating under which
ambient pressure (at which altitude) the vehicle is being driven.
Installed position: under the headlight mask; a 5-cm hose is connected
to the sensor to prevent splashed water from penetrating.
Throttle valve sensor
1
The throttle valve sensor 1 is mounted on the side of the throttle valve
shaft of the front throttle valve and operates like a variable resistor. The
control unit determines the position of the throttle valve based on the
output voltage.
The information acquired is required for the acceleration enrichment,
full-load enrichment, ignition timing and trailing throttle fuel cutoff.
Sensor for the 2nd throttle valve
Operates in the same manner as the throttle valve sensor but is
mounted on the shaft of the rear 2nd throttle valve 2 through which
the control unit controls the power development.
2
7-39
Pulse generator (crankshaft)
2
1
The pulse generator 1 is located under the clutch cover on the right
side of the engine. It is an inductive sensor, i.e. the control unit
calculates the speed and the crankshaft position based on the output
signal.
The pulse generator wheel 2 on the crankshaft is the counterpart of
the pulse generator. The distance between its 22 teeth is equal with a
larger gap between two teeth.
Each tooth induces a signal; the large interval is caused by the gap in
the teeth since the distance between 2 teeth is much larger in this
position; this signal is used to determine the crankshaft position.
!
CAUTION
!
THE
PICKUP RING FOR THE CARBURATOR AND INJECTION VERSIONS ARE
DIFFERENTIATED BY THE POSITION OF THE "TOOTH GAP"; THEY CANNOT BE
INTERCHANGED.
Probe ceramics
Electrodes
Contact
Housing contact
Exhaust pipe
Protective ceramic
layer (porous)
7 Emission
8 Air
Art.-No. 3.206.056-E
1
2
3
4
5
6
Lambda probes
The lambda probes screwed into the exhaust after each cylinder
measure the partial oxygen pressure in the emission compared to the
ambient air, i.e. the sensors compare the oxygen content in the
emission with the fresh air.
A lambda probe basically consists of a ceramic body coated on both
sides with a platinum layer. The platinum layer acts like an electrode.
The outer layer comes into contact with the emission, the inner layer
with the ambient air.
The ceramic body becomes electro-conductive from a temperature of
approx. 350º C; voltage is generated if the oxygen content between the
ambient air (inner electrode) and emission (outer electrode) varies.
The higher the difference in the oxygen level, the greater the voltage;
the lambda probe voltage can lie between 0 and 1 volt in operation.
Normally the lambda probe voltage will fall between 0.2 volt for a lean
combustion and approx. 0.8 volt for a rich combustion.
NOTE:
– For lean mixtures (excess air) only part of the drawn in oxygen is
required for combustion; a large share of oxygen remains in the
emission - resulting in a low lambda probe voltage.
– For rich mixtures (air deficiency) almost all of the oxygen is burned;
hardly any oxygen remains in the emission - resulting in a high
lambda probe voltage.
The ideal operating temperature for a lambda probe is at approx.
600º C, although up to 950º C is possible for short durations.
To reach the operating temperature as quickly as possible, the lambda
probes used in this motorcycle are equipped with a heater switched on
by the control unit.
Repair manual KTM LC8
NOTE: The ceramic body of the lambda probe is very sensitive to shock
which is why it is covered with a slotted sheet-metal sleeve.
7-40
Catalytic converter
The catalytic converter is installed in the main silencer and transforms
most of the main toxic constituents into non-toxic compounds. It is
designed as a three-way catalytic converter and consists of a coiled
metal support whose surface is coated with precious metals such as
platinum and rhodium; the coating only weighs 1 to 2 grams.
Similar to the lambda probe, the catalytic converter is not activated
until a temperature of approx. 300º C is reached; it operates best
between 400º C and 800º C. Thermal aging accelerates at a
temperature of 800º C. Much higher temperatures occur if the
ignition/injection system (e.g.: ignition faults) malfunctions, which can
destroy the catalytic converter.
The main constituents in the emissions are nitrogen (N2, not involved
in combustion), carbon dioxide (CO2, the result of complete
combustion) and water or steam (H2O, is bound in the fuel and
released during combustion); together they comprise approx. 90% of
emitted exhaust gas and are considered harmless.
The rest mainly consists of carbon monoxide and hydrocarbon (CO and
HC, both the result of incomplete combustion) and nitrogen oxide
(NOx, the result of high combustion chamber temperature); all three
are toxic.
To effectively convert these 3 components into harmless carbon
dioxide, water and nitrogen in the catalytic converter, the engine must
be operated close to lambda 1, i.e. the efficiency of combustion is
greatest close to lambda 1.
But lambda 1 is almost impossible to achieve by control engineering,
which is why the control unit continuously (several times each second)
produces mixtures alternating between lambda 0.97 (rich mixture) and
1.03 (lean mixture). Under these conditions the voltage generated by
the lambda probe varies between 0.2 volt and 0.8 volt depending on
the exhaust gas composition.
Idle speed control motor
The idle speed control motor 1 is mounted to the throttle valve body;
it is a stepper motor driven by the control unit to achieve a calculated
speed setting.
1
Servomotor for the 2nd throttle valve
The function, construction and installed position are the same as for
the idle speed control motor; however, the stepper motor for the 2nd
throttle valve 2 controls the position of the 2nd throttle valve.
2
7-41
Ignition coils
The ignition coils are mounted directly on the spark plugs; the same
ignition coils are used for the injection engine as for the carburetor
engine.
Fuel pump relay
The fuel pump relay is installed under the seat.
Each relay has a coil and at least one load contact; a magnetic field is
created when the coil is supplied with current, which attracts a contact
plate, closing the load contact.
The control unit uses the fuel pump relay to switch the fuel pump on or
off if the engine Stalls or a crash is imminent.
Main relay
The main relay is installed under the seat.
Its mode of operation is similar to the fuel pump relay. The main relay
supplies the control unit, heater for both lambda probes, both ignition
coils, the secondary air valve and both injection nozzles with current.
Art.-No. 3.206.056-E
Secondary air valve
The secondary air valve is attached to the air filter box. It consists of a
coil and a valve. The control unit sets up a ground circuit during the
warming-up phase, causing current to flow through the coil which
causes a magnetic field to be created, causing the valve to open.
Fresh air is drawn into the exhaust resulting in afterburning.
Octane selector connections (990 Adventure only)
If fuel having at least 95 octane (ROZ) is not available, you can easily
activate the corresponding ignition curve by reducing the ignition
timing.
Repair manual KTM LC8
A plug and socket connection (brown/black cable) is located near the
upper shock absorber holder.
If the two connectors are joined, the ignition curve for fuel having at
least 95 octane (ROZ) is activated.
If you disconnect the plug and socket connection, the ignition curve for
fuel having 80 - 94 octane (ROZ) will be activated. Although this will
cause the engine to lose some of its power output, it will prevent
knocking combustion from low-grade fuel that ultimately leads to
engine damage.
7-42
Roll angle sensor
A pendulum is positioned in the roll angle sensor that prompts the ECU
to switch off the ignition and injection at an angle of 65º +/- 10º (from
the vertical position); this prevents the engine from running after a
crash. Installation: behind the headlight mask.
Diagnostics connector
1
The diagnostics connector 1 is located under the seat.
The diagnostics connector connects the KTM diagnostics tool and the
control unit to read error codes or perform function tests.
Side stand switch
The side stand switch 2 is mounted on the side stand console and
relays the position of the side stand to the ECU (for the safety start
system). The side stand switch operates according to the Hall generator
principle.
2
Clutch switch
The clutch switch 3 is mounted on the clutch pickup instrument and
relays the position of the clutch lever to the ECU (for the safety start
system and idle speed control). The clutch switch is an on/off switch.
3
Gear switch
The gear switch is mounted on the left side of the engine and relays
the position of the shift roller to the ECU (for safety start system, idle
speed control and EPC). The gear switch is a three-way on/off switch.
The neutral, 2nd gear and 3rd gear positions are relayed.
7-43
SAFETY AGAINST FAILURE/EMERGENCY OPERATION
Defective component
Defect/Effect
Backup value/
Spare sensor
Possible to
start engine?
Possible to
run vehicle?
Fuel pump
Total failure: will not start
no
no
no
Lack of pressure: power loss
no
yes
limited
Pressure regulator
same as fuel pump
no
see above
see above
Injection valve
Electric error
no
no
no
Coolant temperature sensor
poor cold start/engine operation
80°C
yes
limited
Air temperature sensor
Hardly any restriction
25°C
yes
limited
Manifold air pressure sensor
Emergency operation program
Throttle valve position
yes
limited
Ambient air pressure sensor
Hardly any restriction
97 kPa
yes
limited
Throttle valve sensor
Emergency operation program
Manifold air pressure sensor
yes
limited
Sensor for 2nd throttle valve
Emergency operation program
Closed
yes
limited
Pulse generator
No signal
no
no
no
Lambda probes
No lambda control
not necessary
yes
limited
Catalytic converter
No conversion
no
yes
yes
Clogged: lack of power
no
limited
limited
No idle control
no
limited
limited
no
yes
limited
Misfire
no
limited
limited
Short circuit/interruption
no
no
no
Fuel pump relay
Not functioning
no
no
no
Main relay
Not functioning
no
no
no
Secondary air valve
No lambda control
no
yes
limited
Roll angle sensor
Engine does not switch off during crash
no
yes
yes
Repair manual KTM LC8
Art.-No. 3.206.056-E
Idle speed control motor
Stepper motor for 2nd throttle valve Throttle valve can easily be moved
Ignition coil
7-44
COMPONENT TESTS
NOTE:
– Before injection system components are replaced, insure that none
of the engine's mechanical components are defective.
– Check all fuses. Make sure the control unit is being supplied with
ground and positive voltage.
Fuel pump and pressure regulator
Checking the fuel presure
Switch on the ignition, the pump will run for 2 seconds or switch on
the pump with the KTM diagnostics tool. If not, perform the following
tests:
– Scan the fault memory with the KTM diagnostics tool.
– Check whether the fuel pump relay is functioning (see page 7-44).
– Check the ground and voltage on the fuel pump connector (AR4).
NOTE:
– If the fuel pump relay is not being controlled by the control unit,
check the crash switch (see page 7-46).
– The pressure should be 343 kPA (3.5 bar). If the pressure is lower,
check the voltage and ground on the fuel pump connector (AR4).
– If you cannot find a defect in the electric system, dismount the fuel
pump / pressure regulator unit.
Injection valves (output)
The signal from the injection valves can be scanned with the KTM
diagnostics tool
Before replacing an injection valve, perform the following tests:
– Check the positive supply (orange cable) at the injection valve
connector (CL or CL1).
– Check the wiring and the connector for continuity to the control unit
(control unit disconnected).
– Measure the resistance at the respective injection valve.
Resistance of the injection valves at 20ºC: 11.7 Ω
7-45
Coolant temperature sensor (input)
The signal from the coolant temperature sensor 1 can be scanned with
the KTM diagnostics tool (see table for voltage figures).
If the displayed value does not correspond to the actual temperature or
if an error code is displayed, perform the following tests:
– Ground supply (black cable) at the sensor connector AX.
– Check the wiring and the connector for continuity to the control unit
(control unit disconnected).
– Measure the resistance of the coolant temperature sensor.
1
Resistance at -20º C: 15 kΩ +/- 1.5 kΩ
Resistance at 20º C: 2.45 kΩ +/- 240 Ω
Resistance at 80º C: 318 Ω +/- 31 Ω
Sensor-characteristics
TW
TA
140
Art.-No. 3.206.056-E
TW: Coolant temperature sensor
120
TA: Air temperature sensor
100
80
60
Temperature (ºC)
40
20
0
-20
Voltage (Volt)
-40
0
0,5
1
1,5
2
2,5
3
3,5
4
4,5
5
Air temperature sensor (input)
The signal from the air temperature sensor can be scanned with the
KTM diagnostics tool (see table for voltage figures).
Repair manual KTM LC8
If the displayed value does not correspond to the actual temperature or
if an error code is displayed, perform the following tests:
– Ground supply (black cable) at the sensor connector CM.
– Check the wiring and the connector for continuity to the control unit
(control unit disconnected).
– Measure the resistance of the air temperature sensor.
Resistance at -20º C: 18.8 kΩ +/- 2.3 kΩ
Resistance at 40º C: 1.136 kΩ +/- 95 Ω
Resistance at 100º C: 155.3 Ω +/- 7 Ω
7-46
Intake pressure sensors (input)
The signal from the intake pressure sensors (1 mounted on the right
side of the frame and 2 on the left side of the frame) can be scanned
with the KTM diagnostics tool.
Output signal in neutral, engine at operating temperature:
1.6 - 3.3 volt
Output signal with the engine switched off (ignition on):
approx. 3.5 volts
1
2
If the displayed value does not correspond to the actual pressure or if
an error code is displayed, perform the following tests:
NOTE: if the engine is switched off, both values must be equal to the
value of the ambient air pressure sensor.
If an intake pressure sensor breaks down, exchange the two and scan
the values again with the KTM diagnostics tool - if the error is in the
other position, replace the affected intake pressure sensor. If the
position of the defective sensor has not changed, perform the following
tests:
– Apply the ground (black cable) and the 5-volt supply (blue cable) to
the BZ or BZ1 connector with the ignition switched on.
– Check the vacuum connection and vacuum lines from the induction
manifold induction manifold to the intake pressure sensors for
damage and continuity.
– Check the signal cable (purple and blue/black cables) and the
connector from the intake pressure sensors to the control unit for
continuity (control unit disconnected).
Ambient air pressure sensor (input)
The signal from the ambient air pressure sensor 3 can be scanned
with the KTM Diagnostics tool.
Output signal: approx. 3.5 volts at approx. 37 KPa
3
In case of an error, perform the following tests:
– Apply the ground (black cable) and the 5-volt supply (blue cable) to
the BZ2 connector with the ignition switched on.
– Measure the output signal directly on connector BZ2.
– Check the signal cable (green/grey) and connector to the control unit
for continuity (control unit disconnected).
7-47
Throttle valve sensor (input)
The signal from the throttle valve sensor 1 can be scanned with the
KTM diagnostics tool.
1
In case of an error, perform the following tests:
– Apply the ground (black cable) and the 5-volt supply (blue cable) to
the AR1 connector with the ignition on.
– Measure the output signal directly on the AR1 connector:
Output signal - throttle in idle, engine at operating temperature:
approx. 0.6 volt
Output signal - wide-open throttle, with the engine switched off
(ignition on): approx. 3.8 volts
NOTE: If the throttle is opened slowly, the output signal should change
accordingly.
– Check the signal cable (yellow/white cable) and the connector to the
control unit for continuity (control unit disconnected).
Art.-No. 3.206.056-E
Sensor for 2nd throttle valve (input)
The signal from the 2nd throttle valve sensor 2 can be scanned with
the KTM diagnostics tool.
In case of an error, perform the following tests:
– Apply the ground (black cable) and the 5-volt supply (blue cable) to
the AM connector with the ignition switched on.
– Measure the output signal directly on connector AM:
2
Output signal throttle closed: approx. 1.0 volt
Output signal throttle wide open: approx. 4.3 volts
Repair manual KTM LC8
– Check the signal cable (green/red) and connector to the control unit
for continuity (control unit disconnected).
7-48
Pulse generator (input)
The signal from the pulse generator 1 can be scanned with the KTM
diagnostics tool.
In case of an error, perform the following tests:
1
– Check the pulse generator resistance between the two cables at
connector AT (pulse generator).
190 - 290 Ω at 20ºC
– Disconnect connectors AL and AT and check connector AL
(yellow/blue and yellow/white cables) for continuity to the control
unit (control unit disconnected).
– If no error is found, check the distance between the pulse generator
and the pulse generator wheel (see Chapter 6).
!
CAUTION
!
THE
PICKUP RING FOR THE CARBURATOR AND INJECTION VERSIONS ARE
DIFFERENTIATED BY THE POSITION OF THE "TOOTH GAP"; THEY CANNOT BE
INTERCHANGED.
Lambda probes (input)
The signal from the lambda probes 2 can be scanned with the KTM
diagnostics tool.
2
NOTE:
– The engine must be at operating temperature in idle.
– At speeds below approx. 5000 rpm the signal surges rapidly
between 0.2 and 0.8 volt, at higher speeds the signal fluctuates
slightly; if the signal fails to surge below 5000 rpm but is in the
preset range, the injection system has an electrical defect.
– Generally, the lambda probe signal must fall between 0.2 and 0.8
volt.
In case of an error, perform the following tests:
– Check the ground supply (black cable) from the sensor connector CA
or CA1.
– Check the wiring and the connector for continuity to the control unit
(control unit disconnected).
Lambda probe heater (output)
The lambda probe heater can be tested and controlled with the KTM
diagnostics tool.
In case of an error, perform the following tests:
– Check the positive supply (with the ignition on, orange cable) at
sensor connector CA or CA1.
– Check the wiring and the connector for continuity to the control unit
(control unit disconnected).
– Coil resistance of the lambda probe heater: 13 Ω at 20º C
7-49
Catalytic converter
The effectiveness of the catalytic converter can only be tested with an
emissions tester.
Before replacing a catalytic converter suspected to be defective, take a
test ride and use the KTM diagnostics tool to check the injection
system for proper functioning.
Idle speed control motor (output)
The idle speed control motor 1 can be tested and controlled with the
KTM diagnostics tool.
1
In case of an error, perform the following tests:
Art.-No. 3.206.056-E
– Check the wiring and connectors for continuity from the idle speed
control motor to the control unit (control unit disconnected).
– Check the coil resistance of the idle speed control motor (between
the grey and purple or white and green cables). At 20ºC each of the
two coils should have a resistance of approx. 8 Ω.
Control motor for the 2nd throttle valve (output)
Repair manual KTM LC8
2
The control motor 2 can be tested and controlled with the KTM
diagnostics tool.
In case of an error, perform the following tests:
– Check the wiring and connectors for continuity from the idle speed
control motor to the control unit (control unit disconnected).
– Check the coil resistance of the control motor (between the blue and
red or yellow and grey cables). At 20ºC each of the two coils should
have a resistance of approx. 6.5 Ω
7-50
Ignition coil (output)
Defective ignition coils can be tested and controlled with the KTM
diagnostics tool. It allows you to establish which ignition coil is
affected. Both ignition coils must be dismounted but stay connected.
If an ignition coil breaks down, exchange the two and control again
with the KTM diagnostics tool - if the error is in the other position,
replace the affected ignition coil. If not, perform the following tests:
– Check the positive supply (ignition on, orange cable) at the ignition
coil connectors (AS or AS1).
– Check the wiring and the connectors for continuity to the control
unit (control unit disconnected), white/brown and white/violet
cables).
– Measure the resistance of the affected ignition coil:
(measured between the terminals): 1.0 - 1.6 Ω at 20ºC
(measured between one terminal and the spark plug connector):
9.4 - 17.6 KΩ at 20ºC
1
Fuel pump relay (output)
The fuel pump relay 1 can be tested and controlled with the KTM
diagnostics tool.
If the fuel pump is not running, disconnect the control unit and apply
the ground to Pin 2 on the wiring harness connector CO (blue/green
cable). Switch on the ignition, the fuel pump relay should switch (click
once) and the fuel pump should keep running. If not, perform the
following tests:
– Check the positive supply to the relay connector AF1 Pin 1
(yellow/black cable color) and Pin 2 (orange/white cable).
– Check the wiring from connector AF1 to the control unit.
NOTE:
– If the fuel pump relay switches when actuated as described above
but is not actuated by the control unit, check the crash switch - see
page 7-46.
– If the fuel pump relay switches but there is no positive voltage at the
connector AF1 Pin 3 (blue/black cable), replace the relay.
– The fuel pump relay is located on the instrument mount under the
headlight mask in the 990 Adventure model.
7-51
Main relay
1
Switch on the ignition, the main relay 1 should switch on (audible
click). If not, perform the following tests:
– Check the positive voltage at connector AF Pin 2 (orange/white
cable).
– Check the ground supply at connector AF Pin 4 (Braun cable).
If no error is detected, replace the main relay.
NOTE: The fuel pump relay is located on the instrument mount under
the headlight mask in the 990 Adventure model.
If the main relay switches and no error is found during the above tests,
perform the following tests:
2
– Check the positive voltage at connector AF Pin 1 (green/red cable).
– There should be positive voltage at the connector AF Pin 3 (orange
cable).
If there is positive voltage at connector AF Pin 1 but not at Pin 3 with
the ignition switched on, replace the main relay.
Secondary air valve (output)
The secondary air valve 2 can be tested and controlled with the KTM
diagnostics tool. If the secondary air valve fails to switch, perform the
following tests:
Repair manual KTM LC8
Art.-No. 3.206.056-E
– There should be positive voltage at connector CK Pin 2 (ignition on,
orange cable).
– Check the wiring from connector CO to connector CK for continuity.
– The coil resistance of the secondary air valves must be 20 Ohm at
20ºC.
7-52
Roll angle sensor (input)
The signal from the roll angle sensor 1 can be scanned with the KTM
diagnostics tool.
1
Output signal "No crash detected": 0.4 - 1.4 volts
Output signal "Crash detected": 3.7 - 4.1 volts
In case of an error, perform the following tests:
– Ground supply (black cable) at connector AP2.
– 5-volt supply (blue cable) at connector AP2 with the ignition
switched on.
– Measure the output signal directly at connector AP2 Pin 6
(yellow/red cable).
Side stand switch (input)
The signal for the side stand switch 2 can be scanned with the KTM
diagnostics tool.
2
Output signal up (folded up): 2-3 volts
Output signal down (folded down): 4-5 volts
In case of an error, perform the following tests:
3
– Ground supply (black cable) connected to connector AM3 3.
– 5-volt supply (blue cable) connector AM3 with ignition switched on.
– Measure the output signal directly at the connector AR3 Pin 3 (pink
cable).
7-53
Clutch switch (input)
The clutch switch 1 status can be scanned with the KTM diagnostics
tool.
NOTE: the clutch switch delivers a ground signal to the ECU when
actuated, this function is especially important for the idle speed
control.
– Ground supply (brown cable) at connector AL1.
– Check the wiring from connector AL1 to connector AO for continuity.
1
Art.-No. 3.206.056-E
Gear sensor (neutral, 2, 3) (input)
The current status of the gear sensor 2 can be scanned with the KTM
diagnostics tool.
2
3
Respective gear engaged: max. 3.31 volts
Respective gear not engaged: min. 4.14 volts
In case of an error, perform the following tests:
– Check the wiring from connector AM2 3 to connector AO for
continuity.
Repair manual KTM LC8
NOTE: This function is especially important for the idle speed control.
Error lamp (output)
The error lamp (FI) can be tested with the KTM diagnostics tool.
NOTE: the error lamp must light up for 2 seconds and then go out after
the ignition is switched on if no ignition error is detected by the ECU.
If the error lamp does not switch on, perform the following tests:
– There must be positive ouput voltage at connector CO Pin 16 (with
the ignition on, white cable).
– Check the wiring from connector CO to connector AA Pin 8 for
continuity.
7-54
Speed signal (output)
The tachometer output can be tested and controlled with the KTM
diagnostics tool.
If the tachometer fails to react, perform the following tests:
– Check the wiring from connector CO Pin 14 cable colour blue/white
to connector AG Pin 2 for continuity.
Coolant temperature signal (output)
The coolant temperature output can be tested and controlled with the
KTM diagnostics tool.
If the coolant temperature display does not react, perform the following
tests:
– Check the wiring from connector CO Pin 34 (orange/yellow cable) to
connector AA Pin 12 for continuity.
NOTE: the coolant temperature display will rise very slowly when
controlled and will drop very slowly afterwards.
Diagnostics line
If there is not connection between the KTM diagnostics tool and the
vehicle ECU, perform the following test:
– Ground supply (brown cable) at connector AP1 Pin 6.
– 12-volt supply (orange cable) at connector AP1 with the ignition
switched on.
– Check the wiring from connector AP1 to connector AO for continuity
(yellow cable).
7-55
ERROR CODES
Repair manual KTM LC8
Art.-No. 3.206.056-E
DTC (Code) Blink code Signal/Component
Description of error
Engine
P0201
33
Injection valve, rear cylinder
Malfunction
Stalls
P0202
34
Injection valve, front cylinder
Malfunction
Stalls
P0351
37
Ignition coil, rear cylinder
Malfunction
Stalls
P0352
38
Ignition coil, front cylinder
Malfunction
Stalls
P0335
02
Pick up
Malfunction
Stalls
P0032
45
Lambda probe heater
Short circuit to positive
Continues to run
P0031
45
Lambda probe heater
Kurzschluß nach Masse
Continues to run
P0130
17
Lambda probe, rear cylinder
Malfunction
Continues to run
P0052
46
Lambda probe heater, front cylinder
Short circuit to positive
Continues to run
P0051
46
Lambda probe heater, front cylinder
Short circuit to ground
Continues to run
P0150
18
Lambda probe heater, front cylinder
Malfunction
Continues to run
P0122
06
Throttle position sensor
Output signal too low (interruption)
Continues to run
P0123
06
Throttle position sensor
Output signal too high (short circuit)
Continues to run
P0107
09
Manifold air pressure sensor, rear cylinder Output signal too low (interruption)
Continues to run
P0108
09
Manifold air pressure sensor, rear cylinder Output signal too high (short circuit)
Continues to run
P1106
68
Manifold air pressure sensor, rear cylinder Hose pulled off/defective, no vacuum
Continues to run
P1687
11
Manifold air pressure sensor, front cylinder Output signal too low (interruption)
Continues to run
P1688
11
Manifold air pressure sensor, front cylinder Output signal too high (short circuit)
Continues to run
P1105
69
Manifold air pressure sensor, front cylinder Hose pulled off/defective, no vacuum
Continues to run
P1107
14
Ambient air pressure sensor
Output signal too low (interruption)
Continues to run
P1108
14
Ambient air pressure sensor
Output signal too high (short circuit)
Continues to run
P0112
13
Air temperature sensor
Output signal too low (interruption)
Continues to run
P0113
13
Air temperature sensor
Output signal too high (short circuit)
Continues to run
P0117
12
Coolant temperature sensor
Output signal too low (interruption)
Continues to run
P0118
12
Coolant temperature sensor
Output signal too high (short circuit)
Continues to run
P1232
41
Fuel pump relay
Short circuit to positive
Stalls
P1231
41
Fuel pump relay
Short circuit to ground
Stalls
P0413
54
Secondary air valve
Short circuit to positive
Continues to run
P0414
54
Secondary air valve
Short circuit to ground or interruption
Continues to run
P0222
07
Sensor for 2nd throttle valve
Output signal too low (interruption)
Continues to run
P0223
07
Sensor for 2nd throttle valve
Output signal too high (short circuit)
Continues to run
P0638
72
Stepper motor for 2nd throttle valve
Malfunction
Continues to run
P0505
49
Idle speed control motor
Malfunction
Continues to run
P1631
15
Roll angle sensor
Output signal too low (interruption)
Continues to run
P1632
15
Roll angle sensor
Output signal too high (short circuit)
Continues to run
P0560
24
Control unit voltage supply
Malfunction
Continues to run
P1590
25
Side stand switch
Output signal too low (short circuit to ground) Continues to run
P0603
65
EEPROM error
Malfunction
Continues to run
7-56
ABBREVIATIONS, LIMIT VALUES 990 SUPER DUKE/R
Abbreviation Description
THAD
ATP
PM1AD
PM1M
PAAD
PA
VBAT
TWAD
TW
TAAD
TA
HEGO1AD
HEGO2AD
PM2AD
PM2M
TAPAD
SidestandAD
Throttle valve sensor voltage
Throttle valve sensor signal
Manifold air pressure, rear voltage
Manifold air pressure, rear
Ambient air pressure sensor voltage
Ambient pressure
Battery voltage
Coolant temperature voltage
Coolant temperature
Air temperature voltage
Air temperature
Lamda probe, rear voltage
Lamda probe, front voltage
Manifold air pressure, front voltage
Manifold air pressure, front
2nd throttle valve voltage
Side stand switch voltage
RolloverAD
Roll angle sensor voltage
MIL
NCS
Neutral
FI lamp
Number of errors influencing exhaust gas
Neutral switch voltage
Clutch
Clutch switch voltage
Side stand
GP2
Rollover
GP3
FLPR
HGHT1
HGHT2
EXAI
NE
MHG1
CLV
NETRG
MHG2
TIOUT1
TIOUT2
IGLOG1
IGLOG2
IGDWELL1
IGDWELL2
THREF
DTHREF
MREFHG1
MREFHG1ID
MREFHG2
MREFHG2ID
ISCSTEP
OSTEP
2ndTHAngle
STHTRG
STHADLL
STHADHH
Side stand switch voltage
Switch for 2nd gear voltage
Roll angle sensor
Switch for 3rd gear voltage
Fuel pump relay
Lambda probe heater, rear
Lambda probe heater, front
SLS (Secondary air system)
Engine speed
Mixture correction 1
Calculated load value
Desired idle speed
Mixture correction 2
Injection valve, rear Opening time
Injection valve, front Opening time
Ignition timing, rear
Ignition timing, front
Dwell angle, rear
Dwell angle, front
Throttle reference value
Throttle voltage reference value
Mixture correction reference value 1 general
Mixture correction reference value 1 idle
Mixture correction reference value 2 general
Mixture correction reference value 2 idle
Idle speed control motor, actual
Idle speed control motor set-point value
2nd throttle valve, actual steps
2nd throttle valve set-point value steps
Min. initialization voltage 2nd throttle sensor
Max. initialization voltage 2nd throttle sensor
Min. limit value
Max. limit value
Unit
0.3
0
1
13.3
1
13.3
6.5
4.551
-20
4.629
-20
0
0
1
13.3
0.3
1
4.5
75-85
4.2
119.99
4.2
119.99
16
0.342
120
0.288
120
5
5
4.2
119.99
4.5
5
volts
degrees
volts
KPa
volts
KPa
volts
volts
ºC
volts
ºC
volts
volts
volts
KPa
volts
volts
0.4-1.4
3.7-4.1
volts
on
0
max. 3.31 V (on)
off
40
min. 4.14 V (off)
volts
actuated
not actuated
max. 3.31 V
min. 4.14 V
down (folded down) up (folded up)
max. 3.31 V (on) min. 4.14 V (off)
Normal
Crash detected
max. 3.31 V (on) min. 4.14 V (off)
on
off
on
off
on
off
Valve open
Valve closed
0
9600
0.65
1.25
0
100
0.65
1.25
0
20.25
0
20.25
0
54
0
54
0.966
4.000
0.966
4.000
13.8
20
-0.1
0.1
0.9
1.1
0.9
1.1
0.9
1.1
0.9
1.1
0
700
0
700
0
100
0
100
0.518
1.2
3.799
4.5
volts
volts
volts
volts
volts
rpm
%
rpm
msec
msec
º BTDC
º BTDC
msec
msec
º
volts
steps
steps
%
%
volts
volts
Remarks
Completely closed 0.56-0.64 V
Idle, engine min.80ºC: 36-40KPa
rich: 0.8 V; lean: 0.1 V
rich: 0.8 V; lean: 0.1 V
Idle, engine 80ºC: 37-43KPa
closed:1V; open: 4.3V
Side stand up: 2-3 volts
side stand down 4-5 volts
Short circuit 0-1 volts
Normal operation: 0.4-1.4 volts
Crash detected: 3.7-4.1 volts
Error: <0.352, >4.8 volts
Cable break: 2-3 volts
Number of codes
on: idle/no gear engaged
off: random gear engaged
Actuated: clutch pulled
Not actuated: clutch disengaged
on: 2nd gear engaged
on: 3rd gear engaged
13 Ohm at 20ºC
13 Ohm at 20ºC
20 Ohm at 20ºC
1400 rpm
Normal value: 15-17º
Normal value: +/-0.02 V
0 % in idle
0 % in idle
Normal: approx.1V; Error: 0.518V
Normal: approx.4.3V; Error: 3.799V
7-57
ABBREVIATIONS, LIMIT VALUES 990 ADVENTURE / 990 SUPERMOTO
Repair manual KTM LC8
Art.-No. 3.206.056-E
Abbreviation Description
THAD
ATP
PM1AD
PM1M
PAAD
PA
VBAT
TWAD
TW
TAAD
TA
HEGO1AD
HEGO2AD
PM2AD
PM2M
TAPAD
SidestandAD
Throttle valve sensor voltage
Throttle valve sensor signal
Manifold air pressure, rear voltage
Manifold air pressure, rear
Ambient air pressure sensor voltage
Ambient pressure
Battery voltage
Coolant temperature voltage
Coolant temperature
Air temperature voltage
Air temperature
Lamda probe, rear voltage
Lamda probe, front voltage
Manifold air pressure, front voltage
Manifold air pressure, front
2nd throttle valve voltage
Side stand switch voltage
RolloverAD
Roll angle sensor voltage
MIL
NCS
Neutral
FI lamp
Number of errors influencing exhaust gas
Neutral switch voltage
Clutch
Clutch switch voltage
Side stand
GP2
Rollover
GP3
FLPR
HGHT1
HGHT2
EXAI
NE
MHG1
CLV
NETRG
MHG2
TIOUT1
TIOUT2
IGLOG1
IGLOG2
IGDWELL1
IGDWELL2
THREF
DTHREF
MREFHG1
MREFHG1ID
MREFHG2
MREFHG2ID
ISCSTEP
OSTEP
2ndTHAngle
STHTRG
STHADLL
STHADHH
Side stand switch voltage
Switch for 2nd gear voltage
Roll angle sensor
Switch for 3rd gear voltage
Fuel pump relay
Lambda probe heater, rear
Lambda probe heater, front
SLS (Secondary air system)
Engine speed
Mixture correction 1
Calculated load value
Desired idle speed
Mixture correction 2
Injection valve, rear Opening time
Injection valve, front Opening time
Ignition timing, rear
Ignition timing, front
Dwell angle, rear
Dwell angle, front
Throttle reference value
Throttle voltage reference value
Mixture correction reference value 1 general
Mixture correction reference value 1 idle
Mixture correction reference value 2 general
Mixture correction reference value 2 idle
Idle speed control motor, actual
Idle speed control motor set-point value
2nd throttle valve, actual steps
2nd throttle valve set-point value steps
Min. initialization voltage 2nd throttle sensor
Max. initialization voltage 2nd throttle sensor
Min. limit value
Max. limit value
Unit
0.3
0
1
13.3
1
13.3
6.5
4.551
-20
4.629
-20
0
0
1
13.3
0.3
1
4.5
75-85
4.2
119.99
4.2
119.99
16
0.2
140
0.288
120
5
5
4.2
119.99
4.5
5
volts
degrees
volts
KPa
volts
KPa
volts
volts
ºC
volts
ºC
volts
volts
volts
KPa
volts
volts
0.4-1.4
3.7-4.1
volts
on
0
max. 3.31 V (on)
off
40
min. 4.14 V (off)
volts
actuated
not actuated
max. 3.31 V
min. 4.14 V
down (folded down) up (folded up)
max. 3.31 V (on) min. 4.14 V (off)
Normal
Crash detected
max. 3.31 V (on) min. 4.14 V (off)
on
off
on
off
on
off
Valve open
Valve closed
0
9600
0.65
1.25
0
100
0.65
1.25
0
20.25
0
20.25
0
54
0
54
0.966
4.000
0.966
4.000
13.8
20
0
1
0.95
1.05
0.95
1.05
0.95
1.05
0.95
1.05
0
700
0
700
0
100
0
100
0.518
1.2
3.799
4.5
volts
volts
volts
volts
volts
rpm
%
rpm
msec
msec
º BTDC
º BTDC
msec
msec
º
volts
steps
steps
%
%
volts
volts
Remarks
Completely closed 0.56-0.64 V
Idle, engine min.80ºC: 36-40KPa
rich: 0.8 V; lean: 0.1 V
rich: 0.8 V; lean: 0.1 V
Idle, engine 80ºC: 37-43KPa
closed:1V; open: 4.3V
Side stand up: 1-3 volts
side stand down 4-5 volts
Short circuit 0-1 volts
Normal operation: 0.4-1.4 volts
Crash detected: 3.7-4.1 volts
Error: <0.352, >4.8 volts
Cable break: 2-3 volts
Number of codes
on: idle/no gear engaged
off: random gear engaged
Actuated: clutch pulled
Not actuated: clutch disengaged
on: 2nd gear engaged
on: 3rd gear engaged
13 Ohm at 20ºC
13 Ohm at 20ºC
20 Ohm at 20ºC
1450 rpm, Tw min.80ºC
Normal value: 15-17º
Normal value: 0,4-0,5 V
0 % in idle
0 % in idle
Normal: approx.1V; Error: 0.518V
Normal: approx.4.3V; Error: 3.799V
7-58
Alarm system for 990 Super Duke/R (optional)
General information: a Power Parts alarm system is available for the KTM 990 Super Duke which should be retrofitted by your
dealer (under the seat). The vehicle wiring harness is already equipped to accommodate the alarm system
(see mounting instructions).
The alarm system is deactivated/activated with a hand-held transmitter and comes with a separate battery and horn. If someone
attempts to steal the bike, the alarm will be triggered even if the vehicle battery is disconnected.
If the alarm system is activated, the alarm LED will light up on the instrument panel.
The alarm system will react to the following manipulations:
– Change of angle (max. 1.5 degrees/second)
– Removal of seat
– Ignition on/attempt to start the engine
– Disconnection of vehicle battery
– Disconnection of the alarm system
The system reacts by:
– Triggering an acoustic alarm (alarm system horn)
– Triggering an optical alarm (flasher lights unless the alarm system is disconnected)
– Double starter interlock (starting system and injection system are blocked)
The engine cannot be started if the alarm system is activated even if the alarm system control unit is disconnected.
Hand-held transmitter: transmits a radio signal that partially changes each time it is actuated (rolling code); the permanent
changes make it impossible to copy the signal. If the alarm system receives a copied (i.e. identical) signal, it does not
deactivate. If a hand-held transmitter is lost (2 are included in the scope of supply) a reprogrammed hand-held transmitter can
be supplied by KTM, although the new hand-held transmitter must be adapted to the vehicle first. To reprogram the transmitter,
the customer must present the code card for the alarm system which contains the programming code required for
reprogramming. Up to 7 hand-held transmitters can be programmed simultaneously for each vehicle.
If a hand-held transmitter is lost or defective, the motorcycle must be started with the other hand-held transmitter or (if not
available) with an emergency start code. The emergency start code is also programmed on the code card and is different for
each vehicle. The alarm will inevitably be triggered when the emergency start code is entered since the ignition must be switched
on.
If an alarm was triggered, the ignition will deliver a low humming noise when switched on, afterwards the alarm LED will indicate
why the alarm was triggered as information for the driver or as a false alarm for troubleshooting:
1 x blink: Angle sensor (change in vehicle position)
2 x blink: Seat switch (manipulation of the seat)
3 x blink: Ignition switch (ignition was switched on)
4 x blink: Voltage at the vehicle battery (vehicle battery was disconnected)
The alarm system inputs can be checked without triggering the alarm if the ignition is switched to ON, the vehicle is moved or
the seat removed within 26 seconds after activation (neutral time); if the system is faultless, each step will be confirmed with an
acoustic signal. Upon expiration of the neutral time, the normal alarm will be triggered.
7-59
Order for additional hand-held transmitters
New hand-held transmitters 1 for the alarm system 2 will be
delivered by KTM pre-programmed. Indicate the bar code 3 from the
code card 4 and the next available programming space 5 when
ordering.
4
2
Art.-No. 3.206.056-E
1
6
3
5
Adapting the hand-held transmitter
NOTE:
– A new hand-held transmitter must be "adapted" with the alarm
system before it can be operated.
– During the adapting process described below, all of the hand-held
transmitters previously used will be blocked and must be "adapted"
again together with the new hand-held transmitter.
– If the ignition switch is switched ON and the OFF again with the
alarm system deactivated, the alarm LED will blink the number of
"adapted" hand-held transmitters.
– Keep your code card 4 and emergency start code 6 handy.
– Deactivate the alarm system (with the hand-held transmitter or the
emergency code) and immediately turn the ignition switch ON 3x
and OFF 2x (the ignition is now switched on). The alarm LED will
light continuously now.
– Switch the ignition OFF and watch the alarm LED; it will start to
blink for the first digit of the emergency start code (in this case the
2 in code 26673).
– After the alarm LED lights up 2x, immediately switch the ignition
ON and OFF again.
– The alarm LED will blink for the 2nd digit of the emergency start
code (the 6 in our example). After the alarm LED lights up 6x,
immediately switch the ignition ON and OFF again.
– The alarm LED will blink for the 3rd digit of the emergency start
code (the 6 in our example). After the alarm LED lights up 6x,
immediately switch the ignition ON and OFF again.
– The alarm LED will blink for the 4th digit of the emergency start
code (the 7 in our example). After the alarm LED lights up 7x,
immediately switch the ignition ON and OFF again.
– Now the alarm LED will blink for the 5th digit of the emergency start
code (the 3 in our example). After the alarm LED lights up 3x,
immediately switch the ignition ON and leave it on - if the
emergency start code was entered correctly, the alarm system will
give an acoustic signal (2 high tones, 2 low tones). Now you can
program all of the remote controls that are to be used:
– Press the hand-held transmitter until the alarm LED lights up.
– Press the hand-held transmitter again until the alarm LED
extinguishes. You will hear an acoustic signal (1 high tone) to
indicate that the hand-held transmitter was successfully "adjusted".
– "Adjust" the other hand-held transmitters in the same manner.
– Switch off the ignition to complete the programming. You will hear
an acoustic signal (2 high tones, 2 low tones).
Repair manual KTM LC8
– Check whether the hand-held transmitter is operative.
– Mark the new digit 5 (the 3 in our example) with an asterisk.
NOTE: also proceed as described above to block hand-held transmitters
that were lost or stolen.
7-60
Starting with the emergency code
NOTE:
– Use the following procedure if no functioning hand-held transmitter is available to deactivate the alarm system.
– This procedure must be repeated each time the engine is started since the engine lock is automatically activated 50 seconds
after the ignition is switched off
– Switch the ignition to ON. The alarm system will trigger an optical and acoustic alarm, the alarm LED will light up
continuously.
– Switch the ignition OFF and watch the alarm LED. The first digit of the emergency code will start to blink (in this case the 2
in code 26673).
– After the alarm LED lights up 2x, immediately switch the ignition ON and OFF again.
– The alarm LED will blink for the 2nd digit of the emergency start code (the 6 in our example). After the alarm LED lights up
6x, immediately switch the ignition ON and OFF again.
– The alarm LED will blink for the 3rd digit of the emergency start code (the 6 in our example). After the alarm LED lights up
6x, immediately switch the ignition ON and OFF again.
– The alarm LED will blink for the 4th digit of the emergency start code (the 7 in our example). After the alarm LED lights up
7x, immediately switch the ignition ON and OFF again.
– The alarm LED will blink for the 5th digit of the emergency start code (the 3 in our example). After the alarm LED lights up
3x, immediately switch the ignition ON and leave it on. If the emergency start code was entered correctly, the alarm system is
deactivated and you can start the engine.
7-61
ABS SYSTEM 990 ADVENTURE
Checking the fuses
NOTE: 2 fuses for the ABS are located under the starter relay.
– Remove the protection covers and check fuse 1. Always replace a
blown fuse with an equivalent fuse.
1
Checking the ABS fault memory using the KTM diagnostics tool
– Connect the diagnostics plug, switch on the ignition and select
"ABS-ECU" 2 in the KTM diagnostics tool.
– Select "Show diagnostics menu" 3.
3
2
Art.-No. 3.206.056-E
– Select "Show DTC/Freeze data" 4 in the diagnostics menu.
9
4
– Any errors will be listed 5 and a description provided 6 (e.g. "rear
ABS sensor disconnected") and the error status displayed 7 (Error
currently present).
Repair manual KTM LC8
5
8
6
7
– After rectifying/eliminating the error, stored errors can be deleted
with "Clear DTC in ECU" 8.
NOTE: if extreme differences in the rotational speed of the front and
rear wheels arise while driving (e.g. driving on loose ground) error 5032
or 5034 will be stored and can be deleted.
Checking the ABS sensor with the KTM diagnostics tool
bk
bl
– Select "Show Current data" 9 in the diagnostics menu.
– Turn the front and rear wheel.
NOTE:
– The speed of the front ABS sensor will be displayed under "FWS" bk.
– The speed of the rear ABS sensor will be displayed under "RWS" bl.
8-1
FUEL SYSTEM
Repair manual KTM LC8
Art.-No. 3.206.056-E
INDEX
KEIHIN CARBURETOR CVRD 43
DESCRIPTION OF THE ACV (AIR CUT VALVE) SYSTEM . . . . . . . . . . . . . . . . . . . .8-3
DISASSEMBLING THE CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-4
ASSEMBLING THE CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-7
CHECKING THE FLOAT LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-10
ADJUSTING THE MIXTURE CONTROL SCREW . . . . . . . . . . . . . . . . . . . . . . . . . .8-10
CHECKING THE THROTTLE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-11
ADJUSTING THE THOTTLE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-11
ADJUSTING THE CHOKE CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-11
ADJUSTING THE THROTTLE CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-11
SYNCHRONIZING THE CARBURETOR . . . . . . . . . . . . . . . . . . . . . . .SEE CHAPTER 12
ADJUSTING THE IDLE SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . .SEE CHAPTER 12
CARBURETOR HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-12
KEIHIN ELECTRONIC FUEL INJECTION
ADJUSTING THE THROTTLE CABLE . . . . . . . . . . . . . . . . . . . . . . . . .SEE CHAPTER 2
DISMOUNTING/MOUNTING THE THROTTLE BODY . . . . . . . . . . . . . . . . . . . . . . .8-13
DISMOUNTING/MOUNTING THE FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . .8-13
REPLACING THE FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-13
CHECKING THE FUEL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-14
8
Repair manual KTM LC8
Art.-No. 3.206.056-E
8-2
CARBURATOR - KEIHIN CVRD 43
8-3
Description of the ACV (air cut valve) system
ACV stands for Air Cut Valve.
2
The ACV system enriches the mixture by reducing the idle-air quantity
to prevent the exhaust from backfiring in an overrun condition or upon
sudden closure of the throttle valve.
1
Normally the required idle-air reaches the mixture through two air jets,
the idle air jet 1 (jet diameter 50) and the ACV jet 2 (jet diameter
80).
3
4
In an overrun condition or during upon sudden closure of the throttle
valve, the momentary high under-pressure causes the diaphragm 3 of
the ACV valve to close the air channel to the idle-air jet against the
pressure of the ACV spring 4. Now the air can only be drawn in
through the ACV jet 2, resulting in a richer mixture.
The system needs no maintenance. No servicing is required other than
an inspection of the components when the carburetor is overhauled. No
adjustments can be made.
8-4
Disassembling the carburetor
2
– Loosen the throttle linkage arm 1 and remove together with the
shims.
– Unscrew the throttle sensor and cable for the idle setting.
– Loosen the screws and remove both connecting rods 2.
2
NOTE:
– The screws on the connecting rods are glued in. Place the carburetor
on an aluminum plate and tap the screws carefully with a hammer
to loosen.
– The fuel connections must be turned aside before the connecting
rods can be removed.
1
5
– Unscrew the connection for the electric starter system 3 and
remove the starter piston and spring, unless already removed when
the carburetor was dismounted.
– Pull the fuel connection 4 out of the carburetor.
– Remove the diaphragm cover 5.
3
4
– Remove the throttle slide spring 6 and pull the throttle slide 7 out
of the carburetor together with the diaphragm.
Art.-No. 3.206.056-E
6 5
7
Repair manual KTM LC8
8
bl
bk
– Press the jet needle holder 8 together in the direction of the arrows,
carefully unclip from the jet needle and remove.
NOTE: the spring 9 on the jet needle usually remains in the jet needle
holder.
– Check all parts for wear, especially the jet needle and the guide
surfaces bk of the throttle slide.
– Check the throttle slide diaphragm carefully for cracks or fractures.
9
NOTE: the tab of the throttle slide diaphragm contains a small air jet
bl – be carefully not to lose it.
8-5
– Remove the float chamber 1 and discard the gasket.
1
– Loosen the fixing screw 2 on the float hinge pin 3 and remove the
float 4 together with the hinge pin and the needle valve.
– Check the needle valve for wear at the conical seat.
3
2
4
– Unscrew the ACV cover 5 and remove the spring 6 together with
the diaphragm 7.
5
– Remove the O-ring 8 from the recess around the air jet 9.
– Check the diaphragm 7 for cracks or other damage.
– Use a needle or similar tool to press lightly on the ACV valve bk. The
ACV valve should move down. The valve should close completely
when you let go.
9
bk
6
8
7
8-6
– Unscrew the main air jet 1, the ACV jet 2 and the idle-air jet 3
with a suitable screwdriver.
2
1
3
5
4
6
7
– Unscrew the idle-air jet 4, the main jet 5 with the main jet holder
and starter jet 6.
– Before removing the idle-air mixture control screw 7, screw in to
the limit. Count and note down the number of turns. Then remove
the mixture control screw together with the O-ring, shim and spring.
– Check the jets for damage and wear.
– Clean all parts thoroughly and blow compressed air through all of
the bores.
!
CAUTION
!
CAREFULLY
BLOW THE AIR THROUGH THE ACT JET AIR DUCT FROM THE ACV VALVE
SIDE TO AVOID DAMAGING THE ACV VALVE.
– Hold the throttle valve against the light in a closed condition. No
light should be visible on the side of the throttle valve.
Art.-No. 3.206.056-E
NOTE: if any light is visible, check the throttle valve and carburetor
housing for wear. The throttle valve usually becomes worn on the side
near the throttle shaft.
8
– Remove the screws 8.
!
CAUTION
!
HOLD
A SUITABLE MANDREL AGAINST THE THROTTLE SHAFT TO KEEP IT FROM
BENDING.
NOTE: bore out the screws if you are unable to loosen them.
– Remove the throttle valve.
– Remove the lock ring 9 from the throttle shaft and pull the throttle
shaft out from the side of the carburetor.
– Check the throttle shaft for wear and deformation.
Repair manual KTM LC8
9
8-7
Assembling the carburetor
– Push the throttle shaft into the carburetor housing, fit the spring
and mount the lock ring 1.
1
– Mount the throttle valve 2, tighten and caulk the screws.
!
– Screw on the idle-air jet 3, main jet 4 with main jet holder and
starter jet 5.
– Screw the idle-air mixture control screw 6 with the O-ring, shim
and spring in to the limit, unscrew the number of turns previously
noted.
5
7
!
A SUITABLE MANDREL AGAINST THE THROTTLE SHAFT TO KEEP IT FROM
BENDING.
2
4
3
CAUTION
HOLD
6
See pages 8-10 to adjust the mixture control screw.
– Mount the main air jet 7, ACV jet 8 and idle-air jet 9 with a
suitable screwdriver.
8
9
8-8
– Place the O-ring 1 in the recess around the air jet.
– Mount the ACV diaphragm so that the pin 2 presses on the ACV
valve plate 3.
2
3
1
– Place the spring on the diaphragm and mount the ACV cover 4.
Art.-No. 3.206.056-E
4
5
6
7
– Position the float 5 together with the needle valve and float hinge
pin 6 in the carburetor housing.
– Tighten the fixing screw 7 on the float hinge pin.
See pages 8-10 to adjust the float level.
– Mount the float chamber 8 with a new gasket. Tighten the screws.
Repair manual KTM LC8
8
8-9
– Mount the lock ring 1 in the respective position on the jet needle
2 (2nd notch from the top – see technical specifications).
1
2
5
4
3
6
– Insert the spring 3 in the jet needle holder 4 and position in the
throttle slide together with the jet needle. Clip the jet needle holder
into place.
NOTE: a small air jet 5 should be mounted in the tab of the throttle
slide diaphragm.
– Insert the throttle slide and diaphragm 6 in the carburetor, pushing
the jet needle in the needle jet (see arrow).
– Mount the throttle slide spring and screw on the diaphragm cover 7.
– Fit the starter cable in the piston and screw on the connection for
the electric starter system 8.
7
See pages 8-11 to adjust the starter cable.
– Insert the fuel connection 9 in the bore with new O-rings.
8
9
8-10
1
– Position both connecting rods 1, coat the thread of the screws with
Loctite 243 and mount.
NOTE: bend the fuel connections according to the recesses in the
connecting rods before mounting the connecting rods.
1
2
– Mount the throttle linkage arm 2 with shims as shown in the
drawing and secure with the pins.
NOTE: slide the curved plastic shims 3 on the bolts first.
3
– Screw on the throttle sensor and cable for the idle setting.
2
See page 8-11 to adjust/check the throttle sensor.
See Chapter 12 to adjust the idle speed.
See Chapter 12 to synchronize the carburetor.
See page 8-11 to adjust the throttle cable.
Adjusting the float level
5
Art.-No. 3.206.056-E
NOTE: it is not necessary to separate the two carburetors to adjust the
float level.
4
– Remove the float chamber.
– Turn the carburetor aside until the float 4 presses lightly against
the needle valve.
– Place the setting gauge 600.29.016.000 5 on the carburetor at
the highest part of the float. The setting gauge should not press
against the float but there should not be a gap between the setting
gauge and the float. If necessary, bend the arm on the float and
check again.
– Mount the float chamber.
Adjusting the idle mixture control screw
NOTE: the idle mixture control screw can only be adjusted when the
carburetor is dismounted.
Repair manual KTM LC8
6
– Screw the mixture control screws in to the limit.
– Screw out the mixture control screws 2 1/4 turns (see Technical
Specifications).
8-11
Checking the throttle sensor
NOTE: the adjustment must be made in a mounted condition with the
cable connected and the ignition switched on.
– Use a digital multimeter to measure the voltage between the black
and yellow cables at the connector AM 1 (under the fuse box).
!
CAUTION
!
YOU MUST MEASURE WITH THE CONNECTOR ATTACHED, MAKE SURE TO
CAREFULLY PUSH THE MEASURING TIPS ON THE MULTIMETER THROUGH THE
SEALING FROM THE CABLE SIDE AND NOT TO DAMAGE ANY PART OF THE
CONNECTOR.
SINCE
1
– Reading with closed throttle (neutral position): 0.5 – 0.6 volts
– Slowly open the throttle valve with the throttle grip, the measured
voltage should increase uniformly up to the full load reading.
– Reading with fully opened throttle grip (full throttle position):
3.6 – 3.7 volts
Adjusting the throttle sensor
2
– Remove the carburetors from the air filter box: see Chapter 3.
– Loosen the screw on the throttle sensor 2 and turn the throttle
sensor until you reach the reading for the neutral position.
NOTE: make sure that you still have enough throttle cable play when
the carburetors are dismounted.
– Tighten the screw on the throttle sensor and remount the carburetors
(see Chapter 3).
– Check the readings with the carburetors mounted (see above).
Adjusting the choke cable
4
5
3
The choke cable should always have a play of approx. 3 mm.
– Push back the protection cover 3; you should be able to lift the
cable approx. 3 mm away from the adjusting screw 4.
– Loosen the counter nut 5, turn the adjusting screw as needed,
tighten the counter nut again and slide on the protection cover.
!
CAUTION
!
IF THERE IS NO CHOKE CABLE PLAY, THE HOLE IN THE COLD START SYSTEM WILL
NOT BE ABLE TO CLOSE COMPLETELY. THIS WILL RESULT IN A HIGH FUEL
CONSUMPTION, IRREGULAR ENGINE OPERATION AND EXTREME WEAR ON THE
PISTONS AND CYLINDERS.
Adjusting the throttle cable (Carburetor models only)
You should be able to feel 3-5 mm play in the throttle grip when you
start to turn it.
– Loosen the counter nut 6, adjust the adjusting screw 7 as needed
and tighten the counter nut again.
7
6
NOTE: the throttle grip will automatically return to the neutral position
when released. Start the engine and steer to the left and right all the
way to the stop. The idle speed should not change, otherwise the
throttle cable play must be increased.
8-12
Carburetor heater
– Pull the wiring harness connectors 1 from the carburetor heater
elements.
1
1
– Unscrew the carburetor heater elements 2.
2
2
Repair manual KTM LC8
Art.-No. 3.206.056-E
– Check the carburetor heater elements 2 for damage at the
connectors, check the electrical resistance (see Chapter 7).
– Tightening torque for the carburetor heater elements: 4 Nm
2
8-13
INJECTION SYSTEM
Dismounting/mounting the throttle body
(see Chapter 3)
NOTE: never carry out any work on the throttle body; no adjustments
are necessary.
1
Dismounting/mounting the fuel pump with pressure regulator
and fuel level sensor
– Disconnect the fuel line. To disconnect, press down lightly on the
metal shim 1 and pull the connector off.
– Remove the tank side covers, remove the front tank screw,
disconnect the bleeder line and fold up the tank.
– Disconnect connector 2, remove the lock ring 3 from the damper,
loosen the screws 4 and lift off the tank.
5
– Loosen the screws 5 on the fuel pump and pull the fuel pump out
of the tank.
2
4
3
– Remount in the reverse order, always replacing the O-rings 6
(lubricated with engine oil) for the fuel pump and fuel connector.
6
8
7
7
bk
Replacing the fuel filter
NOTE: no prescribed changing interval but recommended if soiled.
– Remove the fuel pump (see above).
– Press the retaining clip 7 towards the outside and pull off the
upper part with the pressure regulator 8.
– Remove and replace the fuel filter 9 and O-ring bk.
– Position the spring bl in the upper part, mount on the fuel pump
and press tightly until the retaining clip engages.
9
bl
– Mount the fuel pump (see above).
8-14
Checking the fuel pressure
– Disconnect the fuel connection (see page 8-13).
1
– Connect the EFI pressure gauge 610.29.094.000 and run the hose
on the pressure manometer to the handlebar if taking a trial run.
Hold in place with cable clips if necessary.
!
DO
CAUTION
!
NOT BEND THE HOSES.
– Start the engine. The fuel pressure should be approx. 3.5 bar, if not,
replace the filter (see page 8-13); if the pressure has not changed
despite the filter change, replace the fuel pump and pressure
regulator (see page 8-13).
2
NOTE: the fuel pressure should also be 3.5 bar at a full engine load,
i.e. if the fuel pressure is correct in neutral, take a trial run.
Repair manual KTM LC8
Art.-No. 3.206.056-E
– Remove the special tool and reconnect the fuel connection with a
new O-ring.
9-1
TROUBLE SHOOTING
INDEX
Repair manual KTM LC8
Art.-No. 3.206.056-E
TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
9
Art.-No. 3.206.056-E
9-2
ERROR
CAUSE
REMEDY
Engine does not start when
the
starter
button
is
actuated
Operating error
Switch on the ignition, switch the transmission to neutral,
switch on the emergency OFF switch
Battery is dead
Charge battery and look for cause of discharging; replace
defective parts
IGNITION fuse is blown
Replace the IGNITION fuse in the fuse box
Main fuse is blown
Replace the main fuse in the starter relay
Ignition lock or emergency OFF
switch is defective
Check the ignition lock and emergency OFF switch, replace
any defective parts
Back-up starter system is defective
Repair the back-up starter system
Engine only switches on
when the clutch lever is
pulled
Back-up starter system is defective
Repair the back-up starter system
Engine switches on although
a gear is engaged
Back-up starter system is defective
Repair the back-up starter system
Engine is cranking but does
not start
Operating error
Open the fuel taps, refuel, do not pull the chock, follow the
starting instructions
Fuel pump hose is blown
Replace the FUEL PUMP fuse
Plug and socket connector on the
wiring harness is oxidizing
Remove the covering and the fuel tank, clean the plug and
socket connector and treat with contact spray
Error in the
(Super Duke)
Error diagnosis with the KTM diagnostics tool, eliminate
error
Engine does
enough power
not
Repair manual KTM LC8
Engine gets too hot
have
injection
system
Fuel supply partly interrupted
Check the fuel taps, run the fuel lines without kinks
Carburetors are leaking
Check the vacuum hoses and vent hoses for a tight fit kinkfree installation
Air filter is heavily soiled
Replace the air filter
Ignition curve for 80 octane is
activated (950 Adventure only)
Activate the ignition curve for 95 octane, provided 95
octane fuel is being used
Error in the
(Super Duke)
system
Error diagnosis with the KTM diagnostics tool, eliminate
error
Not enough coolant in the cooling
system
Add cooling liquid (see maintenance work), check the
cooling system for leakage
Air in the cooling system
Bleed the cooling system (see Chapter 12)
Radiator fins are heavily soiled
Clean the radiator fins with a water jet
Formation of foam in the cooling
system
Replace the cooling liquid, use brand-name antifreeze
Kinked or damaged radiator hose
Install the radiator hose correctly or replace
Thermostat defective
Have the thermostat checked (opening temperature 75°C) or
replaced
Fan fuse is blown
Replace the FAN fuse
Fan or thermoswitch for fan is
defective
Replace defective parts
injection
9-3
ERROR
CAUSE
REMEDY
Engine does not switch on
EPC valve is not mounted correctly,
opens through vibrations
Check the position of the EPC valve (near the oil dipstick):
may not rest against the frame
Engine stalls while driving
No fuel
Refuel
Operating error
Open the fuel taps
Fuel pump fuse is blown
Replace the FUEL PUMP fuse
Carburetor iced (moist, cold intake
air)
Fuse is blown, replace
FI lamp is blinking/lights up
Error in the injection system (Super Duke)
Error diagnosis with the KTM diagnostics tool, eliminate error
Poor idling after replacing
the engine (EFi only)
Control unit was not adapted to
the new engine
Delete preset values using the KTM diagnostics tool (see
Chapter 3) and allow engine to run in neutral for 15 minutes
Sudden loss of power in the
mid-speed range (carburetor
models only)
Camshaft timing or ignition
interval incorrectly adjusted
Check/adjust camshaft position and timing
High oil consumption
Engine oil level is too high
Check the oil level when the engine is warm and correct if
necessary
Engine oil is too thin (viscosity)
Use a thicker engine oil; see "Engine oil" Chapter 11
Headlight and parking light
do not light up
Fuse is blown
Replace the H/L BEAM POSITION fuse
Turn signal, brake light, horn
and multifunctional digital
speedometer do not work
Fuse is blown
Replace the HORN BRAKE LIGHT SPEEDO fuse
The time is not displayed or
not displaced correctly
Fuse is blown, interrupting the
current supply
Replace the CLOCK fuse and set the time
Battery is dead
The ignition (power consumer) was
not switched off
Charge the battery as specified
The battery is not being charged by
the generator
Remove the left engine cowl and check the brown cable
connector on the voltage regulator; check the voltage
regulator and the generator; replace any defective parts
No display in the multifunctional
digital speedometer
Fuse is blown
Replace the HORN BRAKE LIGHT SPEEDO fuse
The speed display in the
multifunctional
digital
speedometer does not work
Pickup cable is damaged or
cable connector contacts are
oxidizing
Check the pickup cable for damage.
ABS warning lamp lights up
Driving situation with extremely
deviating wheel speeds
Stop, switch off the ignition, start again
Fuse is blown
Replace the ABS fuses (under the right engine cowl)
Replace the ABS OPTIONAL fuse
ABS sensors are loose or the cable
damaged
Check the ABS sensors for a tight fit and cables for damage;
replace defective parts
ABS sensor wheel is bent
Replace defective parts
Error in the ABS
Error diagnosis with KTM diagnostics tool
Wait briefly, start the engine again (if not installed, retrofit a
carburetor heater 600.31.003.044)
10-1
CHASSIS
Repair manual KTM LC8
Art.-No. 3.206.056-E
INDEX
DISMOUNTING/MOUNTING THE FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . 10-2
DISMOUNTING/MOUNTING THE REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
REPLACING THE FRONT WHEEL BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-4
REPLACING THE REAR WHEEL BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-5
REPLACING THE FRONT BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-6
REPLACING THE REAR BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-7
REPLACING THE FORK LEGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-8
REPLACING THE SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-9
REPLACING THE STEERING HEAD BEARING . . . . . . . . . . . . . . . . . . . . . . . . . .10-11
REPLACING THE SWING ARM BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-12
REPLACING THE CHAIN, PINION AND REAR SPROCKET . . . . . . . . . . . . . . . . . .10-13
CUTTING AND RIVETING THE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-14
REPLACING THE ABS UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-15
REPLACING THE FRONT ABS SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-15
REPLACING THE REAR ABS SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-15
10
10-2
Dismounting/mounting the front wheel
950/990 Adventure:
– Jack up the motorcycle with the center stand (use 600.03.022.000
if not available), unscrew the left bump rubber and block the center
stand with the lock 600.29.055.000.
– Put a weight on the rear end of the vehicle to lift the front wheel off
the ground.
1 1
1
950 Supermoto/R, 990 Supermoto, 990 Super Duke/R:
– Remove the footrests and jack up the motorcycle on a mounting
rack 625.29.055.000, put a load on the back of the vehicle to lift
the front wheel off the ground; you can also use a suitable
commercial front wheel jack (see Owner's Manual).
1
3
3
2
2
Art.-No. 3.206.056-E
– Remove the two screws 1 and pull the brake caliper off the brake
disk towards the back.
– Remove the collar screw 2 and loosen the clamp screws 3 on both
fork leg axle passages.
– Hold the front wheel and pull out the wheel spindle. Slightly turn
one of the brake calipers towards the outside (950 Adventure) and
take the front wheel out of the fork.
3
3
– Remove both distance bushings 4 from the shaft seal rings 5.
A
!
CAUTION
!
– Do not actuate the hand brake if the front wheel is dismounted.
– To avoid damage, make sure the brake disks do not have contact.
– Mount both distance bushings.
4
Repair manual KTM LC8
NOTE: install the distance bushing with collar A on the left.
5
B
– Lift the front wheel in the fork (pay attention to the rolling direction
B), slightly turn one brake caliper towards the outside and slide the
tire between the brake calipers. Insert the brake disks in the brake
calipers (950/990 Adventure) and mount the wheel spindle. Mount
the brake calipers, apply Loctite 243 to the screws and tighten to 25
Nm (M8) or 45 Nm (M10x1,25).
– Mount the collar screw 2 and slightly tighten, tighten the clamp
screws 3 on the right fork leg axle passage (in the direction of
travel) to prevent the wheel spindle from turning and tighten the
collar nut to 60 Nm.
– Loosen the clamp screws on the right fork leg axle passage, take the
motorcycle off the stand, actuate the front wheel brake and
vigorously compress the fork a few times to align the fork legs.
– Then tighten the clamp screws on both fork leg axle passages to 15 Nm.
!
CAUTION
– ALWAYS
–
!
ACTUATE THE HAND BRAKE AFTER MOUNTING THE FRONT WHEEL UNTIL
YOU FEEL THE PRESSURE POINT.
KEEP THE BRAKE DISKS FREE OF OIL AND GREASE OTHERWISE THE BRAKING
ACTION WILL BE SIGNIFICANTLY REDUCED.
– Finish assembling the motorcycle.
10-3
Dismounting/mounting the rear wheel
950/990 Adventure:
– Place the motorcycle on the center stand to lift the rear wheel off
the ground.
2
950 Supermoto/R, 990 Supermoto, 990 Super Duke/R:
– Jack up the motorcycle with the assembly stand 625.29.055.000,
see Chapter 3.
1
– Unscrew the collar nut 1, remove the chain tensioner 2, hold the
rear wheel and pull out the wheel spindle 3. Push the rear wheel
forward as far as possible, remove the chain from the rear sprocket
and set it aside on the rear sprocket guard (950 Adventure only).
Carefully lift the rear wheel out of the swing arm.
A
!
CAUTION
!
ACTUATE THE FOOT BRAKE IF THE REAR WHEEL IS DISMOUNTED.
SET THE WHEEL ASIDE WITH THE BRAKE DISK FACING UP OTHERWISE
YOU MAY DAMAGE THE BRAKE DISK.
IF YOU DISMOUNT THE WHEEL SPINDLE, THOROUGHLY CLEAN THE THREAD ON
THE WHEEL SPINDLE AND COLLAR NUT AND REGREASE (MOTOREX LONG TERM
2000) TO PREVENT THE THREAD FROM SEIZING.
– DO NOT
– ALWAYS
–
3
A
NOTE: Check the rubber damping seal in the rear wheel hub when the
rear wheel is dismounted.
Before mounting the rear wheel, clean and grease the bearing surface
of the bushing 4 and the shaft seal ring 5.
Mount in the reverse order. Make sure the wheel spindle and chain
tensioner are mounted with the tabs A facing towards the front.
4
Push the rear wheel forward before you tighten the collar nut to
90 Nm, to allow the chain tensioner to rest against the clamp screws.
!
– ALWAYS
–
5
CAUTION
!
ACTUATE THE FOOT BRAKE AFTER MOUNTING THE REAR WHEEL UNTIL
YOU FEEL THE PRESSURE POINT.
KEEP THE BRAKE DISKS FREE OF OIL AND GREASE OTHERWISE THE BRAKING
ACTION WILL BE SIGNIFICANTLY REDUCED.
10-4
Replacing the front wheel bearing
– To dismount the front wheel, see page 10-2.
1
– Pull out both distance bushings 1, pry both shaft seal rings 2 out
of the hub and take the lock ring 3 out of the hub with suitable
pliers.
– Push the bearing spacing tube 4 aside and knock the grooved ball
bearing 5 out from the opposite side with a driver.
– Take the bearing spacing tube out of the hub and knock out the
second grooved ball bearing 6.
2
6
– Press a new grooved ball bearing 6 into the hub with a suitable
tool.
4
!
CAUTION
!
WHEN YOU PRESS IN THE BEARING, MAKE SURE TO PRESS THE OUTER RING ONLY.
IF YOU PRESS THE INNER RING, THE BALLS OR THE BEARING SURFACES OF THE
BALLS WILL BE DAMAGED.
5
3
2
1
– Insert the bearing spacing tube in the hub and press in the grooved
ball bearing 5, again making sure that you only press the outer
bearing ring.
– Mount the lock ring 3, grease the new shaft seal rings 2 and press
in with the back of 584.29.091.000 until flush.
– Attach both distance bushings 1.
NOTE: the collared bushing must be mounted on the left.
Repair manual KTM LC8
Art.-No. 3.206.056-E
– To remount the front wheel, see page 10-2.
10-5
1 2
3
Replacing the rear wheel bearing
– Dismount the rear wheel (see page 10-3).
– Remove the rear sprocket carrier from the rear hub and pull out the
damper rubber.
– Remove the distance bushing 1 and pry the shaft seal ring 2 out of
the hub, then take the lock ring 3 out of the hub with suitable
pliers.
4
5
7
6
– Pull the grooved ball bearing 4 out of the rear hub with the special
tool 600.29.018.000 and the bearing puller 151.12.017.000.
– Remove the distance bushing 5 from the hub.
– Pull out the grooved ball bearing 6 with the special tool
600.29.018.000 and the bearing puller 151.12.017.000 and take
the spacer ring 7 out of the hub.
6
4
– Insert the spacer ring 7 in the hub and tap in a new grooved ball
bearing 6 with the back of special tool 584.29.091.000 A.
– Slide the distance bushing 5 in the hub and tap a new grooved ball
bearing 4 in the hub with the back of special tool 584.29.091.000 A.
– Mount the lock ring 3 in the groove and check for a good fit.
– Mount the shaft seal ring 2, grease and press in the distance bushing 1.
A
A
8
– Pull both distance bushings (8 and 9) out of the rear sprocket
carrier bk with the special tool 600.29.018.000 and the bearing
puller 151.12.017.000.
– Remove the washer bl from the bearing.
bk
bm
– Press out the grooved ball bearing bm from the rear sprocket carrier
with the back of the special tool 584.29.091.000 A.
bl
9
– Press a new grooved ball bearing bm together with a suitable pressing
sleeve into the rear sprocket carrier until flush.
!
CAUTION
!
YOU PRESS IN THE GROOVED BALL BEARING, MAKE SURE TO PRESS THE
OUTER RING ONLY. IF YOU PRESS THE INNER RING, THE BALLS OR THE BEARING
SURFACES OF THE BALLS WILL BE DAMAGED.
WHEN
– Slide the washer bl on the distance bushing 9, mount both
distance bushings (8 and 9).
– Mount the damper rubber in the rear hub and insert the rear
sprocket carrier in the rear hub.
– Mount the rear wheel (see page 10-3).
– Check the chain tension and adjust (see Owner's Manual).
8
A
10-6
Replacing the front brake pads (950/990 Adventure)
– Press the brake caliper against the brake disk to move the brake
pistons into the basic position. Remove the retainers 1, pull out the
bolts 2 and take the brake pads out of the brake caliper.
– Clean the brake caliper and brake caliper support with compressed
air, check the bellows and guide bolt for damage and grease the
guide bolt if necessary.
1
2
– Mount the right brake pad and fix with the bolt. Mount the left brake
pad and slide the bolt in all the way to the stop. Mount the
retainers.
– When mounting the brake pads, make sure the shift rail 3 is
correctly positioned in the brake caliper support and the leaf spring
4 is in place.
!
CAUTION
!
THE BRAKE DISK FREE OF OIL AND GREASE, OTHERWISE THE BRAKING
ACTION WILL BE SIGNIFICANTLY REDUCED.
AFTER MOUNTING, MAKE SURE THE RETAINERS ARE CORRECTLY FASTENED.
AFTER WORKING ON THE BRAKE SYSTEM, ALWAYS ACTUATE THE HAND OR FOOT
BRAKE LEVER TO PRESS THE BRAKE PADS AGAINST THE BRAKE DISK UNTIL YOU
FEEL THE PRESSURE POINT.
– KEEP
–
–
3
4
2
2
1
Art.-No. 3.206.056-E
Replacing the front brake pads (950 Supermoto/R, 990 Supermoto,
990 Super Duke/R)
6
5
7
– Push the retaining clip 5 towards the brake caliper while pushing
upwards, pull the securing bolt 6 out towards the rim.
– Remove the retaining clips, press the brake pads 7 against the
brake piston and take them out of the brake caliper.
– Clean the brake caliper with compressed air.
– Press the brake piston all the way back.
– Mount the brake pads and fasten the retaining clips at the bottom.
– Press the retaining clips towards the brake caliper while pushing
upwards, mount the securing bolt.
!
– KEEP
–
Repair manual KTM LC8
–
8
CAUTION
!
THE BRAKE DISK FREE OF OIL AND GREASE OTHERWISE THE BRAKING
ACTION WILL BE SIGNIFICANTLY REDUCED.
AFTER MOUNTING, MAKE SURE THE RETAINING CLIPS ARE CORRECTLY
POSITIONED IN THE GROOVE 8 OF THE SECURING BOLT.
AFTER WORKING ON THE BRAKE SYSTEM, ALWAYS ACTUATE THE HAND OR FOOT
BRAKE LEVER TO PRESS THE BRAKE PADS AGAINST THE BRAKE DISK UNTIL YOU
FEEL THE PRESSURE POINT.
10-7
Replacing the rear brake pads (950/990 Adventure, 950 Supermoto/R,
990 Supermoto)
– Press the brake caliper towards the rear sprocket to move the brake
piston into the basic position. Remove the retainers 1, pull out the
bolt 2 and remove the brake pads. Thoroughly clean the brake
caliper with compressed air and check the guide bolt bellows for
damage.
1
2
– Slide the left brake pad into the brake caliper and fix with the bolt.
Slide in the right brake pad and push the bolt 2 all the way into the
brake caliper. Mount the retainers 1.
!
CAUTION
!
– KEEP
–
–
THE BRAKE DISK FREE OF OIL AND GREASE OTHERWISE THE BRAKING
ACTION WILL BE SIGNIFICANTLY REDUCED.
AFTER MOUNTING, MAKE SURE THE RETAINERS ARE CORRECTLY POSITIONED.
AFTER WORKING ON THE BRAKE SYSTEM, ALWAYS ACTUATE THE HAND OR FOOT
BRAKE LEVER TO PRESS THE BRAKE PADS AGAINST THE BRAKE DISK UNTIL YOU
FEEL THE PRESSURE POINT.
Replacing the rear brake pads (990 Super Duke/R)
– Press the brake caliper towards the rear sprocket to move the brake
piston into the basic position. Remove the retainer 3, knock out the
bolt 4 from the outside towards the rim.
– Remove the brake pads. Thoroughly clean the brake caliper with
compressed air and check the guide bolt bellows for damage.
3
4
– Slide the left brake pad into the brake caliper and fix with the bolt.
Slide in the right brake pad and push the bolt 4 all the way into the
brake caliper.
– Knock in the bolt towards the outside from the rim until the retainer
3 can be mounted.
!
– KEEP
–
–
CAUTION
!
THE BRAKE DISK FREE OF OIL AND GREASE OTHERWISE THE BRAKING
ACTION WILL BE SIGNIFICANTLY REDUCED.
AFTER MOUNTING, MAKE SURE THE RETAINERS ARE CORRECTLY POSITIONED.
AFTER WORKING ON THE BRAKE SYSTEM, ALWAYS ACTUATE THE HAND OR FOOT
BRAKE LEVER TO PRESS THE BRAKE PADS AGAINST THE BRAKE DISK UNTIL YOU
FEEL THE PRESSURE POINT.
10-8
Replacing the fork legs
– Dismount the front wheel (see page 10-2).
1
– Unscrew the bracket 1 for the brake hose and the speed pickup
cable and remove from the fender (950/990 Adventure only).
– Remove all fender bolts 2 and then the fender.
– Unscrew the speed pickup 3.
2
2 2
3
– Remove the bolts 4 on both brake calipers.
4
– Loosen the clamp bolts on both sides of the bottom 5 and top 6
triple clamps.
– Pull both fork legs down out of the triple clamps.
Art.-No. 3.206.056-E
The new fork legs are mounted in the reverse order used to dismount.
The upper edge of the fork legs must protrude approx. 5 mm from the
top triple clamp 6.
6
Secure the bolts on the brake calipers with Loctite 243 and tighten
to 25 Nm (M8) or 45 Nm (M10x1,25).
Also secure the fixing screws on the speed pickup 3 with Loctite 243.
5
Repair manual KTM LC8
Tighten the clamp bolts on the top triple clamp to 12 Nm (990 Super
Duke) or 20 Nm (950 Supermoto and 950/990 Adventure) and on the
the bottom triple clamp to 15 Nm.
– Mount the front wheel (see page 10-2).
– Adjust the fork legs (see Technical Data).
10-9
Replacing the shock absorber (950/990 Adventure)
– Jack up the motorcycle on the center stand 600.03.022.000,
unscrew the left bump rubber and lock the center stand with the
locking device 600.29.055.000.
2
– Unscrew the left side cover and the seat lock.
3
– Remove the lower shock absorber bolt 1 and press down on the
back of the swing arm to release the shock absorber from the recess
in the swing arm.
– Remove the upper shock absorber bolt 2.
1
– Press the lower end of the shock absorber back against the splash
protector 3, tilt the upper end of the shock absorber outwards and
lift the shock absorber out of the frame.
– Mount the new shock absorber in the same way it was dismounted
and tighten the bolts to 80 Nm.
NOTE: if you cannot press the shock absorber into the recess in the
swing arm, proceed as follows:
4
– Dismount the rear wheel (see page 10-3) and the splash protector 3.
– Lift the back of the swing arm and carefully tap the lower end of the
shock absorber into the recess with a rubber hammer.
– Tighten to bolt to 80 Nm.
– Remount the rear wheel (see page 10-3) and the splash protector.
– Adjust the chain tension (see Owner's Manual).
NOTE: the holding clamps 4 for the brake hose must be open towards
the outside.
– Screw on the left side cover with the seat lock.
To adjust the shock absorber: see Technical Data.
10-10
Replacing the shock absorber (950 Supermoto/R, 990 Supermoto,
990 Super Duke/R)
1
– Jack up the motorcycle and dismount the rear wheel (see page
10-3).
– Remove the seat and the splash protector 1, loosen the tank and
lift slightly in the rear (950 Supermoto only).
– Remove the covering plugs for the upper 2 and lower 3 fork leg
screw.
3
2
Art.-No. 3.206.056-E
– Remove the lower fork leg screw and press the swing arm down to
release the fork leg out of the recess in the swing arm.
NOTE: if the lower fork leg bushing also turns, hold it in place with
pliers.
– Remove the upper fork leg screw.
– Lift the fork leg out of the frame towards the rear.
Repair manual KTM LC8
– Lift a new fork leg into the frame from the rear and mount the upper
fork leg screw.
– Lift the swing arm in the rear and press the lower end of the fork leg
into the recess.
– Apply Loctite 243 to both fork leg screws and tighten to 80 Nm.
– Remount the splash protector and the rear wheel (see page 10-3).
– Adjust the chain tension (see Owner's Manual).
– Fix tank again (950 Supermoto only) and mount the seat.
Fork leg adjustment: see Technical Specifications.
10-11
Replacing the steering head bearing
1
1
– Dismount the fork legs (see page 10-8).
– Unscrew the brake hose guide from the lower and upper triple clamp
(950/990 Adventure) or unscrew the mask support (990 Super
Duke/R).
– Remove the handlebar clamps 1 and lay the handlebar back.
3
2
NOTE: Protect the fairing components and tank from being damaged.
– Loosen the clamp bolt on the steering stem 2, remove the blind
bolt 3 on the steering stem, holding the bottom triple clamp 4 to
prevent it from sliding out of the steering head.
– Remove the top triple clamp 5 and pull the bottom triple clamp 4
and the steering stem down and out of the steering head.
5
6
7
8
bl
– Remove the protective ring 6, seal 7 and the upper steering head
bearing 8.
– Pull the lower steering head bearing 9 off of the steering stem with
a suitable puller and remove the seal bk.
– Slide on a new seal and a new steering head bearing on the steering
stem with a suitable tube.
!
WHEN
CAUTION
!
YOU PRESS IN THE BEARING, MAKE SURE TO PRESS THE INNER RING ONLY.
bm
9
bk
4
– Insert the special tool 584.29.092.000 with the collet
584.29.089.000 into the steering head from below and drive the
outer ring bl on the upper steering head bearing out of the steering
head.
– Insert the special tool 584.29.092.000 with the collet
584.29.089.000 into the steering head from above and the drive
the outer ring bm on the lower steering head bearing out of the
steering head.
– Drive the new outer ring on the upper steering head bearing bl into
the steering head using the special tool 584.29.091.000 with the
collet 584.29.089.000.
– Drive the new outer ring on the lower steering head bearing bm into
the steering head using the special tool 584.29.091.000 with the
collet 584.29.089.000.
NOTE: make sure the outer bearing rings do not cant when they are
driven in.
Assembly is in the reverse order as disassembly.
To adjust the play of the steering head bearing, see Chapter 12.
Tighten the clamp bolt on the steering stem and the collar bolts on the
top triple clamp to 20 Nm (990 Super Duke/R 12 Nm!); tighten the
collar bolts on the bottom triple clamp to 15 Nm.
Tighten the collar bolts on the handlebar clamps to 20 Nm.
Secure the AH bolts on the upper brake hose guide with Loctite 243
and tighten to 8 Nm.
To mount the fork legs, see page 10-8.
10-12
4
7
6
8
7
5
9
9
Replacing the swing arm bearing
1
– Dismount the rear wheel (see page 10-3).
– Dismount the splash protector 1.
– Remove the lower shock absorber bolt 2 and press the swing arm
down to release the shock absorber from the recess in the swing
arm.
– Remove the foot brake cylinder (950/990 Adventure only), pull the
brake caliper back and out of the guide and fasten the foot brake
cylinder again; do not tighten the bolts.
– Tilt the brake caliper to the side and detach the brake hose from the
brackets.
– Loosen the nut on the swing arm bolt 3 and knock the swing arm
bolt out with a suitable tube. Pull the swing arm back and remove.
Art.-No. 3.206.056-E
2
3
– Remove the outer tappet for the shaft seal ring 4 and pull the inner
tappet 5 and inner sleeve 6 out of the bearing.
– Pry out both shaft seal rings 7.
– Place the anvil dolly 600.29.056.000 A underneath and press the
needle bearing 8 out of the swing arm using the special tool
584.29.086.000 B.
B
NOTE: the procedure for the second swing arm bearing is identical
except that the stop disks 9 also need to be removed.
Repair manual KTM LC8
A
B
C
A
– Place the anvil dolly 600.29.056.000 A underneath and press the
new needle bearing into the swing arm with special tool
584.29.086.000 B and 600.10.013.000 C until flush.
– Press in both shaft seal rings until flush.
– Slide the inner tappet for the shaft seal ring 5 and the inner sleeve
6 into the bearing and press in the outer tappet.
NOTE: the procedure for the second swing arm bearing is identical
except that the stop disks 9 need to be mounted.
– Position the swing arm on the motorcycle, knock in the swing arm
bolt and tighten the nut to 130 Nm.
– Press the shock absorber into the recess in the swing arm (see
renewing the shock absorber), tighten bolt with 80 Nm.
– Remove the bolts on the foot brake cylinder, push the brake caliper
into the guide from behind and mount the foot brake cylinder again.
Secure the bolts with Loctite 243 and tighten to 10 Nm (950/990
Adventure only). Press the brake hose into the bracket.
– Remount the rear wheel (to remount, see page 10-3) and the splash
protector.
– Adjust the chain tension (see Owner's Manual).
10-13
Replacing the chain, pinion and rear sprocket
– Unscrew the engine sprocket cover 1, bend up the lock washer 2
and loosen the engine sprocket nut 3.
2
– Open the chain with a cutting/riveting tool (see page 10-14) and
remove the chain.
– Remove the engine sprocket with the lock washer (+ Loctite 243!).
– Slip on a new pinion with a lock washer and screw on the nut.
1
3
950/990 Adventure:
– Loosen the rear sprocket nuts 4 and remove the rear sprocket from
the sprocket carrier.
– Position a new rear sprocket, secure the nuts with Loctite 243 and
tighten to 50 Nm.
4
4
4
4
4
5
– Dismount the rear wheel (see page 10-3) and pull the rear sprocket
carrier out of the rear wheel hub.
4
6
990 Super Duke/R, 950 Supermoto/R, 990 Supermoto
– Loosen the jerk damper bolt 5 and remove the rear sprocket from
the rear sprocket support.
– Position a new rear sprocket, apply Loctite 243 to the jerk damper
bolt and tighten to 50 Nm.
NOTE: the nuts 6 on the jerk damper bolts must fit flush against the
rear sprocket.
– Place the rear sprocket carrier in the hub of the rear wheel and
mount the rear wheel (see page 10-3).
– Pull a new chain over the pinion and rear sprocket.
– Rivet the chain with a cutting/riveting tool (see page 10-14).
– Tighten the engine sprocket nut to 100 Nm, bend up the lock
washer.
– Screw on the engine sprocket cover.
– Adjust the chain tension (see Owner's Manual).
10-14
Opening the chain with a separating/rivet tool
4
1
2
3
2
3
1
NOTE: an X-ring chain, type 525 HV (5/8 x 5/16“), is used for the
KTM models with LC8-engine. You will need special tool
600.29.020.000 to separate or rivet the chain according to the
manufacturer's specifications. This special tool consists of a bracket 1
with 2 marks (A and B), a pressing tool 2 with spindle and a locking
screw, pressing pin 3 and the end plate 4.
– Place bracket 1 over the chain from behind. The marks (A, B)
should face up.
– Insert pressing pin 3 with the larger diameter into the spindle of
pressing tool 2 and turn spindle back.
– Apply pressing tool 2 with pressing pin 3 to a chain link, the
locking screw must face up.
– Slide bracket 1 into pressing tool 2 from the side, positioning the
bracket in such a way that the arrow on mark A points to the locking
screw.
– Screw in the locking screw to fix bracket 1 in position A.
– Holding pressing tool 2 with a ring wrench (wrench size 27 mm),
screw in the spindle of the pressing tool and press out the chain
through the hole in the bracket.
Art.-No. 3.206.056-E
Riveting the chain
5
– Grease the connecting link 5, slide an X-ring 6 on each bolt and
connect the ends of the chain.
– Fasten another X-ring 6 to each bolt.
6
6
6
7
6
4
Repair manual KTM LC8
1
1
7
2
3
2
7
3
– Place bracket 1 over the chain from behind. The marks (A, B) must
face up.
– Slide pressing pin 3 with the smaller diameter into the spindle of
pressing tool 2 and turn spindle back.
– Insert the chain joint shim 7 in the end plate 4 and slide both into
the pressing tool.
– Apply pressing tool 2 with end plate 4 and the chain joint shim 7
to the connecting link 5 in such a way that the locking screw faces
up; the hole on the back of the end plate will accommodate pressing
pin 3.
– Slide bracket 1 into pressing tool 2 fromt he side, positioning the
bracket in such a way that the arrow on mark A points to the locking
screw.
– Screw in the locking screw to fix bracket 1 in position A.
– Holding pressing tool 2 with a ring wrench (wrench size 27 mm),
screw in the spindle of the pressing tool and press on the chain joint
shim 7.
– Loosen the locking screw, remove pressing tool 2 and end plate 4.
– Apply pressing tool 2 to the chain again without end plate 4. The
bracket 1 must be mounted in such a way that the arrow on mark B
points to the locking screw.
– Screw in the locking screw to fix bracket 1 in position B.
– Holding pressing tool 2 with a ring wrench (wrench size 27 mm),
screw in the spindle of the pressing tool and press both bolts of the
connecting links together.
– Completely remove the separating/riveting tool.
10-15
Replacing the ABS unit
1
– Gently actuate the hand brake lever and foot brake lever until you
start to feel resistance; this closes the supply bore to the brake
cylinder pistons and prevents the brake fluid from leaking out; fix in
this position.
NOTE: the fixation must be stiff; the position of the brake lever should
not move when the brake lines are unscrewed.
2
1
4
NOTE: immediately wash off any spilled brake fluid with water.
4
3
– Unscrew all 4 brake lines.
– Remove the 3 retaining screws 1, lift the ABS unit and disconnect
the DL connector 2.
– Remount the holder for the ABS unit and tighten the nuts to 8 Nm.
– Position the ABS unit and connect the DL connector.
– Screw in the 3 retaining screws and tighten.
– Connect the banjo bolts (M10x1) for the brake line with new sealing
washers and tighten to 25 Nm.
– Bleed the brake system (see chapter 12).
Replacing the front ABS sensor
4
– Remove the screw on the ABS sensor 3 and the left screws on the
fender 4.
– Remove the ABS sensor and the protective sleeve, remove the
headlight mask and disconnect the DM1 connector (see chapter
13).
– Unclip the ABS sensor cable and remove.
– Run a new ABS sensor cable along the brake hose and clip on. Join
the connectors.
– Run the ABS sensor cable as illustrated and hold in place with cable
clips.
5
– Mount the ABS sensor with the protective sleeve 5. The collar on
the protective sleeve should face the ABS sensor (see photo).
– Apply Loctite 243 to the screw on the ABS sensor 3 and tighten to
6 Nm.
– Measure the air gap between the ABS sensor and the pulse
generator wheel:
max. 1.85 mm.
Replacing the rear ABS sensor
6
– Remove the screw on the ABS sensor and remove the ABS sensor
and the protective sleeve. Disconnect the connector DM (see
chapter 13).
– Unclip the ABS sensor cable and remove.
– Mount a new ABS sensor and protective sleeve 6. The collar on the
protective sleeve should face the ABS sensor (see photo).
– Apply Loctite 243 to the screw on the ABS sensor and tighten to 6
Nm.
– Run the ABS sensor cable along the brake hose and clip on. Join the
connectors.
– Measure the air gap between the ABS sensor and the pulse
generator wheel:
max. 1.85 mm.
11-1
TECHNICAL SPECIFICATIONS
INDEX
950 ADVENTURE
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
Art.-No. 3.206.056-E
990 SUPER DUKE / SUPER DUKE R
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
950 SUPERMOTO / SUPERMOTO R
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-8
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-9
990 ADVENTURE
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-11
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-12
990 SUPERMOTO
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-14
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-15
Repair manual KTM LC8
950 SUPER ENDURO
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-17
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-18
TOLERANCES, MOUNTING CLEARANCES . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-20
TIGHTENING TORQUES
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-22
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-23
11
11-2
TECHNICAL SPECIFICATIONS – ENGINE 950 ADVENTURE
Repair manual KTM LC8
Art.-No. 3.206.056-E
Engine
Design
Displacement
Bore / Stroke
Compression ratio
Fuel
Valve timing
Valve diameter
Valve clearance, cold
Crankcase bearing
Conrod bearing
Piston pin bearing
Piston
Piston rings
Engine lubrication
Engine oil
Quantity of engine oil
Primary drive
Clutch
Transmission
Gear ratio
Ignition system
Ignition timing
Generator
Spark plug
Electrode distance
Cooling system
Cooling liquid
Starting aid
LC8
Liquid-cooled, 2-cylinder 4-stroke engine with 75° V arrangement with balancer shaft and electric starter
942 cm3
100/60 mm
11.5:1
unleaded premium fuel with at least RON 95 (ROZ 80 - 94 for other ignition curve)
4 valves controlled over bucket tappet and 2 camshafts, camshaft drive with gears/chain
Intake: 38 mm Exhaust: 33 mm
Intake: 0,10 - 0,15 mm Exhaust: 0,25 - 0,30 mm
Friction bearings (2 main bearings / 1 supporting bearing)
Friction bearing
Dual-fuel bearing
Light alloy – forged
1 compression ring, 1 taper face ring, 1 single-piece oil scraper ring with spiral-type expander
Dry sump with 2 trochoidal pumps (pressure pump and suction pump)
SAE 5W/40, 10W-50 (f.ex. Motorex Power Synt 4T)
approx. 3.0 liters during oil/filter change or approx. 3.3 liters for dry engine
Straight-toothed spur wheels 35:67
Multi-disc clutch in oil bath
6-speed claw shifted
1st gear 12:35
2nd gear 15:32
3rd gear 18:30
4th gear 20:27
5th gear 24:27
6th gear 26:27
breakerless transistorized electronic ignition system with digital ignition advance
5° from TDC at 1200 rpm
12V 450W at 6000 rpm
NGK CR 8 EK
0.7 mm
liquid cooled, permanent circulation of cooling liquid through water pump
2.1 liters, 50% antifreeze, 50% destilled water, at least –25° C
0.9 kW electric starter
BASIC CARBURETOR SETTING
Type of carburetor
Main jet
Main air jet
Idling jet
Idle air jet
Idle air cutoff jet
Jet needle
Needle position
Mixture control screw open
Starting jet
950 LC8 ADVENTURE
CVRD 43
155 (front) / 160 (rear)
40
42
50
80
NDFB
2nd from top
2 1/4 turns
68
11-3
TECHNICAL SPECIFICATIONS – CHASSIS 950 ADVENTURE/ADVENTURE S
Frame
Fork
Spring travel front
Rear suspension
Spring travel rear
Front brake
Rear brake
Tires, front
Air pressure
Tires, rear
Air pressure
Fuel tank capacity
Gear ratio – rear wheel
Chain
Lighting
Battery
Steering head angle
Wheel base
Seat height, unloaded
Ground clearance, unloaded
Dry weight
Max. axle load, front
Max. axle load, rear
Max. total weight
950 ADVENTURE / 950 ADVENTURE S
Tubular chrome-molybdenum-steel space frame, powder-coated
White Power – Up Side Down 4860 MXMA (Multiadjuster)
model year 2003/2004: ADVENTURE = 230 mm, ADVENTURE S = 265 mm
model year 2005/2006: ADVENTURE = 210 mm, ADVENTURE S = 245 mm
WP Progressive Damping System shock absorber with hydraulic preload adjuster,
aluminum rear wheel swinging fork supported by needle bearings
model year 2003/2004: ADVENTURE = 230 mm, ADVENTURE S = 265 mm
model year 2005/2006: ADVENTURE = 210 mm, ADVENTURE S = 245 mm
Disk brake, 2 perforated brake disks Ø 300 mm, floating brake calipers
Disk brake, perforated brake disk Ø 240 mm, floating brake caliper
Pirelli MT90 FRONT Scorpion A/T 90/90-21 M/C 54V TL
(Metzeler MCE Karoo 2 FRONT 90/90-21 M/C 54R M+S max. 170 km/h)
on road/alone 2,4 bar passenger 2,4 bar
Pirelli MT90 Scorpion A/T 150/70 R18 M/C 70V TL
(Metzeler MCE Karoo 150/70 R18 M/C 70R M+S TL max. 170 km/h)
on road/alone 2,6 bar passenger 2,8 bar
22 liters, 4 liters reserve
17:42
525 HV (5/8 x 5/16”) X-ring, 118 rolls
High beam headlight H3 12V 55W (PK22s base)
Low beam headlight H7 12V 55W (PX26d base)
High + low beam headlight H4 12V 60/55 W (P43t base) (USA)
Front + rear parking light 12V 5W (W2,1x9.5d base)
Instrument lights + indicator lamps LED
Brake light 12V 21W (BA15s base)
Turn signal 12V 10W (BA15s base)
License plate illumination 12V 5W (W2,1x9.5d base)
maintenance-free battery 12V 11.2 Ah
63,4°
1570 mm
model year 2003/04: ADVENTURE = 880 mm, ADVENTURE S = 915 mm
model year 2005/06: ADVENTURE = 860 mm, ADVENTURE S = 895 mm
model year 2003/04: ADVENTURE = 281 mm, ADVENTURE S = 316 mm
model year 2005/06: ADVENTURE = 261 mm, ADVENTURE S = 296 mm
206 kg
200 kg
240 kg
400 kg
11-4
STANDARD ADJUSTMENT – FORK
950 LC8 ADVENTURE
WP USD 4860 MXMA
4,8 N/mm
100 mm
SAE 5 (WP 4860.0211)
Spring
Air chamber length
Fork oil
STANDARD ADJUSTMENT – SHOCK ABSORBER
950 ADVENTURE / ADVENTURE S
WP PDS 5018 PA
140/255
140/265
Spring
STANDARD ADJUSTMENT – FORK AND SHOCK ABSORBER
Repair manual KTM LC8
Standard adjustment
Driver Sport
Maximum load
Driver comfort
Maximum load
Driver comfort
Standard adjustment
Driver Sport
Maximum load
–
8
1,5
12
6
–
6
1
10
8
–
6
1
10
18
20 15 15 15
– – – –
– – – –
18 18 15 18
5 5 8 5
–
15
1,5
20
6
–
12
1,5
17
6
–
8
1
13
12
–
8
1
13
12
Driver Sport
Driver comfort
Standard adjustment
Maximum load
950 ADVENTURE S
FORK
SHOCK ABSORBER
–
12
1,5
17
6
Driver Sport
Standard adjustment
950 ADVENTURE
SHOCK ABSORBER
Compression damping (clicks)
20 15 15 15
Compression damping, low speed (clicks) – – – –
Compression damping, high speed (turns) – – – –
Rebound (clicks)
18 18 15 18
Preload adjuster (turns)
5 5 8 5
Driver comfort
Art.-No. 3.206.056-E
FORK
11-5
TECHNICAL SPECIFICATIONS – ENGINE 990 SUPER DUKE / SUPER DUKE R
Engine
Design
Displacement
Bore / Stroke
Compression ratio
Fuel
Valve timing
Valve diameter
Valve clearance, cold
Crankcase bearing
Conrod bearing
Piston pin bearing
Piston
Piston rings
Engine lubrication
Engine oil
Quantity of engine oil
Primary drive
Clutch
Transmission
Gear ratio
Mixture preparation
Ignition system
Ignition timing
Generator
Spark plug
Electrode distance
Cooling system
Cooling liquid
Starting aid
LC8
Liquid-cooled, 2-cylinder 4-stroke engine with 75° V arrangement with balancer shaft and electric starter
999.9 cm3
101/62.4 mm
11.8:1
unleaded premium fuel with at least RON 95
4 valves controlled over bucket tappet and 2 camshafts, camshaft drive with gears/chain
Intake: 38 mm Exhaust: 33 mm
Intake: 0.10 - 0.15 mm Exhaust: 0.25 - 0.30 mm
Friction bearings (2 main bearings / 1 supporting bearing)
Friction bearing
Dual-fuel bearing
Light alloy – forged
1 compression ring, 1 taper face ring, 1 single-piece oil scraper ring with spiral-type expander
Dry sump with 2 trochoidal pumps (pressure pump and suction pump)
SAE 5W/40, 10W-50 (f.ex. Motorex Power Synt 4T)
approx. 3.1 liters during oil/filter change or approx. 3.3 liters for dry engine
Straight-toothed spur wheels 35:67
Multi-disc clutch in oil bath
6-speed claw shifted
1st gear 14:36
2nd gear 16:30
3rd gear 20:30
4th gear 21:27
5th gear 23:26
6th gear 25:26
EFi (Electronic Fuel Injection)
breakerless transistorized electronic ignition system with digital ignition advance
map-controlled
12V 450W at 6000 rpm
NGK CR 8 EK
0.8 mm
liquid cooled, permanent circulation of cooling liquid through water pump
2.1 liters, 50% antifreeze, 50% destilled water, at least –25° C
0.9 kW electric starter
11-6
Art.-No. 3.206.056-E
TECHNICAL SPECIFICATIONS – CHASSIS 990 DUKE / SUPER DUKE R
CHASSIS
990 SUPER DUKE / R 2007
Frame
Tubular chrome-molybdenum-steel space frame
Fork
WP Suspension – Up Side Down 4860 ROMA
Spring travel front
135 mm (5.3 in)
Rear suspension
WP Suspension 4618 BAVP
Spring travel rear
Super Duke: 160 mm (6.3 in)
Front brake
Disk brake, 2 perforated brake disks Ø 320 mm (12.6 in), brake calipers radially bolted
Rear brake
Disk brake, perforated brake disk Ø 240 mm (9.4 in), floating brake caliper
Authorized front tires *
120/70 ZR17 M/C 58W
Air pressure front
Road, driver only...............................................2.4 bar
Road, with passenger / maximum payload ...........2.4 bar
Authorized rear tires *
180/55 ZR17 M/C 73W
Air pressure rear
Road, driver only...............................................2.4 bar
Road, with passenger / maximum payload ...........2.6 bar
Fuel tank capacity
15 liters, 4 liters Reserve (-2006), 18.5 liters, 3.5 liters Reserve (2007-)
Gear ratio – rear wheel
17:38
Chain
5/8 x 5/16” X-ring
Lighting
high beam ............................................H3 12V 55W (socket PK22s)
low beam ..............................................H7 12V 55W (socket PX26d)
USA: high beam + low beam ..................H4 12V 60/55 W (socket P43t)
position light front ..................................12V 5W (socket W2,1x9,5d)
indicator lamps .....................................LED
position light rear ...................................12V WR5W (socket W2,1x9,5d), Super Duke R: LED
USA: position light rear ...........................12V 5W (socket W2,1x9,5d), Super Duke R: LED
stoplight ...............................................12V PR21W (socket BAW15s), Super Duke R: LED
USA: stoplight .......................................12V 21W (socket BA15s), Super Duke R: LED
flashers .................................................12V RY10W (socket BAU15s)
licens plate illumination .........................12V 5W (socket W2,1x9,5d)
Battery
maintenance-free battery 12V 11.2 Ah
Steering head angle
Super Duke: 66.1°
Wheel base
1450 ± 10 mm (57 ± 0.4 in)
Seat height, unloaded
Super Duke: 850 mm (33.5 in)
Super Duke R: 860 mm (33.9 in)
Ground clearance, unloaded
Super Duke: 140 mm (5.5 in)
Super Duke R: 150 mm (5.9 in)
Dry weight
186 kg (410.6 lbs)
Max. axle load front
180 kg (397.3 lbs)
Max. axle load rear
250 kg (551.8 lbs)
Max. total load
387 kg (854.2 lbs)
Repair manual KTM LC8
* tire releases are available on the Internet at www.ktm.com
Super Duke R: 150 mm (5.9 in)
Super Duke R: 67.3°
11-7
Maximum Payload
Super Duke R
Spring
5 5 5 5 5 5 5 5
9.5 N/mm
Air chamber length
Fork oil
9.5 N/mm
110 mm (4.3 in)
SAE 5 (WP 4860.0401)
Super Duke R
Compression adj. High Speed (turns)
Rebound adjuster (clicks)
Spring preload (mm)
Spring
Race course
Basic Setting
Driving Sport
25 20 10 10 20 16 10 16
Driving Sport
Compression adj. Low Speed (clicks)
Basic Setting
BASIC SETTING
SHOCK ABSORBER WP 4618 BAVP
Driving Comfort
Maximum Payload
Super Duke
Maximum Payload
Spring preload (turns)
Race course
20 15 10 10 16 16 12 16
Driving Sport
Rebound adjuster (clicks)
Basic Setting
20 15 10 10 18 18 14 18
Driving Sport
Compression adjuster (clicks)
Basic Setting
BASIC SETTING
FORK WP 4860 ROMA
Driving Comfort
Maximum Payload
Super Duke
2 1.5 1 1 2.5 1.5 1 1.5
20 12 8 8 12 12 8 12
6 6 6 6 5 5 5 5
170/185
180/185
11-8
TECHNICAL SPECIFICATIONS – ENGINE 950 SUPERMOTO / SUPERMOTO R
Repair manual KTM LC8
Art.-No. 3.206.056-E
Engine
Design
Displacement
Bore / Stroke
Compression ratio
Fuel
Valve timing
Valve diameter
Valve clearance, cold
Crankcase bearing
Conrod bearing
Piston pin bearing
Piston
Piston rings
Engine lubrication
Engine oil
Quantity of engine oil
Primary drive
Clutch
Transmission
Gear ratio
Ignition system
Ignition timing
Generator
Spark plug
Electrode distance
Cooling system
Cooling liquid
Starting aid
LC8
Liquid-cooled, 2-cylinder 4-stroke engine with 75° V arrangement with balancer shaft and electric starter
942 cm3
100/60 mm
11.5:1
unleaded premium fuel with at least RON 95
4 valves controlled over bucket tappet and 2 camshafts, camshaft drive with gears/chain
Intake: 38 mm Exhaust: 33 mm
Intake: 0,10 - 0,15 mm Exhaust: 0,25 - 0,30 mm
Friction bearings (2 main bearings / 1 supporting bearing)
Friction bearing
Dual-fuel bearing
Light alloy – forged
1 compression ring, 1 taper face ring, 1 single-piece oil scraper ring with spiral-type expander
Dry sump with 2 trochoidal pumps (pressure pump and suction pump)
SAE 5W/40, 10W-50 (f.ex. Motorex Power Synt 4T)
approx. 3.0 liters during oil/filter change or approx. 3.3 liters for dry engine
Straight-toothed spur wheels 35:67
Multi-disc clutch in oil bath
6-speed claw shifted
1st gear 12:35
2nd gear 15:32
3rd gear 18:30
4th gear 20:27
5th gear 24:27
6th gear 26:27
breakerless transistorized electronic ignition system with digital ignition advance
5° from TDC at 1200 rpm
12V 450W at 6000 rpm
NGK CR 8 EK
0.7 mm
liquid cooled, permanent circulation of cooling liquid through water pump
2.1 liters, 50% antifreeze, 50% destilled water, at least –25° C
0.9 kW electric starter
BASIC CARBURETOR SETTING
Type of carburetor
Main jet
Main air jet
Idling jet
Idle air jet
Idle air cutoff jet
Jet needle
Needle position
Mixture control screw open
Starting jet
950 LC8 ADVENTURE
CVRD 43
155 (front) / 160 (rear)
40
42
50
80
NDFB
2nd from top
2 1/4 turns
68
11-9
TECHNICAL SPECIFICATIONS – CHASSIS 950 SUPERMOTO / SUPERMOTO R
Frame
Fork
Spring travel front
Rear suspension
Spring travel rear
Front brake
Front rear
Tire, front
Air pressure
Tires, rear
Air pressure
Fuel tank capacity
Gear ratio – rear wheel
hain
bulbs
Battery
Steering head angle
Wheel base
Seat height, unloaded
Ground clearance, unloaded
Dry weight
Max. axle load, front
Max. axle load, rear
Max. total weight
950 SUPERMOTO / R
Tubular chrome-molybdenum-steel space frame, powder-coated
White Power – Up Side Down 4860 ROMA
200 mm
WP 4618 BAVP
210 mm
Disk brake, 2 perforated brake disks Ø 305 mm, fixed brake caliper
Disk brake, perforated brake disk Ø 240 mm, floating brake caliper
120/70 ZR17 M/C 58W
on road/alone 2.4 bar
passenger 2.4 bar
maximum load 2.4 bar
180/55 ZR17 M/C 73W
on road/alone 2.4 bar
passenger 2.6 bar
maximum load 2.6 bar
17 liters (950 Supermoto), 14 liters (950 Supermoto R), 4 liters reserve
17:41
525 HV (5/8 x 5/16") X-Ring
High/low beam headlight H4 12V 55/60W (base P43t)
Front parking light 12V 5W (base W2,1x9,5d)
Instrument lights+ indicator lamps LED
Rear parking light 12V 5W (base W2,1x9,5d)
Brake light 12V 21W (base BA15s)
Turn signal 12V 10W (base BA15s)
License plate illumination 12V 5W (base W2,1x9,5d)
maintenance-free battery 12V 11,2 Ah
65.1 °
1510 +/- 10 mm
865 mm
190 mm
191 kg
190 kg
250 kg
400 kg
11-10
STANDARD ADJUSTMENT – FORK
950 SUPERMOTO
WP 4860 ROMA
5.6-450
110 mm
SAE 5 (WP 4860.0401)
Spring
Air chamber length
Fork oil
STANDARD ADJUSTMENT – FORK
950 SUPERMOTO R
WP 4860 ROMA
5.8-450
110 mm
SAE 5 (WP 4860.0401)
Spring
Air chamber length
Fork oil
STANDARD ADJUSTMENT – SHOCK ABSORBER
950 SUPERMOTO / R
WP 4618 BAVP
130/215
Spring
Repair manual KTM LC8
Maximum load
Driver comfort
Standard adjustment
Driver Sport
Maximum load
Compression damping (clicks)
20 15 10 15
Compression damping, low speed (clicks) – – – –
Compression damping, high speed (turns) – – – –
Rebound (clicks)
22 17 12 17
Preload adjuster (turns)
5 5 5 5
–
20
3
20
9
–
15
2
15
9
–
10
1
10
9
–
10
1
10
9
Driver Sport
Standard adjustment
950 SUPERMOTO / R
FORK
SHOCK ABSORBER
Driver comfort
Art.-No. 3.206.056-E
STANDARD ADJUSTMENT – FORK AND SHOCK ABSORBER
11-11
TECHNICAL SPECIFICATIONS – ENGINE 990 ADVENTURE
Engine
Design
Displacement
Bore / Stroke
Compression ratio
Fuel
Valve timing
Valve diameter
Valve clearance, cold
Crankcase bearing
Conrod bearing
Piston pin bearing
Piston
Piston rings
Engine lubrication
Engine oil
Quantity of engine oil
Primary drive
Clutch
Transmission
Gear ratio
Mixture preparation
Ignition system
Ignition timing
Generator
Spark plug
Electrode distance
Cooling system
Cooling liquid
Starting aid
LC8
Liquid-cooled, 2-cylinder 4-stroke engine with 75° V arrangement with balancer shaft and electric starter
999.9 cm3
101/62.4 mm
11.8:1
unleaded premium fuel with at least RON 95 (ROZ 80 - 94 for other ignition curve)
4 valves controlled over bucket tappet and 2 camshafts, camshaft drive with gears/chain
Intake: 38 mm Exhaust: 33 mm
Intake: 0.10 - 0.15 mm Exhaust: 0.25 - 0.30 mm
Friction bearings (2 main bearings / 1 supporting bearing)
Friction bearing
Dual-fuel bearing
Light alloy – forged
1 compression ring, 1 taper face ring, 1 single-piece oil scraper ring with spiral-type expander
Dry sump with 2 trochoidal pumps (pressure pump and suction pump)
SAE 5W/40, 10W-50 (f.ex. Motorex Power Synt 4T)
approx. 3.0 liters during oil/filter change or approx. 3.3 liters for dry engine
Straight-toothed spur wheels 35:67
Multi-disc clutch in oil bath
6-speed claw shifted
1st gear 12:35
2nd gear 15:32
3rd gear 18:30
4th gear 20:27
5th gear 24:27
6th gear 26:27
EFi (Electronic Fuel Injection)
breakerless transistorized electronic ignition system with digital ignition advance
map-controlled
12V 450W at 6000 rpm
NGK CR 8 EK
0.8 mm
liquid cooled, permanent circulation of cooling liquid through water pump
2.1 liters, 50% antifreeze, 50% destilled water, at least –25° C
0.9 kW electric starter
11-12
TECHNICAL SPECIFICATIONS – CHASSIS 990 ADVENTURE/ADVENTURE S
Frame
Fork
Spring travel front
Rear suspension
Spring travel rear
Front brake
Rear brake
ABS (antilock brake system)
Approved front tires
Luftdruck
Approved rear tires
Repair manual KTM LC8
Art.-No. 3.206.056-E
Luftdruck
Fuel tank capacity
Gear ratio – rear wheel
Chain
Lighting
Battery
Steering head angle
Wheel base
Seat height, unloaded
Ground clearance, unloaded
Dry weight
Max. axle load, front
Max. axle load, rear
Max. total weight
990 ADVENTURE / 990 ADVENTURE S
Tubular chrome-molybdenum-steel space frame, powder-coated
White Power – Up Side Down 4860 MXMA (Multiadjuster)
ADVENTURE = 210 mm, ADVENTURE S = 265 mm
WP Progressive Damping System shock absorber with hydraulic preload adjuster,
aluminum rear wheel swinging fork supported by needle bearings
ADVENTURE = 210 mm, ADVENTURE S = 265 mm
Disk brake, 2 perforated brake disks Ø 300 mm, floating brake calipers
Disk brake, perforated brake disk Ø 240 mm, floating brake caliper
Brembo/Bosch system with 2 independent brake circuits
Pirelli MT90 90/90-21 M/C 54V
up to a maximum of 160 KPH: Continental TKC80 90/90-21 M/C 54S TT M+S
Straße solo 2,4 bar
Straße Sozius 2,4 bar
Pirelli MT90 150/70-18 M/C 70V
up to a maximum of 160 KPH: Continental TKC80 150/70B18 M/C 70Q TT M+S
Straße solo 2,6 bar
Straße Sozius 2,8 bar
19.5 liters, 4 liters reserve
17:42
525 HV (5/8 x 5/16”) X-ring, 118 rolls
High beam headlight H3 12V 55W (PK22s base)
Low beam headlight H7 12V 55W (PX26d base)
High + low beam headlight H4 12V 60/55 W (P43t base) (USA)
Front + rear parking light 12V 5W (W2,1x9.5d base)
Instrument lights + indicator lamps LED
Brake light 12V 21W (BA15s base)
Turn signal 12V 10W (BA15s base)
License plate illumination 12V 5W (W2,1x9.5d base)
maintenance-free battery 12V 11.2 Ah
63,4°
1570 mm
ADVENTURE: 860 mm, ADVENTURE: 915 mm
ADVENTURE: 261 mm, ADVENTURE: 316 mm
ADVENTURE: 209 kg, ADVENTURE: 207 kg
200 kg
250 kg
430 kg
11-13
STANDARD ADJUSTMENT – FORK
990 ADVENTURE
WP USD 4860 MXMA
4,8 N/mm
100 mm
SAE 5 (WP 4860.0211)
Spring
Air chamber length
Fork oil
STANDARD ADJUSTMENT – SHOCK ABSORBER
990 ADVENTURE / ADVENTURE S
WP PDS 5018 PA
140/255
140/265
Spring
STANDARD ADJUSTMENT – FORK AND SHOCK ABSORBER
Maximum load
Driver comfort
Maximum load
Driver comfort
Standard adjustment
Driver Sport
Maximum load
–
20
1,5
15
6
–
15
1
10
10
–
15
1
10
18
20 15 10 10
– – – –
– – – –
23 18 13 13
5 5 8 7
–
25
2
20
6
–
20
1,5
15
6
–
15
1
10
10
–
15
1
10
12
Driver Sport
Driver Sport
Standard adjustment
Standard adjustment
–
25
2
20
6
Driver Sport
Driver comfort
990 ADVENTURE S
FORK
SHOCK ABSORBER
Maximum load
990 ADVENTURE
SHOCK ABSORBER
Compression damping (clicks)
20 15 10 10
Compression damping, low speed (clicks) – – – –
Compression damping, high speed (turns) – – – –
Rebound (clicks)
23 18 13 13
Preload adjuster (turns)
5 5 8 7
Driver comfort
Standard adjustment
FORK
11-14
TECHNICAL SPECIFICATIONS – ENGINE 990 SUPERMOTO
Repair manual KTM LC8
Art.-No. 3.206.056-E
Engine
Design
Displacement
Bore / Stroke
Compression ratio
Fuel
Valve timing
Valve diameter
Valve clearance, cold
Crankcase bearing
Conrod bearing
Piston pin bearing
Piston
Piston rings
Engine lubrication
Engine oil
Quantity of engine oil
Primary drive
Clutch
Transmission
Gear ratio
Mixture preparation
Ignition system
Ignition timing
Generator
Spark plug
Electrode distance
Cooling system
Cooling liquid
Starting aid
LC8
Liquid-cooled, 2-cylinder 4-stroke engine with 75° V arrangement with balancer shaft and electric starter
999.9 cm3
101/62.4 mm
11.8:1
unleaded premium fuel with at least RON 95 (ROZ 80 - 94 for other ignition curve)
4 valves controlled over bucket tappet and 2 camshafts, camshaft drive with gears/chain
Intake: 38 mm Exhaust: 33 mm
Intake: 0.10 - 0.15 mm Exhaust: 0.25 - 0.30 mm
Friction bearings (2 main bearings / 1 supporting bearing)
Friction bearing
Dual-fuel bearing
Light alloy – forged
1 compression ring, 1 taper face ring, 1 single-piece oil scraper ring with spiral-type expander
Dry sump with 2 trochoidal pumps (pressure pump and suction pump)
SAE 5W/40, 10W-50 (f.ex. Motorex Power Synt 4T)
approx. 3.0 liters during oil/filter change or approx. 3.3 liters for dry engine
Straight-toothed spur wheels 35:67
Multi-disc clutch in oil bath
6-speed claw shifted
1st gear 12:35
2nd gear 15:32
3rd gear 18:30
4th gear 20:27
5th gear 24:27
6th gear 26:27
EFi (Electronic Fuel Injection)
breakerless transistorized electronic ignition system with digital ignition advance
map-controlled
12V 450W at 6000 rpm
NGK CR 8 EK
0.8 mm
liquid cooled, permanent circulation of cooling liquid through water pump
2.1 liters, 50% antifreeze, 50% destilled water, at least –25° C
0.9 kW electric starter
11-15
TECHNICAL SPECIFICATIONS – CHASSIS 990 SUPERMOTO
CHASSIS
990 SUPERMOTO 2008
Frame
tubular chrome-molybdenum-steel space frame
Fork
Wheel travel front
WP Suspension – Up Side Down fork 4860 ROMA
Rear suspension
Wheel travel rear
WP Suspension - Progressive Damping System shock absorber 4618 BAVP
Front brake
disk brake, 2 floating perforated brake disks Ø 305 mm (12 in), brake calipers radially bolted
Rear brake
disk brake, perforated brake disk Ø 240 mm (9.4 in), floating brake caliper
Authorized front tires *
PIRELLI Scorpion Sync 120/70 ZR17 M/C 58W
Air pressure front
road, driver only................................................2.2 bar (31 psi)
road, with passenger / maximum payload ............2.4 bar (34 psi)
Authorized rear tires *
PIRELLI Scorpion Sync 180/55 ZR17 M/C 73W
Air pressure rear
road, driver only................................................2.2 bar (31 psi)
road, with passenger / maximum payload ............2.5 bar (36 psi)
Fuel tank capacity
19 liters / 5 USgal, 3.7 liters / 0.9 USgal reserve
Gear ratio – rear wheel
17:41
Chain
5/8 x 5/16” X-ring
Lighting
headlight .........................................................H4 12V 60/55W (socket P43t)
position light front ............................................12V 5W (socket W2,1x9,5d)
indicator lamps ................................................LED
position light rear..............................................12V WR5W (socket W2,1x9,5d)
stoplight .........................................................12V PR21W (socket BAW15s)
licens plate illumination ...................................12V 5W (socket W2,1x9,5d)
flasher .............................................................12V RY10W (socket BAU15s)
Battery
12V 11.2 Ah maintenance-free
Steering head angle
65.1°
Wheel base
1510 ± 10 mm (59.4 in)
Seat height, unloaded
875 mm (34.4 in)
Ground clearance, unloaded
195 mm (7.7 in)
Dry weight
191 kg (421.6 lbs)
Max. axle load, front
190 kg (419.4 lbs)
Max. axle load, rear
250 kg (552 lbs)
Payload
195 kg (430.5 lbs)
Max. total weight
400 kg (883 lbs)
200 mm (7.9 in)
210 mm (8.3 in)
* further tire releases are available on the Internet at www.ktm.com
11-16
FORK
990 SUPERMOTO 2008
Type
14187D20 WP Suspension
Spring
6.2-450
Spring preload
5 mm (0.2 in)
Air chamber lenght
110 mm (4.3 in)
Fork oil
SAE 5 (WP 4860.0401)
SHOCK ABSORBER
990 SUPERMOTO 2008
Type
15187D15 WP Suspension
Spring
130-215
Spring preload
11 mm (0.43 in)
Repair manual KTM LC8
Art.-No. 3.206.056-E
990 Supermoto
2008
Compression
Rebound
Spring preload
(turns)
Compression
Low Speed
Compression
High Speed
Rebound
Spring preload
(mm)
SHOCK
SETTING
FORK
Comfort
20
22
7
20
2.5
20
11
Basic Setting 15
17
5
15
2
15
11
Sport
10
12
5
10
1
10
11
Max. payload
15
17
5
15
2
15
11
11-17
TECHNICAL SPECIFICATIONS – ENGINE 950 SUPER ENDURO
Engine
Design
Displacement
Bore / Stroke
Compression ratio
Fuel
Valve timing
Valve diameter
Valve clearance, cold
Crankcase bearing
Conrod bearing
Piston pin bearing
Piston
Piston rings
Engine lubrication
Engine oil
Quantity of engine oil
Primary drive
Clutch
Transmission
Gear ratio
Ignition system
Ignition timing
Generator
Spark plug
Electrode distance
Cooling system
Cooling liquid
Starting aid
LC8
Liquid-cooled, 2-cylinder 4-stroke engine with 75° V arrangement with balancer shaft and electric starter
942 cm3
100/60 mm
11.5:1
unleaded premium fuel with at least RON 95
4 valves controlled over bucket tappet and 2 camshafts, camshaft drive with gears/chain
Intake: 38 mm Exhaust: 33 mm
Intake: 0,10 - 0,15 mm Exhaust: 0,25 - 0,30 mm
Friction bearings (2 main bearings / 1 supporting bearing)
Friction bearing
Dual-fuel bearing
Light alloy – forged
1 compression ring, 1 taper face ring, 1 single-piece oil scraper ring with spiral-type expander
Dry sump with 2 trochoidal pumps (pressure pump and suction pump)
SAE 5W/40, 10W-50 (f.ex. Motorex Power Synt 4T)
approx. 3.0 liters during oil/filter change or approx. 3.3 liters for dry engine
Straight-toothed spur wheels 35:67
Multi-disc clutch in oil bath
6-speed claw shifted
1st gear 12:35
2nd gear 15:32
3rd gear 18:30
4th gear 20:27
5th gear 24:27
6th gear 26:27
breakerless transistorized electronic ignition system with digital ignition advance
5° from TDC at 1200 rpm
12V 450W at 6000 rpm
NGK CR 8 EK
0.7 mm
liquid cooled, permanent circulation of cooling liquid through water pump
2.1 liters, 50% antifreeze, 50% destilled water, at least –25° C
0.9 kW electric starter
BASIC CARBURETOR SETTING
Type of carburetor
Main jet
Main air jet
Idling jet
Idle air jet
Idle air cutoff jet
Jet needle
Needle position
Mixture control screw open
Starting jet
950 LC8 ADVENTURE
CVRD 43
155 (front) / 160 (rear)
40
42
50
80
NDFB
2nd from top
2 1/4 turns
68
11-18
TECHNICAL SPECIFICATIONS – CHASSIS 950 SUPER ENDURO
Repair manual KTM LC8
Art.-No. 3.206.056-E
Frame
Fork
Spring travel front
Rear suspension
Spring travel rear
Front brake
Rear brake
Tires, front
Air pressure
Tires, rear
Air pressure
Fuel tank capacity
Gear ratio – rear wheel
Chain
Lighting
Battery
Steering head angle
Wheel base
Seat height, unloaded
Ground clearance, unloaded
Dry weight
Max. axle load, front
Max. axle load, rear
Max. total weight
950 SUPER ENDURO
Tubular chrome-molybdenum-steel space frame, powder-coated
WP Up Side Down 4860 MXMA PA (Multi/Preloadadjuster)
250 mm
WP 4618 BAVP, aluminum rear wheel swinging fork supported by needle bearings
255 mm
Disk brake, perforated brake disks Ø 300 mm, floating brake caliper
Disk brake, perforated brake disk Ø 240 mm, floating brake caliper
90/90-21 M/C 54Q
on road/alone 2.4 bar passenger 2.4 bar off road 1.7 bar
140/80-18 M/C 70Q
on road/alone 2,5 bar passenger 2,8 bar off road 1.5 bar
14 liters, 4 liters reserve
17:45
525 HV (5/8 x 5/16”) X-ring, 118 rolls
High + low beam headlight H4 12V 60/55 W (P43t base)
Front + rear parking light 12V 5W (W2,1x9.5d base)
Instrument lights + indicator lamps LED
Brake light 12V 21W (BA15s base)
Turn signal 12V 10W (BA15s base)
License plate illumination 12V 5W (W2,1x9.5d base)
maintenance-free battery 12V 11.2 Ah
64.4°
1577 mm +/- 10 mm
965 mm
330 mm
190 kg
190 kg
250 kg
400 kg
11-19
STANDARD ADJUSTMENT – FORK
950 SUPER ENDURO
WP 4860 MXMA PA
5.9-450
100 mm
SAE 5 (WP 4860.0401)
Spring
Air chamber length
Fork oil
STANDARD ADJUSTMENT – SHOCK ABSORBER
950 SUPER ENDURO
WP 4618 BAVP
(59) 140-215
Spring
STANDARD ADJUSTMENT – FORK AND SHOCK ABSORBER
Maximum load
Driver comfort
Standard adjustment
Driver Sport
Maximum load
–
25
2
22
8
–
20
1.5
18
8
–
15
1
15
8
–
15
1
15
8
Driver Sport
Compression damping (clicks)
25 20 15 20
Compression damping, low speed (clicks) – – – –
Compression damping, high speed (turns) – – – –
Rebound (clicks)
25 20 15 20
Preload adjuster (turns)
1 5 8 5
Driver comfort
Standard adjustment
950 SUPER ENDURO
FORK
SHOCK ABSORBER
11-20
TOLERANCES AND FITTING CLEARANCES
COMPONENT
Valves
Valve springs 950
Valve springs 990
Camshafts/cylinder head
950
Camshafts/cylinder head
990 Super Duke
Camshafts/cylinder head
990 Adventure/SM
Art.-No. 3.206.056-E
Cylinder 950
Cylinder 990
Piston 950
Piston 990
Repair manual KTM LC8
Piston ring 950
Piston ring 990
Piston pin / piston
MEASUREMENT/TEST . . . . . . . . . . . . . . . . . . . . . . .SETPOINT VALUE .TOLERANCE LIMIT
Valve clearance (at 20ºC) intake . . . . . . . . . . . . . . . .0,10 mm - 0,15 mm
Valve clearance (at 20ºC) exhaust . . . . . . . . . . . . . . .0,25 mm - 0,30 mm
Valve shaft runout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.1mm
Sealing seat width, intake . . . . . . . . . . . . . . . . . . . . .1.2 mm – 1.8 mm
Sealing seat width, exhaust . . . . . . . . . . . . . . . . . . . .1.5 mm – 2.0 mm
Valve disk runout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.03 mm
Valve guide, inner diameter . . . . . . . . . . . . . . . . . .6.006 mm – 6.018 mm . . .max. 6.05 mm
Valve shaft, outer diameter, intake . . . . . . . . . . . . .5.967 mm – 5.980 mm
Valve shaft, outer diameter, exhaust . . . . . . . . . . . .5.973 mm – 5.987 mm
Inner length, unloaded . . . . . . . . . . . . . . . . . . . . . . . . .new 39.4 mm . . . . . .min. 38.0 mm
Outer length, unloaded . . . . . . . . . . . . . . . . . . . . . . . . .new 42.8 mm . . . . . .min. 41.3 mm
Inner length, unloaded . . . . . . . . . . . . . . . . . . . . . . . . .new 37.8 mm . . . . . . .min.37.0 mm
Outer length, unloaded . . . . . . . . . . . . . . . . . . . . . . . . new 42.0 mm . . . . . . .min.41.2 mm
Cam height, intake . . . . . . . . . . . . . . . . . . . . . . . .37.80 mm – 37.90 mm
Cam height, exhaust . . . . . . . . . . . . . . . . . . . . . . .36.45 mm – 36.55 mm
Cam height, intake . . . . . . . . . . . . . . . . . . . . . . . .38.75 mm – 38.85 mm
Cam height, exhaust . . . . . . . . . . . . . . . . . . . . . . .38.15 mm – 38.25 mm
Cam height, intake . . . . . . . . . . . . . . . . . . . . . . . .36.96 mm – 37.04 mm
Cam height, exhaust . . . . . . . . . . . . . . . . . . . . . . .36.96 mm – 37.04 mm
Camshaft bearing bore . . . . . . . . . . . . . . . . . . . .24.000 mm – 24.021 mm
Camshaft bearing journal . . . . . . . . . . . . . . . . . . .23.960 mm – 23.980 mm
Camshaft bearing clearance . . . . . . . . . . . . . . . . . .0.020 mm – 0.061 mm . . .max. 0.09 mm
Cylinder head distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.05 mm
Size I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100.000 mm – 100.012 mm
Size II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100.013 mm – 100.025 mm
Cylinder distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.05 mm
Size I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101.000 mm – 101.012 mm
Size II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101.012 mm – 101.025 mm
Cylinder distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.05 mm
Size I – 9 mm (from lower edge) . . . . . . . . . . . . .99.953 mm – 99.967 mm
Size II – 9 mm (from lower edge) . . . . . . . . . . . . .99.963 mm – 99.977 mm . . . .99.930 mm
Mounting clearance . . . . . . . . . . . . . . . . . . . . . . . .0.04 mm – 0.06 mm . . . . . . . .0.10 mm
Size I – 9 mm (from lower edge) . . . . . . . . . . . .100.943 mm – 100.957 mm
Size II – 9 mm (from lower edge) . . . . . . . . . . . .100.953 mm – 100.967 mm . .100.930 mm
Mounting clearance . . . . . . . . . . . . . . . . . . . . . . . .0.05 mm – 0.07 mm . . . . . . . .0.10 mm
Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.15 mm – 0.35 mm . . . . . . . . .0.5 mm
Width of piston ring groove – 1st ring (L-ring) . . . . . .0.92 mm – 0.94 mm
Width of piston ring groove – 1st ring (L-ring) . . . . . .1.80 mm – 1.84 mm . . . . . . . . . . . . . .
Width of piston ring groove – 2nd ring . . . . . . . . . . .1.27 mm – 1.29 mm . . . . . . . . . . . . . .
Width of piston ring groove – oil scraper ring . . . . . . .2.51 mm – 2.53 mm . . . . . . . . . . . . . .
Thickness of 1st ring (L-ring) . . . . . . . . . . . . . . . . . .0.85 mm – 0.87 mm . . . . . . . . . . . . . .
Thickness of 1st ring (L-ring) . . . . . . . . . . . . . . . . . .1.20 mm – 1.22 mm . . . . . . . . . . . . . .
Thickness of 2nd ring . . . . . . . . . . . . . . . . . . . . . . .1.22 mm – 1.24 mm . . . . . . . . . . . . . .
Thickness of oil scraper ring . . . . . . . . . . . . . . . . . .2.47 mm – 2.49 mm
Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.15 mm – 0.35 mm . . . . . . . . .0.5 mm
Width of piston ring groove – 1st ring (L-ring) . . . . . .0.92 mm – 0.94 mm
Width of piston ring groove – 1st ring (L-ring) . . . . . .1.80 mm – 1.84 mm
Width of piston ring groove – 2nd ring . . . . . . . . . . .1.25 mm – 1.29 mm
Width of piston ring groove – oil scraper ring . . . . . . .2.50 mm – 2.53 mm
Thickness of 1st ring (L-ring) . . . . . . . . . . . . . . . . . .0.85 mm – 0.88 mm
Thickness of 1st ring (L-ring) . . . . . . . . . . . . . . . . . .1.20 mm – 1.27 mm
Thickness of 2nd ring . . . . . . . . . . . . . . . . . . . . . . .1.22 mm – 1.24 mm
Thickness of oil scraper ring . . . . . . . . . . . . . . . . . .2.47 mm – 2.49 mm
Diameter of piston ring bore . . . . . . . . . . . . . . . .22.006 mm – 22.011 mm . . . .22.030 mm
Diameter of piston pin . . . . . . . . . . . . . . . . . . . .21.996 mm – 22.000 mm . . . .21.980 mm
11-21
TOLERANCES AND FITTING CLEARANCE
COMPONENT
Crankshaft/conrod
Oil pressure
Oil consumption
Pressure pump
Suction pump
Bypass valve
Clutch
Thermostat/radiator
Transmission
MEASUREMENT/TEST . . . . . . . . . . . . . . . . . . . . . .SETPOINT VALUE . .TOLERANCE LIMIT
Diameter of crankshaft journal . . . . . . . . . . .49.965 mm – 49.975 mm (yellow)
Diameter of crankshaft journal . . . . . . . . . . .49.976 mm – 49.985 mm (blue)
Diameter of crankshaft journal . . . . . . . . . . . .49.986 mm – 49.995 mm (red)
Mounting clearance of crankshaft journal . . . . . . .0.025 mm – 0.055 mm . . . . . . .0.08 mm
Diameter of support bearing journal . . . . . . . . . .27.985 mm – 28.000 mm
Mounting clearance of support bearing . . . . . . . . .0.030 mm – 0.070 mm . . . . . . .0.09 mm
Axial clearance of crankshaft . . . . . . . . . . . . . . . . . .0.1 mm – 1.3 mm . . . . . . . . . .2.0 mm
Diameter of conrod eye . . . . . . . . . . . . . . . . . . .22.010 mm – 22.020 mm . . . .22.040 mm
Diameter of conrod journal . . . . . . . . . . . . .41.978 mm – 41.989 mm (yellow)
Diameter of conrod journal . . . . . . . . . . . . . .41.990 mm – 42.000 mm (blue)
Diameter of conrod journal . . . . . . . . . . . . . .42.001 mm – 42.011 mm (red)
Mounting clearance of conrod bearing . . . . . . . . .0.030 mm – 0.060 mm . . . . . .0.080 mm
Axial clearance of conrod eye on conrod journal . . .0.30 mm – 0.45 mm . . . . . . . .0.60 mm
Width of conrod bottom . . . . . . . . . . . . . . . . . .21.948 mm – 22.000 mm
Width of conrod journal . . . . . . . . . . . . . . . . . . .44.30 mm – 44.35 mm
Oil pressure with engine at operating temperature (oil temperature 100ºC in oil tank) . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .min. 0,8 bar at 1500 U/min
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .min. 2,4 bar - max 3,5 bar at 6000 U/min
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0,6 lt/1000 km
Clearance between inner and outer rotor . . . . . . . . . . . . .0.1 mm . . . . . . . . . . . . .0.25 mm
Clearance between outer rotor and case . . . . . . . . . . . . . .0.2 mm . . . . . . . . . . . . . .0.4 mm
Axial clearance . . . . . . . . . . . . . . . . . . . . . . . . . .0.04 mm – 0.09 mm . . . . . . . .0.25 mm
Clearance between inner and outer rotor . . . . . . . . . . . . .0.1 mm . . . . . . . . . . . . .0.25 mm
Clearance between outer rotor and housing . . . . . . . . . . .0.2 mm . . . . . . . . . . . . .0.40 mm
Axial clearance . . . . . . . . . . . . . . . . . . . . . . . . . .0.04 mm – 0.09 mm . . . . . . . .0.25 mm
Length of spring, unloaded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .min. 41.5 mm
Spring tension . . . . . . . . . . . . . . . . . . . . . .27 mm at a load of at least 3.5 kg
Total height of disk package . . . . . . . . . . . . . . . .50.20 mm – 51.20 mm . . . .min. 48.0 mm
Thickness of lining disks . . . . . . . . . . . . . . . . . . . .2.72 mm – 2.88 mm . . . . . . . .2.65 mm
Thickness of steel disks . . . . . . . . . . . . . . . . . . . . . .1.95 – 2.05 mm . . . . . . . . . .1.85 mm
Length of clutch springs, unloaded . . . . . . . . . . . . . . . .30.77 mm . . . . . . . . . . . .29.0 mm
Spring tension . . . . . . . . . . . . . . . . . . . .19.0 at a load of at least 20 kg – 24 kg
Opening temperature of thermostat . . . . . . . . . . . . . . .73° C – 77° C
Opening stroke of thermostat . . . . . . . . . . . . . . . .over 7 mm at 100° C
Discharge pressure of radiator cap . . . . . . . . . . . . . . . . . .1.4 bar
Switch-on temperature of radiator fan switch . . . . . . . . . .102° C
Axial clearance of the mainshaft . . . . . . . . . . . . . .0.05 mm - 0.15 mm
Clearance between shift fork and groove . . . . . . . . .0.1 mm – 0.25 mm . . . . . . . . . .0.4 mm
Width of shift fork groove . . . . . . . . . . . . . . . . . . .5.02 mm – 5.12 mm
Thickness of shift fork . . . . . . . . . . . . . . . . . . . . .4.85 mm – 4.95 mm
11-22
Repair manual KTM LC8
Art.-No. 3.206.056-E
TIGHTENING TORQUES – ENGINE
Hexagon nut on primary gear
Multipoint head bolt on conrod caps
Hexagon nut on balancer shaft
Hexagon nut on balancer shaft preloaded (spreader)
Hexagon nut on cylinder head
AH bolts on cylinder head
Hexagon nut on cylinder head
Studs in engine case
Studs in engine case
Stud on exhaust flange
Plug on front cylinder head
Bolts to attach bearings
Collar screws for bearing shell retaining brackets
Crankshaft locking bolt
Bearing bolts on tensioning rail
Bearing bolts on guide rail
Bearing bolts on double timing gear
Bolt on chain tensioner
AH bolts on camshaft bearing bridges
AH bolts on camshaft bearing bridges
HH bolts on valve covers
HH bolts on engine case halves
HH bolts on engine case halves
AH bolts on freewheel support
HH bolts on freewheel holder
Oil plug (clutch lubrication)
Oil drain plug
Oil line screw connections
HH bolts on oil pump cover
Plug on oil filter housing
Oil jets
Oil jets bended
Oil pressure switch
AH bolt on shift locating drum
HH bolt on shift locking lever
HH bolt on the shift lever (Adventure)
Hexagon nut on clutch clutch hub
HH bolts on clutch pressure cap
HH bolt on clutch cover
HH bolt on clutch cover
HH bolt on outer clutch cover
AH bolt on ignition rotor
AH bolt on ignition rotor
HH bolt on generator cover
Fixing bolts on the stator
Plug on generator cover
Bleeder flange on generator cover
Bearing bolt on generator cover
Fixing bolts on ignition pickup
AH bolts on gear sensor
Spark plugs
Spark plugs
Collar bolt on water pump wheel
HH bolt on water pump cover
Water temperature sensor
Water connections for cylinder head
HH bolt on the starter motor
Vacuum connections for intake port
Hexagon nut on chain sprocket
AH screw for carburetor trumpet fixture
Hose clamps for intake rubber
Lambda probe
Other engine bolts
M33x1.5 left
M10x1
M20x1.5
M20x1.5
M10
M8
M6
M6
M10
M8
M12x1.5
M5
M5
M8
M8
M8
M10
M16x1.5
M8 10.9
M6 10.9
M6
M6
M8
M6 10.9
M6
M10
M22x1.5
M6
M6
M14x1.5
M6x0.75
M4
M10x1
M6
M5
M6
M22x1.5
M6
M6
M8
M6
M16
M16x1.5
M6
M6
M24x1.5
M16x1.5
M6
M6
M5
M10x1.0
M12x1.5
M6
M6
M12x1.5
M20x1.5
M6
M6
M20x1.5
M4
M4
M18x1,5
M5
M6
Loctite 243 + 130 Nm
25 Nm/30Nm/60°
Loctite 243 + 150 Nm
Loctite 243 + 120 Nm
lubricated, 25 Nm /38 Nm
Loctite 243 + 18 Nm/23 Nm
8 Nm
Loctite 243 + 10 Nm
Loctite 243 + 20 Nm
15 Nm
25 Nm
Loctite 243 + 6 Nm
Loctite 243 + 6 Nm
10 Nm
Loctite 243 + 20 Nm
Loctite 243 + 15 Nm
30 Nm
20 Nm
10 Nm/18 Nm
10 Nm
10 Nm
10 Nm
20 Nm
Loctite 648 + 13 Nm
Loctite 243 + 10 Nm
15 Nm
35 Nm
10 Nm
Loctite 243 + 10 Nm
Loctite 243 + 15 Nm
Loctite 243 + 4 Nm
Loctite 243 + 6 Nm
10 Nm
Loctite 243 + 10 Nm
Loctite 243 + 6 Nm
Loctite 243 + 10 Nm
Loctite 243 + 130 Nm
10 Nm
10 Nm
15 Nm
10 Nm
Loctite 243 + 180 Nm
Loctite 243 + 150 Nm
10 Nm
Loctite 243 + 10 Nm
8 Nm
Loctite 243 + 10 Nm
Loctite 243 + 10 Nm
Loctite 243 + 10 Nm
Loctite 243 + 3 Nm
12 Nm
20 Nm
Loctite 243 + 10 Nm
10 Nm
12 Nm
Loctite 577 + 10 Nm
10 Nm
Loctite 243 + 5 Nm
sheet retainer+Loctite 243+100 Nm
4 Nm
1.5 Nm
45 Nm
6 Nm
10 Nm
11-23
TIGHTENING TORQUES – CHASSIS
Collar bolt on front wheel spindle (except 950 Super Enduro)
Collar bolt on front wheel spindle (950 Super Enduro only)
Collar nut wheel spindle rear
AH bolt shock absorber top/bottom
Collar nut for swing arm bolt
AH bolts on subframe
AH bolts on subframe
AH bolts on back of footrest support
Engine carrier bolts
HH clamp bolts on top triple clamp (Super Duke)
HH clamp bolts on top triple clamp (Adventure, Supermoto)
HH clamp bolts on bottom triple clamp
HH screw for steering head
AH/HH clamp bolts on fork legs
Collar bolts for handlebar clamps
AH bolt for handlebar mount
HH clamp bolts for steering stem
Collar bolt brake disks
Collar bolt brake disks
HH bolts on front brake caliper
HH bolts on front brake caliper
HH bolts on handbrake cylinder
HH bolts on footbrake cylinder
AH bearing bolt for foot brake pedal, shift lever
HH screw on cover plate for foot brake lever/shift mechanism
Relay for shift shaft (on connecting support)
Relay for shift shaft (on shift shaft)
Gearshift rod attachment
AH/HH bolt for brake-hose guide
HH bolts on foot brake pedal surface
AH bolts for side stand bracket - engine
HH bolts for side stand fixture - side stand bracket
HH bolts for side stand mounting
HH bolt for spring rest on side stand
HH bolt for side stand switch
HH bolt for side stand switch
HH nuts on rear sprocket bolts
Drain plug on oil tank
Exhaust nuts on manifold
Exhaust clamps (except Adventure)
Exhaust clamps (Adventure only)
Exhaust clamps for ball joint
HH bolts on exhaust suspension
HH bolts for underride protection
AH bolt on gas level indicator
AH bolts on tank cover
HH bolts on tank mounting
AH bolts on tank mounting
HH bolts for fuel taps
Collar screws for in-tank pump
Collar screw on retaining bracket for fuel pump (950 Supermoto)
AH screw on arm for tank support
Collar screw for gas pressure shock absorber
Seat fixing plate
Jerk damper bolt
HH nut for seat lock
Chainguard
Chain sliding guard
Spoke nipple
Front spoiler
Tail light
Torx screw for front ABS sensor holder
HH screw for ABS sensor
Torx screw for rear ABS sensor cable guide
Hexagon nut to mount ABS modulator
Hexagon nut for positive terminal extension
Other bolts on chassis
Other collar nuts on chassis
M24x1.5
M24x1.5
M25x1.5
M14x1.5
M19x1.5
M8
M10x1.25
M8
M10
M8
M8
M8
M20x1,5
M8
M8
M10
M8
M6
M8x1,25
M8
M10x1.25
M6
M6
M8
M6
M8
M6
M6
M6
M5
M10
M10
M10
M8
M4
M6
M10
M12x1.5
M8
M8
M8
M8
M6
M8
M5
M5
M6
M8
M6
M6
M6
M10
M6
M5
M10x1,25
M19x1
M5
M5
M5
M6
M6
M5
M6
M5
M6
M6
M6
M8
M10
M6
M8
M10
60 Nm
40 Nm
90 Nm
80 Nm
130 Nm
Loctite 243 + 25 Nm
Loctite 243 + 45 Nm
Loctite 243 + 25 Nm
45 Nm
12 Nm
20 Nm
15 Nm
12 Nm
15 Nm
20 Nm
20 Nm
20 Nm
Loctite 243 + 14 Nm
Loctite 243 + 30 Nm
Loctite 243 + 25 Nm
Loctite 243 + 45 Nm
10 Nm
Loctite 243 + 10 Nm
Loctite 243 + 25 Nm
Loctite 243 + 10 Nm
Loctite 243 + 25 Nm
Loctite 243 + 18 Nm
Loctite 243 + 12 Nm
Loctite 243 + 8 Nm
Loctite 243 + 6 Nm
Loctite 243 + 45 Nm
Loctite 243 + 25 Nm
Loctite 243 + 35 Nm
Loctite 243 + 25 Nm
Loctite 243 + 2 Nm
Loctite 243 + 10 Nm
Loctite 243 + 50 Nm
25 Nm
evenly, do not bend sheet metal
8 Nm
12 Nm
35 Nm
Loctite 243 + 12 Nm
Loctite 243 + 25 Nm
3 Nm
5 Nm
6 Nm
25 Nm
6 Nm
6 Nm
6 Nm
15 Nm
6 Nm
4 Nm
Loctite 243 + 50 Nm
8 Nm
5 Nm
5 Nm
4-6 Nm
Loctite 243 + 10 Nm
8 Nm
Loctite 243 + 4 Nm
Loctite 243 + 6 Nm
3 Nm
8 Nm
4 Nm
10 Nm
25 Nm
45 Nm
15 Nm
30 Nm
50 Nm
12-1
PERIODIC MAINTENANCE SCHEDULE
INDEX
Repair manual KTM LC8
Art.-No. 3.206.056-E
950 ADVENTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-2
990 SUPER DUKE/R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-4
950 SUPERMOTO/R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-6
990 ADVENTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-8
990 SUPERMOTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-10
950 SUPER ENDURO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-12
MAINTENANCE WORK
CHANGING THE ENGINE OIL AND THE OIL FILTER . . . . . . . . . . . . . . . . . . . . . .12-14
CLEANING THE OIL SCREENS IN THE ENGINE AND OIL TANK . . . . . . . . . . . . . .12-14
CLEANING THE MAGNETS ON THE DRAIN PLUG FOR THE ENGINE AND OIL TANK . .12-14
REPLACING THE SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-16
CHECKING AND ADJUSTING THE VALVE CLEARANCE . . . . . . . . . . . . . . . . . . .12-17
CHECKING THE CLUTCH LINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-19
CHECKING THE CLUTCH PRESSURE BOOSTER SYSTEM . . . . . . . . . . . . . . . . .12-19
CLEAN THE OIL JET FOR THE CLUTCH LUBRICATION . . . . . . . . . . . . . . . . . . . .12-19
CARBURETOR SYNCHRONIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-21
IDLE ADJUSTMENT 950 ADVENTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-21
IDLE ADJUSTMENT 950 SUPERMOTO/SUPER ENDURO . . . . . . . . . . . . . . . . . .12-22
CHECK FAULT MEMORY WITH THE KTM DIAGNOSIS TOOL . . . . . . . . . . . . . . .12-22
PERFORM A STATUS CHECK USING THE KTM DIAGNOSIS TOOL . . . . . . . . . . .12-22
REPLACE THE O-RING OF THE FUEL HOSE CONNECTION . . . . . . . . . . . . . . . . .12-21
CHECKING THE COOLING SYSTEM FOR LEAKAGE AND ANTIFREEZE . . . . . . . . .12-22
CHECKING THE RADIATOR FAN FOR PROPER FUNCTIONING . . . . . . . . . . . . . .12-22
LUBRICATING THE CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-22
CHECKING THE AIR FILTER, REPLACING IF NECESSARY, CLEANING THE AIR FILTER BOX . .12-22
CHECKING THE BRAKE FLUID LEVEL, LINING THICKNESS, BRAKE DISKS . . . . .12-22
CHANGING THE BRAKE FLUID FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-23
CHANGING THE BRAKE FLUID REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-24
CHECKING THE BOLTS ON THE BRAKE SYSTEM FOR FORCE FIT . . . . . . . . . . . .12-24
CHECK ABS FAULT MEMORY WITH THE KTM DIAGNOSIS TOOL . . . . . . . . . . . .12-24
CLEANING THE DUST BOOTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-25
BLEEDING THE FORK LEGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-25
CHECKING THE SWING ARM SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-25
CHECKING/ADJUSTING THE STEERING HEAD BEARING . . . . . . . . . . . . . . . . . .12-25
CHECKING ALL CHASSIS BOLTS FOR FORCE FIT . . . . . . . . . . . . . . . . . . . . . . .12-25
CHECKING THE SPOKE TENSION AND RIM RUN-OUT . . . . . . . . . . . . . . . . . . .12-26
CHECKING THE CHAIN AND CHAIN GUIDES FOR WEAR, FORCE FIT AND TENSION . .12-26
CHECKING THE NUTS/BOLTS ON THE ENGINE SPROCKET AND
THE REAR SPROCKET FOR THE SECURING AGENT AND A TIGHT FIT . . . . . . . . .12-26
CHECKING THE WHEEL BEARING AND JERK DAMPER FOR CLEARANCE . . . . . .12-26
SERVICING THE FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-27
SERVICING THE SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-27
CLEANING AND GREASING THE STEERING HEAD BEARING AND SEALING ELEMENTS . .12-27
CLEANING AND ADJUSTING THE CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . .12-28
CHANGING THE COOLING LIQUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-28
12
12-2
WHEELS
CHASSIS
BRAKES
ADD-ON-PARTS
CARBURETOR
15000 km or
after 2 years
22500 km or
after 3 years
30000 km or
after 4 years
37500 km or
after 5 years
45000 km or
after 6 years
52500 km or
after 7 years
60000 km or
after 8 years
Change engine oil and oil filter
Clean oil screens of engine and oil tank
Clean magnetic drain plugs of engine and oil tank
Check oil lines for damage and kink-less arrangement
Replace the oil line connection from the front valve cover to the oil tank
Renew spark plugs
Check the spark plug connector for a tight fit to the spark plug
Check and adjust valve clearance
Check engine fastening bolts for tight fit
Check all engine bolts accessible from the outside for tight fit
Check clutch linings
Check the outer clutch hub and clutch drive for wear from the clutch disks
Check clutch pressure booster system
Clean the oil jet for the clutch lubrication
Replace the water pump seal; check the water pump shaft for wear
Check the pretensioning of the timing chain tensioner
Check carburetor connection boots for cracks and leaks
Check synchronisation of carburators using special tool, if necessary adjust
Check idle setting (1400 rpm)
Check bleeder hoses for damage and kink-free arrangement
Check cooling system for leaks and antifreeze protection
Check radiator fan for proper operation
Check exhaust system for leaks and correct fit
Check actuating cables for damage, smooth operation, and kink-less arrangement,
adjust and lubricate
Check the oil level in the hydraulic clutch reservoir
Check air filter, renew if necessary, clean air filter box
Check cables for damage and kink-less arrangement
Check headlamp adjustment
Check electrical system for function (low/high beams, stop light, turn indicators,
headlamp flasher, tell-tale lamps, speedometer illumination, horn, sidestand
switch, clutch switch, emergency-off switch)
Make sure all bolts and nuts are tight
Check brake fluid level, lining thickness and brake discs
Change brake fluid
Check brake lines for damage and leaks
Check/adjust smooth operation, free travel of handbrake/footbrake levers
Check the guide bolt on floating brake calipers for wear
Check bolts of brake system for tight fit
Check shock absorber and fork for leaks and proper operation
Clean fork dust sleeves
Bleed fork legs
Check swingarm pivot
Check/adjust steering-head bearing
Check all chassis bolts for tight fit (fork clamps, fork leg, axle nuts/bolts, swinging
arm pivot, shock absorber)
Check spoke tension and rim joint
Check tire condition and inflation pressure
Check chain and chain guides for wear, force fit and tension
Check bolts/nuts on pinion and chain sprocket for locking devices and a tight fit
Lubricate chain
Check wheel bearings and jerk damper for play
Check the distance bushing and seal rings for damage or wear
7500 km or
after 1 year
ENGINE
950 ADVENTURE
1.Service after
1000 km
PERIODIC MAINTENANCE SCHEDULE
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IF MOTORCYCLE IS USED FOR COMPETITION 7500 KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE!
SERVICE INTERVALLS SHOULD NEVER BE EXCEEDED BY MORE THAN 500 KM.
MAINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE OF CARE AND CHECKS DONE BY THE RIDER!
12-3
PERIODIC MAINTENANCE SCHEDULE
IMPORTANT MAINTENANCE PROCEDURES TO BE PERFORMED BASED ON A SEPARATE SUPPLEMENT ORDER
at least
once a year
Perform complete fork maintenance
Perform complete shock absorber maintenance
Clean and lubricate steering-head bearing and sealing elements
Clean and adjust the carburetors
Treat the electrical contacts and switches with contact spray
Treat battery connections with contact grease
Change coolant fluid
Check the wheel spindles/swing arm pivot; replace in case of damage to the surface or corrosion
every 2 years or
15000 km
every 4 years or
30000 km
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Perform a compression test
8 years/60000 km
Repair manual KTM LC8
Art.-No. 3.206.056-E
VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC
Check oil level
Check brake fluid level
Check brake pads for wear
Check lighting system for proper operation
Check horn for proper operation
Lubricate and adjust actuating cables and nipples
Bleed fork legs in regular intervals
Clean chain
Lubricate chain
Check chain tension, lubricate chain if necessary
Check tire pressure and wear
Check coolant level
Check fuel lines for leaks
Check all control elements for smooth running
Check brake performance
Treat exposed metal components (except for the braking and exhaust
systems) with wax-based anti-corrosion agents
Treat ignition/steering lock and light switch with contact spray
before each
start
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after every
cleaning
every 1000 km or
after off road use
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12-4
PERIODIC MAINTENANCE SCHEDULE
WHEELS
CHASSIS
BRAKES
ADD-ON-PARTS
INJECTION
ENGINE
990 SUPER DUKE/R
Change engine oil and oil filter
Clean oil screens of engine and oil tank
Clean magnetic drain plugs of engine and oil tank
Check oil lines for damage and kink-less arrangement
Renew spark plugs
Check and adjust valve clearance
Check engine fastening bolts for tight fit
Check all engine bolts accessible from the outside for tight fit
Check clutch linings
Check clutch pressure booster system
Clean the oil jet for the clutch lubrication
Check rubber boot for cracks or leaks
Check fault memory with the KTM diagnosis tool
Perform a status check of neutral, clutch, 2nd/3rd gear and side stand switch
using the KTM diagnosis tool
Check the fuel hose, the vent hoses, hoses on the vacuum sensors and
secondary air system hoses for correct installation, kink-free installation and damage
Replace the O-ring on the fuel hose connection and check for leaks
Check the wiring harness on the throttle body for proper installation and damage
Check cooling system for leaks and antifreeze protection
Check radiator fan for proper operation
Check the exhaust system for leaks and correct suspension and the clamps for a tight fit
Replace the graphite gasket in the rear exhaust manifold slide
Check actuating cables for damage, smooth operation, and kink-less arrangement,adjust and lubricate
Check the oil level in the hydraulic clutch reservoir
Check air filter, renew if necessary, clean air filter box
Check cables for damage and kink-less arrangement
Check headlamp adjustment
Check electrical system for function (low/high beams, stop light, turn indicators,headlamp flasher,
tell-tale lamps, speedometer illumination, horn, side-stand switch, clutch switch, emergency-off switch)
Make sure all bolts and nuts are tight
Check brake fluid level, lining thickness, and brake discs
Change brake fluid
Check brake lines for damage and leaks
Check/adjust smooth operation, free travel of handbrake/footbrake levers
Check bolts of brake system for tight fit
Check shock absorber and fork for leaks and proper operation
Clean fork dust sleeves
Bleed fork legs
Check swingarm pivot
Check/adjust steering-head bearing
Check all chassis bolts for tight fit (fork plates, fork leg, axle nuts/bolts,
swinging-fork pivot, reversing lever, shock absorber)
Check rim joint
Check tire condition and inflation pressure
Check chain and chain guides for wear, force fit and tension
Check bolts/nuts on pinion and chain sprocket for locking devices and a tight fit
Lubricate chain
Check wheel bearings and jerk damper for play
1. Service 7500 km 15000 km
after
or every
or once
1000 km
2 years
a year
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IF MOTORCYCLE IS USED FOR COMPETITION 7500 KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE!
SERVICE INTERVALLS SHOULD NEVER BE EXCEEDED BY MORE THAN 500 KM.
MAINTENANCE WORK PERFORMED BY AN AUTHORIZED KTM WORKSHOP IS NOT A SUBSTITUTE FOR CARE AND MAINTENANCE BY THE DRIVER!
12-5
PERIODIC MAINTENANCE SCHEDULE
IMPORTANT MAINTENANCE PROCEDURES TO BE PERFORMED BASED ON A SEPARATE SUPPLEMENT
ORDER
at least
once a year
Perform complete fork maintenance
Perform complete shock absorber maintenance
Clean and lubricate steering-head bearing and sealing elements
Treat the electrical contacts and switches with contact spray
Treat battery connections with contact grease
Change coolant fluid
every 2 years or
15000 km
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z
z
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Repair manual KTM LC8
Art.-No. 3.206.056-E
VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC
Check oil level
Check brake fluid level
Check brake pads for wear
Check lighting system for proper operation
Check horn for proper operation
Lubricate and adjust actuating cables and nipples
Clean chain
Lubricate chain
Check chain tension, lubricate chain if necessary
Check tire pressure and wear
Check coolant level
Check fuel lines for leaks
Check all control elements for smooth running
Grease the hand brake lever and clutch lever
Check brake performance
Treat exposed metal components (except for the braking and exhaust
systems) with wax-based anti-corrosion agents
Treat ignition/steering lock and light switch with contact spray
before each
start
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after every
cleaning
every 1000 km
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12-6
PERIODIC MAINTENANCE SCHEDULE
WHEELS
CHASSIS
BRAKES
ADD-ON-PARTS
CARBURETOR
ENGINE
950 SUPERMOTO/R
Change engine oil and oil filter
Clean oil screens of engine and oil tank
Clean magnetic drain plugs of engine and oil tank
Check oil lines for damage and kink-less arrangement
Renew spark plugs
Check and adjust valve clearance
Check engine fastening bolts for tight fit
Check all engine bolts accessible from the outside for tight fit
Check clutch linings
Check clutch pressure booster system
Clean the oil jet for the clutch lubrication
Check carburetor connection boots for cracks and leaks
Check synchronisation of carburators using special tool, if necessary adjust
Check idle setting (1400 rpm)
Check bleeder hoses for damage and kink-free arrangement
Check cooling system for leaks and antifreeze protection
Check radiator fan for proper operation
Check exhaust system for leaks and correct fit
Replace the graphite gasket in the rear exhaust manifold slide
Check actuating cables for damage, smooth operation, and kink-less arrangement,adjust and lubricate
Check the oil level in the hydraulic clutch reservoir
Check air filter, renew if necessary, clean air filter box
Check cables for damage and kink-less arrangement
Check headlamp adjustment
Check electrical system for function (low/high beams, stop light, turn indicators,headlamp flasher,
tell-tale lamps, speedometer illumination, horn, side-stand switch, clutch switch, emergency-off switch)
Make sure all bolts and nuts are tight
Check brake fluid level, lining thickness, and brake discs
Change brake fluid
Check brake lines for damage and leaks
Check/adjust smooth operation, free travel of handbrake/footbrake levers
Check bolts of brake system for tight fit
Check shock absorber and fork for leaks and proper operation
Clean fork dust sleeves
Bleed fork legs
Check swingarm pivot
Check/adjust steering-head bearing
Check all chassis bolts for tight fit (fork plates, fork leg, axle nuts/bolts,
swinging-fork pivot, reversing lever, shock absorber)
Check rim joint
Check tire condition and inflation pressure
Check chain and chain guides for wear, force fit and tension
Check bolts/nuts on pinion and chain sprocket for locking devices and a tight fit
Lubricate chain
Check wheel bearings and jerk damper for play
1. Service 7500 km or 15000 km or
after
every
once
1000 km
2 years
a year
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IF MOTORCYCLE IS USED FOR COMPETITION 7500 KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE!
SERVICE INTERVALLS SHOULD NEVER BE EXCEEDED BY MORE THAN 500 KM.
MAINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE OF CARE AND CHECKS DONE BY THE RIDER!
12-7
PERIODIC MAINTENANCE SCHEDULE
IMPORTANT MAINTENANCE PROCEDURES TO BE PERFORMED BASED ON A SEPARATE SUPPLEMENT
ORDER
at least
once a year
Perform complete fork maintenance
Perform complete shock absorber maintenance
Clean and lubricate steering-head bearing and sealing elements
Clean and adjust the carburetors
Treat the electrical contacts and switches with contact spray
Treat battery connections with contact grease
Change coolant fluid
every 2 years or
15000 km
z
z
z
z
z
z
z
Repair manual KTM LC8
Art.-No. 3.206.056-E
VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC
Check oil level
Check brake fluid level
Check brake pads for wear
Check lighting system for proper operation
Check horn for proper operation
Lubricate and adjust actuating cables and nipples
Bleed fork legs in regular intervals
Clean chain
Lubricate chain
Check chain tension, lubricate chain if necessary
Check tire pressure and wear
Check coolant level
Check fuel lines for leaks
Check all control elements for smooth running
Check brake performance
Treat exposed metal components (except for the braking and exhaust
systems) with wax-based anti-corrosion agents
Treat ignition/steering lock and light switch with contact spray
before each
start
z
z
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z
z
after every
cleaning
every 1000 km
z
z
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z
z
z
z
z
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z
z
z
z
z
12-8
PERIODIC MAINTENANCE SCHEDULE
WHEELS
CHASSIS
BRAKES
ADD-ON-PARTS
INJECTION
ENGINE
990 ADVENTURE
Change engine oil and oil filter
Clean oil screens of engine and oil tank
Clean magnetic drain plugs of engine and oil tank
Check oil lines for damage and kink-less arrangement
Renew spark plugs
Check and adjust valve clearance
Check engine fastening bolts for tight fit
Check all engine bolts accessible from the outside for tight fit
Check clutch linings
Check clutch pressure booster system
Clean the oil jet for the clutch lubrication
Check rubber boot for cracks or leaks
Check fault memory with the KTM diagnosis tool
Perform a status check of neutral, clutch, 2nd/3rd gear and side stand switch
using the KTM diagnosis tool
Check the fuel hose, the vent hoses, hoses on the vacuum sensors and
secondary air system hoses for correct installation, kink-free installation and damage
Replace the O-ring on the fuel hose connection and check for leaks
Check the wiring harness on the throttle body for proper installation and damage
Check cooling system for leaks and antifreeze protection
Check radiator fan for proper operation
Check exhaust system for leaks and correct fit
Check actuating cables for damage, smooth operation, and kink-less arrangement,adjust and lubricate
Check the oil level in the hydraulic clutch reservoir
Check air filter, renew if necessary, clean air filter box
Check cables for damage and kink-less arrangement
Check headlamp adjustment
Check electrical system for function (low/high beams, stop light, turn indicators,headlamp flasher,
tell-tale lamps, speedometer illumination, horn, side-stand switch, clutch switch, emergency-off switch)
Make sure all bolts and nuts are tight
Check brake fluid level, lining thickness, and brake discs
Change brake fluid
Check brake lines for damage and leaks
Check/adjust smooth operation, free travel of handbrake/footbrake levers
Check bolts of brake system for tight fit
Check ABS fault memory with the KTM diagnosis tool
Check shock absorber and fork for leaks and proper operation
Clean fork dust sleeves
Bleed fork legs
Check swingarm pivot
Check/adjust steering-head bearing
Check all chassis bolts for tight fit (fork plates, fork leg, axle nuts/bolts,
swinging-fork pivot, reversing lever, shock absorber)
Check spoke tension and rim joint
Check tire condition and inflation pressure
Check chain and chain guides for wear, force fit and tension
Check bolts/nuts on pinion and chain sprocket for locking devices and a tight fit
Lubricate chain
Check wheel bearings and jerk damper for play
1. Service 7500 km or 15000 km or
after
every
once
1000 km
2 years
a year
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IF MOTORCYCLE IS USED FOR COMPETITION 7500 KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE!
SERVICE INTERVALLS SHOULD NEVER BE EXCEEDED BY MORE THAN 500 KM.
MAINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE OF CARE AND CHECKS DONE BY THE RIDER!
12-9
PERIODIC MAINTENANCE SCHEDULE
IMPORTANT MAINTENANCE PROCEDURES TO BE PERFORMED BASED ON A SEPARATE SUPPLEMENT
ORDER
at least
once a year
Perform complete fork maintenance
Perform complete shock absorber maintenance
Clean and lubricate steering-head bearing and sealing elements
Treat the electrical contacts and switches with contact spray
Treat battery connections with contact grease
Change coolant fluid
every 2 years or
15000 km
z
z
z
z
z
z
Repair manual KTM LC8
Art.-No. 3.206.056-E
VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC
Check oil level
Check brake fluid level
Check brake pads for wear
Check lighting system for proper operation
Check horn for proper operation
Lubricate and adjust actuating cables and nipples
Bleed fork legs in regular intervals
Clean chain
Lubricate chain
Check chain tension, lubricate chain if necessary
Check tire pressure and wear
Check coolant level
Check fuel lines for leaks
Check all control elements for smooth running
Check brake performance
Treat exposed metal components (except for the braking and exhaust
systems) with wax-based anti-corrosion agents
Treat ignition/steering lock and light switch with contact spray
before each
start
z
z
z
z
z
after every
cleaning
every 1000 km or
after off road use
z
z
z
z
z
z
z
z
z
z
z
z
z
z
12-10
PERIODIC MAINTENANCE SCHEDULE
WHEELS
CHASSIS
BRAKES
ADD-ON-PARTS
INJECTION
ENGINE
990 SUPERMOTO
Change engine oil and oil filter
Clean oil screens of engine and oil tank
Clean magnetic drain plugs of engine and oil tank
Check oil lines for damage and kink-less arrangement
Renew spark plugs
Check and adjust valve clearance
Check engine fastening bolts for tight fit
Check all engine bolts accessible from the outside for tight fit
Check clutch linings
Check clutch pressure booster system
Clean the oil jet for the clutch lubrication
Check rubber boot for cracks or leaks
Check fault memory with the KTM diagnosis tool
Perform a status check of neutral, clutch, 2nd/3rd gear and side stand switch
using the KTM diagnosis tool
Check the fuel hose, the vent hoses, hoses on the vacuum sensors and
secondary air system hoses for correct installation, kink-free installation and damage
Replace the O-ring on the fuel hose connection and check for leaks
Check the wiring harness on the throttle body for proper installation and damage
Check cooling system for leaks and antifreeze protection
Check radiator fan for proper operation
Check exhaust system for leaks and correct fit
Check actuating cables for damage, smooth operation, and kink-less arrangement,adjust and lubricate
Check the oil level in the hydraulic clutch reservoir
Check air filter, renew if necessary, clean air filter box
Check cables for damage and kink-less arrangement
Check headlamp adjustment
Check electrical system for function (low/high beams, stop light, turn indicators,headlamp flasher,
tell-tale lamps, speedometer illumination, horn, side-stand switch, clutch switch, emergency-off switch)
Make sure all bolts and nuts are tight
Check brake fluid level, lining thickness, and brake discs
Change brake fluid
Check brake lines for damage and leaks
Check/adjust smooth operation, free travel of handbrake/footbrake levers
Check bolts of brake system for tight fit
Check shock absorber and fork for leaks and proper operation
Clean fork dust sleeves
Bleed fork legs
Check swingarm pivot
Check/adjust steering-head bearing
Check all chassis bolts for tight fit (fork plates, fork leg, axle nuts/bolts,
swinging-fork pivot, reversing lever, shock absorber)
Check rim joint
Check tire condition and inflation pressure
Check chain and chain guides for wear, force fit and tension
Check bolts/nuts on pinion and chain sprocket for locking devices and a tight fit
Lubricate chain
Check wheel bearings and jerk damper for play
1. Service 7500 km or 15000 km or
after
every
once
1000 km
2 years
a year
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IF MOTORCYCLE IS USED FOR COMPETITION 7500 KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE!
SERVICE INTERVALLS SHOULD NEVER BE EXCEEDED BY MORE THAN 500 KM.
MAINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE OF CARE AND CHECKS DONE BY THE RIDER!
12-11
PERIODIC MAINTENANCE SCHEDULE
IMPORTANT MAINTENANCE PROCEDURES TO BE PERFORMED BASED ON A SEPARATE SUPPLEMENT
ORDER
at least
once a year
Perform complete fork maintenance
Perform complete shock absorber maintenance
Clean and lubricate steering-head bearing and sealing elements
Treat the electrical contacts and switches with contact spray
Treat battery connections with contact grease
Change coolant fluid
every 2 years or
15000 km
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Repair manual KTM LC8
Art.-No. 3.206.056-E
VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC
Check oil level
Check brake fluid level
Check brake pads for wear
Check lighting system for proper operation
Check horn for proper operation
Lubricate and adjust actuating cables and nipples
Bleed fork legs in regular intervals
Clean chain
Lubricate chain
Check chain tension, lubricate chain if necessary
Check tire pressure and wear
Check coolant level
Check fuel lines for leaks
Check all control elements for smooth running
Check brake performance
Treat exposed metal components (except for the braking and exhaust
systems) with wax-based anti-corrosion agents
Treat ignition/steering lock and light switch with contact spray
before each
start
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after every
cleaning
every 1000 km or
after off road use
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12-12
PERIODIC MAINTENANCE SCHEDULE
WHEELS
CHASSIS
BRAKES
ADD-ON-PARTS
CARBURETOR
ENGINE
950 SUPER ENDURO
Change engine oil and oil filter
Clean oil screens of engine and oil tank
Clean magnetic drain plugs of engine and oil tank
Check oil lines for damage and kink-less arrangement
Renew spark plugs
Check and adjust valve clearance
Check engine fastening bolts for tight fit
Check all engine bolts accessible from the outside for tight fit
Check clutch linings
Check clutch pressure booster system
Clean the oil jet for the clutch lubrication
Check carburetor connection boots for cracks and leaks
Check synchronisation of carburators using special tool, if necessary adjust
Check idle setting (1400 rpm)
Check bleeder hoses for damage and kink-free arrangement
Check cooling system for leaks and antifreeze protection
Check radiator fan for proper operation
Check exhaust system for leaks and correct fit
Check actuating cables for damage, smooth operation, and kink-less arrangement,adjust and lubricate
Check the oil level in the hydraulic clutch reservoir
Check air filter, renew if necessary, clean air filter box
Check cables for damage and kink-less arrangement
Check headlamp adjustment
Check electrical system for function (low/high beams, stop light, turn indicators,headlamp flasher,
tell-tale lamps, speedometer illumination, horn, side-stand switch, clutch switch, emergency-off switch)
Make sure all bolts and nuts are tight
Check brake fluid level, lining thickness, and brake discs
Change brake fluid
Check brake lines for damage and leaks
Check/adjust smooth operation, free travel of handbrake/footbrake levers
Check bolts of brake system for tight fit
Check shock absorber and fork for leaks and proper operation
Clean fork dust sleeves
Bleed fork legs
Check swingarm pivot
Check/adjust steering-head bearing
Check all chassis bolts for tight fit (fork plates, fork leg, axle nuts/bolts,
swinging-fork pivot, reversing lever, shock absorber)
Check spoke tension and rim joint
Check tire condition and inflation pressure
Check chain and chain guides for wear, force fit and tension
Check bolts/nuts on pinion and chain sprocket for locking devices and a tight fit
Lubricate chain
Check wheel bearings and jerk damper for play
1. Service 7500 km or 15000 km or
after
every
once
1000 km
2 years
a year
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IF MOTORCYCLE IS USED FOR COMPETITION 7500 KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE!
SERVICE INTERVALLS SHOULD NEVER BE EXCEEDED BY MORE THAN 500 KM.
MAINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE OF CARE AND CHECKS DONE BY THE RIDER!
12-13
PERIODIC MAINTENANCE SCHEDULE
IMPORTANT MAINTENANCE PROCEDURES TO BE PERFORMED BASED ON A SEPARATE SUPPLEMENT
ORDER
at least
once a year
Perform complete fork maintenance
Perform complete shock absorber maintenance
Clean and lubricate steering-head bearing and sealing elements
Clean and adjust the carburetors
Treat the electrical contacts and switches with contact spray
Treat battery connections with contact grease
Change coolant fluid
every 2 years or
15000 km
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VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC
Repair manual KTM LC8
Art.-No. 3.206.056-E
before each
start
Check oil level
Check brake fluid level
Check brake pads for wear
Check lighting system for proper operation
Check horn for proper operation
Lubricate and adjust actuating cables and nipples
Bleed fork legs in regular intervals
Clean chain
Lubricate chain
Check chain tension, lubricate chain if necessary
Check tire pressure and wear
Check coolant level
Check fuel lines for leaks
Check all control elements for smooth running
Check brake performance
Treat exposed metal components (except for the braking and exhaust
systems) with wax-based anti-corrosion agents
Treat ignition/steering lock and light switch with contact spray
Check spoke tension (sound test)
Check the rims for damage and deformation
Check exhaust system for leaks and correct fit
Check air filter, renew if necessary, clean air filter box
Check shock absorber and fork for leaks and proper operation
Clean fork dust sleeves
after every
cleaning
every 1000 after off road
km
use
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12-14
Lubrication and maintenance work - engine
Changing the engine oil and filter, cleaning the oil screens
and magnets on the drain plugs
NOTE: Change the engine oil when the engine is at operating
temperature.
WARNING


THE
ENGINE AND ENGINE OIL ARE VERY HOT AT OPERATING TEMPERATURE
CAREFUL NOT TO BURN YOURSELF.
–
BE
NOTE: before you start with the lubricating and maintenance work
described below, remove the engine guard, seat and both tanks
(950/990 Adventure), the seat, both tank covers and the front spoiler
for the 990 Super Duke model or the seat, tank and the spoiler for the
950 Supermoto; also tilt up the tank for the 990 Super Duke (see
Chapter 3). The vehicle must be jacked up with the corresponding
special tool. After you finish, assemble the vehicle in the reverse order.
1
– Remove the oil drain plug on the engine 1 and allow the oil to drain
into a receptacle.
– Clean the magnet on the drain plug.
– Mount a new seal ring on the drain plug, screw back in and tighten
to 35 Nm.
– Unscrew the oil drain plug 2 on the oil tank and allow the oil to
drain into a receptacle.
NOTE: dispose of the used oil properly.
Do not pour the used oil into the sewer system.
1 liter of used oil will pollute 1,000,000 liters of water.
– Clean the magnet on the drain plug.
– Mount a new seal ring on the drain plug, screw back in and tighten
to 25 Nm.
2
4
3
– Remove the oil screen cover 3 and carefully pull out the oil screen
4 with a pair of pliers.
– Clean the oil screen, remount with the TOP mark facing up and
mount the cover.
– Remove the oil filter cover 5 and pull the engine out of the engine
case with circlip pliers (upside-down).
5
– Insert a new oil filter in the engine case, grease the O-ring and
mount the oil filter cover together with the O-ring. Tighten the bolts
to 6 Nm.
!
ONLY
USE ORIGINAL
FILTERS ARE USED.
KTM
CAUTION
THE ENGINE
OIL FILTERS.
!
CAN BE DAMAGED IF OTHER
12-15
– Remove both bolts 1 from the oil tank connection 2 and tilt the oil
tank aside together with the oil return valve.
– Remove the screen and cleanse.
Adventure/Super Duke
2
1
1
Supermoto
2
1
– Grease the seal ring and carefully slide the oil screen into the oil
tank. Position the oil tank connection together with the oil return
valve, mount the bolts and tighten to 10 Nm.
Art.-No. 3.206.056-E
Adventure/Super Duke
Supermoto
Repair manual KTM LC8
Engine oil
JASO T903 MA
TEMPERATUR
0°C
32°F
5W/40
10W/50
Automobile engine oil used to be used for four-stroke motorcycles
before there were separate motorcycle specifications. Different
technical developments made it necessary to have a separate
specification for four-stroke motorcycles - the JASO T903 MA standard.
Whereas car engines require long changing intervals, motorcycle
engines require a higher power output at higher speeds. Most
motorcycle engines also use the same oil to lubricate the transmission
and the clutch. The JASO MA standard responds to these special
requirements.
Only use fully synthetic engine oils that meet the JASO MA quality
requirements (see information on the can).
KTM recommends Motorex Power Synt 4T in the 10W/50 viscosity (for
temperatures over 0°C) or 5W/40 (for temperatures under 0°C).
– Fill approx. 2.7 liters of engine oil into the oil tank. The oil tank will
be filled up to the top.
– Start the engine and allow to idle for about one minute without
accelerating.
– Switch off the engine and pour another 0.3 liters into the oil tank.
Check the oil system for leakage.
!
DO
CAUTION
!
NOT REV UP THE ENGINE RIGHT AFTER CHANGING THE OIL SINCE ALL OF THE
LUBRICATING POINTS WILL NOT BE SUPPLIED WITH ENOUGH OIL YET.
12-16
Checking the engine oil level
1
Check the engine oil level when the engine is warm (at least 4 bars on
the temperature indicator will light up). Place the motorcycle on a level
surface (not on the side stand).
Turn off the engine, unscrew the oil dipstick 1 and wipe off with a
cloth. Screw the oil dipstick all the way back in and back out again.
The oil level should fall between the lower end of the oil dipstick (MIN)
and the MAX mark.
The oil capacity between the MIN and MAX mark is 0.5 liters. For
engines with an inspection pipe, the oil level should be between the
MIN and MAX marks. Add more engine oil if necessary and check the
engine for leakage.
!
CAUTION
!
ENOUGH ENGINE OIL OR LOW-QUALITY OIL WILL LEAD TO PREMATURE
ENGINE WEAR.
DO NOT EXCEED THE MAXIMUM LEVEL.
DO NOT ALLOW TO FALL BELOW THE MINIMUM LEVEL.
– NOT
–
–
MAX
MIN
Replacing the spark plugs
NOTE: the carburetors are dismounted during the 15000 km
inspection to check/adjust the valve clearance. This work is described
in Chapter 3 and will not be described in detail at this point.
2
– Disconnect the cable connectors (2 and 3) from both ignition
coils.
– Dismount the throttle body (see Chapter 3).
– Pull the ignition coils out of the spark plug shafts.
– Unscrew the spark plugs with the special tool 600.29.073.000.
3
– Check the new spark plugs for the correct electrode distance. The
distance should be 0.7 mm (Carburator) and 0.8 (Injection).
– Insert new spark plugs with the special tool 600.29.073.000 and
tighten to 12 Nm (M10) or 20 Nm (M12x1.5).
!
DO
CAUTION
!
NOT EXCEED THE FIXED TORQUE SINCE SPARK PLUGS BREAK EASILY.
– Insert the ignition coils in the spark plug shafts and push to the stop
by hand.
NOTE: if you are checking the valve clearance, insert the ignition coils
later.
!
CAUTION
!
– DO NOT INSTALL THE IGNITION COILS WITH A HAMMER OR SIMILAR TOOL.
– TURN THE CONNECTIONS ON THE IGNITION COILS SO THEY DO NOT COME CLOSE
TO THE VALVE COVER BOLTS (SEE PHOTOS) SINCE THIS COULD CAUSE
ELECTROMAGNETIC INTERFERENCE.
– Connect the cable connectors to both ignition coils.
12-17
Checking and adjusting the valve clearance
NOTE: to make it easier to work on the front cylinder, remove the 4
radiator retaining bolts and pull the radiator forward.
2
1
1
2
– Pull the EPC valve on the front cylinder from the bracket.
– Disconnect the ignition coil connectors 1 and pull the ignition coils
out.
– Push back the spring-loaded band-type clamps 2 with the special
pliers 600.29.057.100 and pull the vent hoses from the valve cover
connections.
– Remove both valve covers and the gaskets.
– Remove the plug 3, turn the crankshaft to the rear cylinder TDC
position and lock with special tool 0113 080802 4. In the TDC
position, the cams of the rear cylinder must point towards the inside
and the crosses on the camshaft gears must coincide with the plane
outer surface of the cylinder head (see Chapter 4).
3
4
Art.-No. 3.206.056-E
– Check the valve clearance with the feeler gauge. The minimum
clearance when the engine is cold should be 0.10 – 0.15 mm
(intake) and 0.25 – 0.30 mm (exhaust).
NOTE: if the valve clearance is incorrect for one or more valves,
measure how large the deviation is. Use thinner or thicker
compensating washers depending on whether the valve clearance is too
small or too large.
– Dismount the camshafts (see Chapter 4) and correct the thickness
of the shims.
NOTE: compensating shims from 1.85 mm to 3.20 mm are available in
graduations of 0.05 mm
– Unscrew the locking bolt, turn the engine to the TDC position of the
front cylinder and lock again (see Chapter 4).
– Check the valve clearance of the front cylinder and adjust if
necessary - See table on page 12-16 and 12-17 for a list of the
required shims.
NOTE: the procedure for the front cylinder is the same as for the rear
cylinder.
Repair manual KTM LC8
– Mount the EPC valve.
!
CAUTION
!
THE RETAINING CLIP FOR THE FRONT EPC VALVE IS BENT, THE EPC VALVE WILL
BE ABLE TO TOUCH THE FRAME. THE ENGINE VIBRATIONS CAN CAUSE IT TO OPEN
SLIGHTLY, RESULTING IN A LACK OF POWER FOR THE ENTIRE SPEED RANGE.
IF
– Mount both valve covers.
– Connect the vent hoses to the connections on the valve covers and
attach the spring-loaded band-type clamps 1 with the special pliers
600.29.057.100.
– Mount the ignition coils and connect the connector.
– Screw the radiator back on.
-
-
0,06 - 0,10
1,85 1,90 1,95 2,00 2,05 2,10 2,15 2,20 2,25 2,30 2,35 2,40 2,45 2,50 2,55 2,60 2,65 2,70 2,75 2,80 2,85 2,90 2,95 3,00 3,05 3,10
1,95 2,00 2,05 2,10 2,15 2,20 2,25 2,30 2,35 2,40 2,45 2,50 2,55 2,60 2,65 2,70 2,75 2,80 2,85 2,90 2,95 3,00 3,05 3,10 3,15 3,20
2,00 2,05 2,10 2,15 2,20 2,25 2,30 2,35 2,40 2,45 2,50 2,55 2,60 2,65 2,70 2,75 2,80 2,85 2,90 2,95 3,00 3,05 3,10 3,15 3,20
2,05 2,10 2,15 2,20 2,25 2,30 2,35 2,40 2,45 2,50 2,55 2,60 2,65 2,70 2,75 2,80 2,85 2,90 2,95 3,00 3,05 3,10 3,15 3,20
2,10 2,15 2,20 2,25 2,30 2,35 2,40 2,45 2,50 2,55 2,60 2,65 2,70 2,75 2,80 2,85 2,90 2,95 3,00 3,05 3,10 3,15 3,20
2,15 2,20 2,25 2,30 2,35 2,40 2,45 2,50 2,55 2,60 2,65 2,70 2,75 2,80 2,85 2,90 2,95 3,00 3,05 3,10 3,15 3,20
2,20 2,25 2,30 2,35 2,40 2,45 2,50 2,55 2,60 2,65 2,70 2,75 2,80 2,85 2,90 2,95 3,00 3,05 3,10 3,15 3,20
2,25 2,30 2,35 2,40 2,45 2,50 2,55 2,60 2,65 2,70 2,75 2,80 2,85 2,90 2,95 3,00 3,05 3,10 3,15 3,20
2,30 2,35 2,40 2,45 2,50 2,55 2,60 2,65 2,70 2,75 2,80 2,85 2,90 2,95 3,00 3,05 3,10 3,15 3,20
2,35 2,40 2,45 2,50 2,55 2,60 2,65 2,70 2,75 2,80 2,85 2,90 2,95 3,00 3,05 3,10 3,15 3,20
2,40 2,45 2,50 2,55 2,60 2,65 2,70 2,75 2,80 2,85 2,90 2,95 3,00 3,05 3,10 3,15 3,20
2,45 2,50 2,55 2,60 2,65 2,70 2,75 2,80 2,85 2,90 2,95 3,00 3,05 3,10 3,15 3,20
2,50 2,55 2,60 2,65 2,70 2,75 2,80 2,85 2,90 2,95 3,00 3,05 3,10 3,15 3,20
2,55 2,60 2,65 2,70 2,75 2,80 2,85 2,90 2,95 3,00 3,05 3,10 3,15 3,20
2,60 2,65 2,70 2,75 2,80 2,85 2,90 2,95 3,00 3,05 3,10 3,15 3,20
2,65 2,70 2,75 2,80 2,85 2,90 2,95 3,00 3,05 3,10 3,15 3,20
2,70 2,75 2,80 2,85 2,90 2,95 3,00 3,05 3,10 3,15 3,20
2,75 2,80 2,85 2,90 2,95 3,00 3,05 3,10 3,15 3,20
2,80 2,85 2,90 2,95 3,00 3,05 3,10 3,15 3,20
2,85 2,90 2,95 3,00 3,05 3,10 3,15 3,20
2,90 2,95 3,00 3,05 3,10 3,15 3,20
2,95 3,00 3,05 3,10 3,15 3,20
3,00 3,05 3,10 3,15 3,20
3,05 3,10 3,15 3,20
3,10 3,15 3,20
3,15 3,20
3,20
0,21 - 0,25
0,26 - 0,30
0,31 - 035
0,36 - 0,40
0,41 - 0,45
0,46 - 0,50
0,51 - 0,55
0,56 - 0,60
0,61 - 0,65
0,66 - 0,70
0,71 - 0,75
0,76 - 0,80
0,81 - 0,85
0,86 - 0,90
0,91 - 0,95
0,96 - 1,00
1,01 - 1,05
1,06 - 1,10
1,11 - 1,15
1,16 - 1,20
1,21 - 1,25
1,26 - 1,30
1,31 - 1,35
1,36 - 1,40
1,41 - 1,45
1,46 - 1,50
New shim required: 2.55 mm
Measured valve clearance: 0.48 mm
Demounted shim: 2.20 mm
Specified valve clearance: 0.10 - 0.15 mm
NOTE to example:
1,90 1,95 2,00 2,05 2,10 2,15 2,20 2,25 2,30 2,35 2,40 2,45 2,50 2,55 2,60 2,65 2,70 2,75 2,80 2,85 2,90 2,95 3,00 3,05 3,10 3,15 3,20
Specified valve clearance - no correction required
1,85 1,90 1,95 2,00 2,05 2,10 2,15 2,20 2,25 2,30 2,35 2,40 2,45 2,50 2,55 2,60 2,65 2,70 2,75 2,80 2,85 2,90 2,95 3,00 3,05 3,10 3,15
-
0,16 - 0,20
0,10 - 0,15
Number/thickness of the demounted compensating washer(shim)in mm
1,85 1,90 1,95 2,00 2,05 2,10 2,15 2,20 2,25 2,30 2,35 2,40 2,45 2,50 2,55 2,60 2,65 2,70 2,75 2,80 2,85 2,90 2,95 3,00 3,05 3,10 3,15 3,20
0,00 - 0,05
Measured valve
clearance (mm)
INTAKE
12-18
-
-
-
-
-
0,06 - 0,10
0,11 - 0,15
0,16 - 0,20
0,21 - 0,25
1,85 1,90 1,95 2,00 2,05 2,10 2,15 2,20 2,25 2,30 2,35 2,40 2,45 2,50 2,55 2,60 2,65 2,70 2,75 2,80 2,85 2,90 2,95
1,85 1,90 1,95 2,00 2,05 2,10 2,15 2,20 2,25 2,30 2,35 2,40 2,45 2,50 2,55 2,60 2,65 2,70 2,75 2,80 2,85 2,90 2,95 3,00
-
1,85 1,90 1,95 2,00 2,05 2,10 2,15 2,20 2,25 2,30 2,35 2,40 2,45 2,50 2,55 2,60 2,65 2,70 2,75 2,80 2,85 2,90 2,95 3,00 3,05
-
-
1,85 1,90 1,95 2,00 2,05 2,10 2,15 2,20 2,25 2,30 2,35 2,40 2,45 2,50 2,55 2,60 2,65 2,70 2,75 2,80 2,85 2,90 2,95 3,00 3,05 3,10
-
-
-
1,95 2,00 2,05 2,10 2,15 2,20 2,25 2,30 2,35 2,40 2,45 2,50 2,55 2,60 2,65 2,70 2,75 2,80 2,85 2,90 2,95 3,00 3,05 3,10 3,15 3,20
2,00 2,05 2,10 2,15 2,20 2,25 2,30 2,35 2,40 2,45 2,50 2,55 2,60 2,65 2,70 2,75 2,80 2,85 2,90 2,95 3,00 3,05 3,10 3,15 3,20
2,05 2,10 2,15 2,20 2,25 2,30 2,35 2,40 2,45 2,50 2,55 2,60 2,65 2,70 2,75 2,80 2,85 2,90 2,95 3,00 3,05 3,10 3,15 3,20
2,10 2,15 2,20 2,25 2,30 2,35 2,40 2,45 2,50 2,55 2,60 2,65 2,70 2,75 2,80 2,85 2,90 2,95 3,00 3,05 3,10 3,15 3,20
2,15 2,20 2,25 2,30 2,35 2,40 2,45 2,50 2,55 2,60 2,65 2,70 2,75 2,80 2,85 2,90 2,95 3,00 3,05 3,10 3,15 3,20
2,20 2,25 2,30 2,35 2,40 2,45 2,50 2,55 2,60 2,65 2,70 2,75 2,80 2,85 2,90 2,95 3,00 3,05 3,10 3,15 3,20
2,25 2,30 2,35 2,40 2,45 2,50 2,55 2,60 2,65 2,70 2,75 2,80 2,85 2,90 2,95 3,00 3,05 3,10 3,15 3,20
2,30 2,35 2,40 2,45 2,50 2,55 2,60 2,65 2,70 2,75 2,80 2,85 2,90 2,95 3,00 3,05 3,10 3,15 3,20
2,35 2,40 2,45 2,50 2,55 2,60 2,65 2,70 2,75 2,80 2,85 2,90 2,95 3,00 3,05 3,10 3,15 3,20
2,40 2,45 2,50 2,55 2,60 2,65 2,70 2,75 2,80 2,85 2,90 2,95 3,00 3,05 3,10 3,15 3,20
2,45 2,50 2,55 2,60 2,65 2,70 2,75 2,80 2,85 2,90 2,95 3,00 3,05 3,10 3,15 3,20
2,50 2,55 2,60 2,65 2,70 2,75 2,80 2,85 2,90 2,95 3,00 3,05 3,10 3,15 3,20
2,55 2,60 2,65 2,70 2,75 2,80 2,85 2,90 2,95 3,00 3,05 3,10 3,15 3,20
2,60 2,65 2,70 2,75 2,80 2,85 2,90 2,95 3,00 3,05 3,10 3,15 3,20
2,65 2,70 2,75 2,80 2,85 2,90 2,95 3,00 3,05 3,10 3,15 3,20
2,70 2,75 2,80 2,85 2,90 2,95 3,00 3,05 3,10 3,15 3,20
2,75 2,80 2,85 2,90 2,95 3,00 3,05 3,10 3,15 3,20
2,80 2,85 2,90 2,95 3,00 3,05 3,10 3,15 3,20
2,85 2,90 2,95 3,00 3,05 3,10 3,15 3,20
2,90 2,95 3,00 3,05 3,10 3,15 3,20
2,95 3,00 3,05 3,10 3,15 3,20
3,00 3,05 3,10 3,15 3,20
3,05 3,10 3,15 3,20
0,36 - 0,40
0,41 - 0,45
0,46 - 0,50
0,51 - 0,55
0,56 - 0,60
0,61 - 0,65
0,66 - 0,70
0,71 - 0,75
0,76 - 0,80
0,81 - 0,85
0,86 - 0,90
0,91 - 0,95
0,96 - 1,00
1,01 - 1,05
1,06 - 1,10
1,11 - 1,15
1,16 - 1,20
1,21 - 1,25
1,26 - 1,30
1,31 - 1,35
1,36 - 1,40
1,41 - 1,45
1,46 - 1,50
New shim required: 2.40 mm
Measured valve clearance: 0.48 mm
Demounted shim: 2.20 mm
Specified valve clearance: 0,25 - 0,30 mm
NOTE to example:
1,90 1,95 2,00 2,05 2,10 2,15 2,20 2,25 2,30 2,35 2,40 2,45 2,50 2,55 2,60 2,65 2,70 2,75 2,80 2,85 2,90 2,95 3,00 3,05 3,10 3,15 3,20
Specified valve clearance - no correction required
1,85 1,90 1,95 2,00 2,05 2,10 2,15 2,20 2,25 2,30 2,35 2,40 2,45 2,50 2,55 2,60 2,65 2,70 2,75 2,80 2,85 2,90 2,95 3,00 3,05 3,10 3,15
-
-
-
-
0,31 - 035
0,25 - 0,30
Number/thickness of the demounted compensating washer(shim)in mm
Art.-No. 3.206.056-E
1,85 1,90 1,95 2,00 2,05 2,10 2,15 2,20 2,25 2,30 2,35 2,40 2,45 2,50 2,55 2,60 2,65 2,70 2,75 2,80 2,85 2,90 2,95 3,00 3,05 3,10 3,15 3,20
0,00 - 0,05
Measured valve
clearance (mm)
EXHAUST
Repair manual KTM LC8
12-19
12-20
Checking the clutch lining
– Remove the lock clip on the foot brake lever bolt and pull out the
bolt.
– Loosen the bearing bolt on the foot brake lever and remove the foot
brake lever.
– Dismount the clutch lining (see Chapter 4).
– Measure the total height of the clutch disk package (all of the lining
disks and steel disks together)
Wear limit: 48.0 mm
– Check the clutch disks for damage (breakage, recesses).
Checking the clutch pressure booster system
– Check the outer and inner part for wear and breakage, especially
near the pressure areas 1 and the toothing 2.
1
1
1
– Assemble the clutch again (see Chapter 6).
1
2
– Mount the foot brake lever, secure the bearing bolt with Loctite 243
and tighten to 25 Nm.
– Mount the foot brake lever bolt and attach the lock clip.
Cleaning the oil jet for the clutch lubrication
– Remove the clutch cylinder, engine sprocket cover and chain
securing guide.
– Remove the AH plug 3 (6 mm) for the clutch lubrication.
3
4
– Unscrew the oil jet 4 with a suitable screwdriver.
– Remove the oil jet from the hole with a pair of tweezers or
compressed air.
– Clean and blow compressed air through the oil jet. Check for
damage and make sure it is not clogged.
– Remount the oil jet and the AH plug (tightening torque 15 Nm).
– Remount the clutch cylinder, engine sprocket cover and chain
securing guide.
12-21
LUBRICATION AND MAINTENANCE WORK – CARBURETOR
Check the carburetor synchronization with an vacuum gauge
and adjust if necessary
2
– Disconnect the vacuum hoses from the air filter box 1 and from the
secondary air system valve 2 and run up on the side between the
frame and the air filter box.
– Mount both tanks and connect the fuel lines, open the fuel taps.
NOTE: before you use the special tool 600.29.011.000, always check
both dial gauges for synchronism:
– Connect both dial gauges to one cylinder with the vacuum hoses and
a T-fitting.
– Tighten the knurled nuts on the special tool by turning them in a
clockwise direction almost to the stop.
– Start the engine and unscrew the two knurled nuts until the dials
barely begin to vibrate. You should still be able to read the gauge
clearly. Both dial gauges should indicate the same value. If not, the
special tool is damaged and should not be used.
– Turn off the engine, disconnect the hoses and the T-fitting.
1
!
CAUTION
!
THE FOLLOWING RULES ARE NOT OBSERVED, THE MEASURING MECHANISM IN
THE SPECIAL TOOL WILL BE DAMAGED OR DESTROYED:
– ADJUST THE DAMPING FIRST, THEN START THE ENGINE.
– DO NOT DROP THE SPECIAL TOOL.
– DO NOT RUN THE ENGINE WITH DEFECTIVE CARBURETORS (RISK OF THE ENGINE
MISFIRING).
IF
Art.-No. 3.206.056-E
– Connect each dial gauge on the special tool to a cylinder. You can
also use the on-board hoses (see photo).
– Tighten the knurled nuts again (also adjust stiff damping).
– Start the engine and unscrew both knurled nuts until the dials
barely begin to vibrate. You should still be able to read the gauge
clearly.
Both dial gauges should indicate the same value. If not, dismount the
air filter and turn the synchronization screw 3 on the carburetor
linkage until the dial gauges indicate a value of +/- 0.03 bar.
3
NOTE: before making the adjustment, make sure the cold-start system
(choke) is completely closed and the engine is at operating
temperature.
Repair manual KTM LC8
– Remove the vacuum gauge and connect the vacuum hoses to the
secondary air system valve or to the air filter box again.
Checking the idle setting (950 Adventure)
– Set the idle speed to 1400 rpm.
4
NOTE:
– before make the adjustment, make sure the cold-start system
(choke) is completely closed and the engine has reached operating
temperature.
– If the idle speed deviates from the set-point value, correct the value
with the adjusting screw 4: turning in a clockwise direction will
increase the idle speed, turning in a counterclockwise direction will
decrease the idle speed.
12-22
Checking the idle setting (950 Supermoto/Super Enduro)
– Pull the ignition coil for the rear cylinder from the spark plug.
– Attach the intermediate adapter for the ignition cable
625.29.093.000 1 to the spark plug and ignition coil.
– Measure the idle speed with the tachometer 451.29.075.000 2 or
a shop tester and adjust to 1400 rpm.
2
1
NOTE:
– before make the adjustment, make sure the cold-start system
(choke) is completely closed and the engine has reached operating
temperature.
– If the idle speed deviates from the set-point value, correct the value
with the adjusting screw: turning in a clockwise direction will
increase the idle speed, turning in a counterclockwise direction will
decrease the idle speed.
LUBRICATION AND MAINTENANCE WORK - INJECTION
Check the fault memory with the KTM diagnostics tool
See KTM diagnostics tool operating instructions
Scan the status of the neutral, clutch, 2nd/3rd gear and side stand switch using the KTM diagnostics tool
See KTM diagnostics tool operating instructions
Replacing the O-ring on the fuel hose connector
3
Disconnect the fuel hose connector (see Chapter 8), remove the O-ring
3, carefully mount a new O-ring and connect the hose connector
again. Turn on the ignition , the fuel pump will start up and build up
pressure. Check the connection for leakage.
NOTE: Do not connect the hose connection until the tank no longer
needs to be folded up for servicing.
LUBRICATION AND MAINTENANCE WORK – ADD-ON PARTS
Checking the cooling system for leakage and the antifreeze concentration
– Check the cooling liquid level in the radiator and in the compensating tank. Fill up if necessary (see Owner's Manual).
– Check the antifreeze concentration with a suitable gauge. The antifreeze concentration should be 50% antifreeze and 50%
destilled water (at least -25ºC).
NOTE: if the cooling liquid level is far below the minimum mark, check for leakage.
Checking the radiator fan for proper functioning.
– Following the test drive, let the engine run idle until the fan switches on.
!
WATCH
CAUTION
!
THE TEMPERATURE INDICATOR FOR THE COOLING LIQUID TO AVOID ENGINE DAMAGE IN CASE THE RADIATOR FAN IS DEFECTIVE.
Lubricating the cables
NOTE: only use lubricants that are free of resin and acid otherwise they can destroy the inner cable coating and cause the cable
to block. Do not use MoS2 spray.
Checking the air filter, replacing if necessary, cleaning the air filter box
– See Chapter 3 for dismounting the air filter.
NOTE: the air filter insert cannot be cleaned and should be replaced when soiled. Do not use filter oil.
– When mounting the filter, proceed in the reverse order used to dismount.
LUBRICATION AND MAINTENANCE WORK - BRAKES
Checking the brake fluid level, lining thickness, brake disks
– See Owner's Manual
12-23
Changing the front brake fluid
– Open the brake fluid reservoir 1.
1
– Use a syringe to extract the used brake fluid and add fresh DOT 5.1
brake fluid (Motorex Brake Fluid DOT 5.1).
– Press the front brake caliper pistons all the way back (950/990
Adventure only).
– Use a commercial extractor (shop equipment) to extract the used
brake fluid out of the system through the bleeder screw 2 on the
left brake caliper. Make sure the brake fluid reservoir is always filled
with enough fresh brake fluid.
– Tighten the bleeder screw again.
Art.-No. 3.206.056-E
2
– Now extract the used brake fluid through the bleeder screw 3 on
the right brake caliper, also making sure there is always enough
fresh brake fluid in the brake fluid reservoir.
– Tighten the bleeder screw again.
3
950/990 Adventure:
– Move the hand brake cylinder into a horizontal position and add
DOT 5.1 brake fluid (Motorex Brake Fluid DOT 5.1) up to 5 mm
under the top edge of the reservoir. Remount the rubber boot, cover
and screws.
950 Supermoto/990 Super Duke:
– Fill the brake fluid reservoir up to the "max" mark 4 and close
again.
5 mm
– Wash off any overflowing or spilled brake fluid with water.
!
CAUTION
!
USE DOT 5 BRAKE FLUID. IT IS BASED ON SILICONE OIL AND DYED
PURPLE. GASKETS AND BRAKE HOSES WILL BE DAMAGED IF DOT 5 BRAKE
FLUID IS USED.
BRAKE FLUID CAN CAUSE SKIN IRRITATIONS. AVOID COMING INTO CONTACT WITH
THE SKIN OR EYES. IF BRAKE FLUID SPLASHES INTO YOUR EYES, RINSE
THOROUGHLY WITH WATER AND CONSULT A DOCTOR.
MAKE SURE NO BRAKE FLUID COMES INTO CONTACT WITH PAINTED PARTS SINCE
BRAKE FLUID WILL CORRODE THE PAINTWORK.
ONLY USE CLEAN, NEW BRAKE FLUID FROM TIGHTLY SEALED CONTAINERS.
– NEVER
Repair manual KTM LC8
–
–
–
– Actuate the hand brake lever until you feel the point of pressure.
4
NOTE to the ABS system: allow at least 3 full brake fluid reservoirs to
pump through to make sure no air is left in the system.
12-24
Changing the rear brake fluid
1
– Unscrew the cover on the brake fluid reservoirs 1 and remove
together with the diaphragm 2.
– Use a syringe to extract the used brake fluid and add fresh DOT 5.1
brake fluid (Motorex Brake Fluid DOT 5.1).
– Press the brake caliper pistons all the way back.
2
3
12 mm
– Use a commercial extractor (shop equipment) to extract the used
brake fluid out of the system through the bleeder screw 3 on the
brake caliper. Make sure the brake fluid reservoir is always filled
with enough fresh brake fluid.
– Tighten the bleeder screw again.
– Add DOT 5.1 brake fluid (Motorex Brake Fluid DOT 5.1) up to
12 mm under the top edge of the reservoir. Remount the rubber
boot, cover and screws. Wash off any overflowing or spilled brake
fluid with water.
!
CAUTION
!
USE DOT 5 BRAKE FLUID. IT IS BASED ON SILICONE OIL AND DYED
PURPLE. GASKETS AND BRAKE HOSES WILL BE DAMAGED IF DOT 5 BRAKE
FLUID IS USED.
BRAKE FLUID CAN CAUSE SKIN IRRITATIONS. AVOID COMING INTO CONTACT WITH
THE SKIN OR EYES. IF BRAKE FLUID SPLASHES INTO YOUR EYES, RINSE
THOROUGHLY WITH WATER AND CONSULT A DOCTOR.
MAKE SURE NO BRAKE FLUID COMES INTO CONTACT WITH PAINTED PARTS SINCE
BRAKE FLUID WILL CORRODE THE PAINTWORK.
ONLY USE CLEAN, NEW BRAKE FLUID FROM TIGHTLY SEALED CONTAINERS.
– NEVER
–
–
–
– Actuate the foot brake lever until you feel the point of pressure.
NOTE to the ABS system: see Technical Information to replace the
brake fluid /bleed the brake system.
Checking the bolts on the brake system for force fit
NOTE: check the bolts listed below with a torque wrench. If a bolt is
not tightened to the specified torque (if it can easily be screwed in
further), remove the bolt, clean, secure with Loctite 243 and tighten to
the correct torque (see technical data).
Check ABS fault memory with the KTM diagnosis tool
see chapter 7
12-25
LUBRICATION AND MAINTENANCE WORK - CHASSIS
Cleaning the dust boots
– See Owner's Manual
Bleeding the fork legs
– See Owner's Manual
Checking the swing arm support
– Try to move the rear wheel to each side in an unloaded condition.
You should not feel any clearance
NOTE:
– If you feel any clearance, check whether the swing arm support is
worn or the wheel bearing is defective.
– See Chapter 10 to replace the swing arm support or the wheel
bearing.
Checking/adjusting the steering head bearing
Art.-No. 3.206.056-E
– Try to move the fork back and forth in an unloaded condition.
– If you feel any clearance, loosen the 5 clamp bolts on the top triple
clamp and turn in the blind nut 1 until no clearance is left.
1
NOTE: do not tighten the blind nut since you may damage the bearing.
– Gently tap on the top triple clamp with a plastic hammer to relieve
any distortion and tighten the 5 clamp bolts (tigtening torques see
technical data).
Repair manual KTM LC8
Checking all chassis bolts for force fit
NOTE: check the bolts listed below with a torque wrench. If a bolt
secured with Loctite 243 is not tightened to the specified torque (if it
can easily be screwed in further), remove the bolt, clean, secure with
Loctite 243 and tighten to the correct torque.
12-26
LUBRICATION AND MAINTENANCE WORK - WHEELS
Checking the spoke tension and rim run-out
– Spoke nipple: 5 Nm
– maximum radial/lateral run-out of the rim (without tires): 1.2 mm
– maximum radial/lateral run-out of the rim (with tires): front 2.3 mm, rear 2.5 mm
Checking the chain and chain guides for wear, force fit and tension.
NOTE:
– Replacing the drive elements: see Chapter 10.
– Checking and adjusting the chain tension: see Owner's Manual
Checking the nuts/bolts on the engine sprocket and the rear sprocket for the securing agent and a tight fit
NOTE: check the nuts/bolts listed below with a torque wrench. If a nut secured with Loctite 243 is not tightened to the specified
torque (if it can easily be screwed in further), remove, clean, secure with Loctite 243 and tighten to the correct torque.
Hexagon nuts on the rear sprocket bolts: Loctite 243 + 50 Nm
Hexagon nut on the engine sprocket: Loctite 243 + 100 Nm + sheet retainer
Checking the wheel bearing and jerk damper for clearance
– To check the wheel bearing: jack up the motorcycle, lifting the
wheel to be inspected off the ground. Try to tilt the wheel to each
side. You should not feel any clearance. If you feel any wheel
bearing clearance, replace the wheel bearings (see Chapter 10).
– To check the jerk damper: hold the rear wheel while you try to move
the rear sprocket back and forth in the running direction.
NOTE: the transmission should be switched to neutral.
Maximum clearance: 5 mm (measured on the outside of the rear
sprocket)
To replace, see Owner's Manual.
12-27
LUBRICATION AND MAINTENANCE WORK – ADDITIONAL WORK
Completely servicing the fork
– Dismounting the fork legs: see Chapter 10
– Maintenance: see WP-documentation
Completely servicing the shock absorber
– Dismounting the shock absorber: see Chapter 10
– Maintenance: see WP-documentation
Cleaning and greasing the steering head bearing and sealing
elements
1
– Jack up the motorcycle until the front wheel no longer touches the
ground.
– Loosen the 5 clamp bolts on the upper triple clamp and remove the
blind nut on the steering stem.
– Move the upper triple clamp upwards but do not pull the triple
clamp all the way off of the steering stem 1. The weight of the front
wheel and the fork will give you access to the lower steering head
bearing.
– Clean the gasket element 2 and grease the lower steering head
bearing 3.
Art.-No. 3.206.056-E
3
2
– Lift the front wheel to have access to the upper steering head
bearing. Clean the gasket element, raise the protection ring 4 and
grease the upper steering head bearing 5.
4
– Place the front wheel on the ground, press the upper triple clamp
down, screw the blind nut back in until the bearings have no
clearance.
NOTE: do not tighten the blind nut since you may damage the bearing.
Repair manual KTM LC8
5
– Gently tap on the upper triple clamp with a plastic hammer to
relieve any distortion and tighten the 5 clamp bolts on the top triple
clamp (tigtening torques see technical data).
12-28
LUBRICATION AND MAINTENANCE WORK – ADDITIONAL WORK
Cleaning and adjusting the carburetor
– See Chapter 8
1
Changing the cooling liquid
NOTE: change the cooling liquid after you have finished the general
lubrication and maintenance work.
!
CAUTION
!
AVOID BURNING YOURSELF, ALWAYS DRAIN THE COOLING LIQUID WHEN THE
ENGINE IS COLD.
TO
3
5
2
– Open the radiator cap 1.
– Remove the drain plug 2 on the engine and allow the cooling liquid
to drain into a receptacle. Mount the oil drain plug with a new seal
ring and tighten to 10 Nm.
– Remove the compensating tank 3, open and drain the coolant into
a receptacle.
– Mount the compensating tank again.
– Remove the drain plug 4 on the radiator and allow the cooling
liquid to drain into a receptacle. Mount the drain plug again and
tighten.
– Fill approx. 2.1. liters of a mixture of 50% antifreeze (e.g. Motorex
Antifreeze) and 50% destilled water (minimum protection -25ºC),
into the radiator and compensating tank.
6
4
NOTE: to completely bleed the cooling system, the motorcycle must be
raised approx. 50 cm in the front - see Technical Information.
– Unscrew the bleeder screws on the water pump 5 and the radiators
6 until cooling liquid runs out without bubbles, tighten the screws
again, close the radiator cap.
!
CAUTION
!
USE HIGH-GRADE ANTIFREEZE (E.G. MOTOREX ANTIFREEZE) TO AVOID THE
RISK OF CORROSION AND FOAMING.
USE DISTILLED WATER TO PREVENT CALCIFICATION, ESPECIALLY OF THE
RADIATOR CAP AND THE ASSOCIATED, PREMATURE PRESSURE RELEASE.
– ONLY
–
– Lower the motorcycle again, Start the engine and allow to run warm
until the radiator fan switches on.
– Allow the cooling system to cool down and add more coolant if
necessary.
13-1
WIRING DIAGRAMS
INDEX
Repair manual KTM LC8
Art.-No. 3.206.056-E
950 ADVENTURE
WIRING DIAGRAM 2003-2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-6
EXPLANATION OF CONNECTORS, CABLE COLORS . . . . . . . . . . . . . . . . . . . . . . .13-7
WIRING DIAGRAM 2005 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-8
EXPLANATION OF CONNECTORS, CABLE COLORS . . . . . . . . . . . . . . . . . . . . . . .13-9
START SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-10
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-12
ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-14
FLASHER, HORN, COOLING FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-16
LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-18
LIGHTS USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-20
INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-22
GROUND CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-24
POSITIVE CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-25
CONNECTOR LIST 950 ADVENTURE
CONNECTOR AA - AF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-26
CONNECTOR AG - AH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-27
CONNECTOR AI - AK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-28
CONNECTOR AL - AM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-29
CONNECTOR AN - AR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-30
CONNECTOR AR - AT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-31
CONNECTOR AU - AW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-32
CONNECTOR AX - AZ, BA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-33
CONNECTOR BB - BG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-34
CONNECTOR BH - BK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-35
13
13-2
13
WIRING DIAGRAMS
INDEX
990 SUPER DUKE / SUPER DUKE R
WIRING DIAGRAM ((990 SUPER DUKE 2005/2006) . . . . . . . . . . . . . . . . . . . .12-36
EXPLANATION OF CONNECTORS, CABLE COLORS . . . . . . . . . . . . . . . . . . . . . .13-37
START/CHARGING SYSTEM (990 SUPER DUKE 2005/2006) . . . . . . . . . . . . . .13-38
START/CHARGING SYSTEM (990 SUPER DUKE/R 2007) . . . . . . . . . . . . . . . . .13-39
START/CHARGING SYSTEM (990 SUPER DUKE 2007/2008) . . . . . . . . . . . . . .13-42
START/CHARGING SYSTEM (990 SUPER DUKE R 2008) . . . . . . . . . . . . . . . . .13-43
ECU (990 SUPER DUKE 2005/2006) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-40
ECU (990 SUPER DUKE/R 2007) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-41
EFI (990 SUPER DUKE 2007/2008) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-46
EFI (990 SUPER DUKER R 2008) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-47
FLASHER, HORN, COOLING FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-42
LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-44
INSTRUMENTS (990 SUPER DUKE 2005/2006) . . . . . . . . . . . . . . . . . . . . . .13-46
INSTRUMENTS (990 SUPER DUKE/R 2007) . . . . . . . . . . . . . . . . . . . . . . . . .13-47
INSTRUMENTS (990 SUPER DUKE 2007/2008) . . . . . . . . . . . . . . . . . . . . . .13-54
INSTRUMENTS (990 SUPER DUKE R 2008) . . . . . . . . . . . . . . . . . . . . . . . . .13-55
GROUND CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-48
POSITIVE CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-49
CONNECTOR LIST 990 SUPER DUKE / SUPER DUKE R
CONNECTOR AA - AE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-50
CONNECTOR AF - AH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-51
CONNECTOR AI - AL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-52
CONNECTOR AM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-53
CONNECTOR AO - AR1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-54
CONNECTOR AR2 - AS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-55
CONNECTOR AT - AX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-56
CONNECTOR AY - AZ, BB - BD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-57
CONNECTOR BE - BI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-58
CONNECTOR BJ - BV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-59
CONNECTOR BZ, CA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-60
CONNECTOR CC - CK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-61
CONNECTOR CL - CQ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-62
CONNECTOR CR, DJ - DK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-63
13-3
WIRING DIAGRAMS
INDEX
Repair manual KTM LC8
Art.-No. 3.206.056-E
950 SUPERMOTO / SUPERMOTO R
WIRING DIAGRAM (UP TO THE 2007 MODEL) . . . . . . . . . . . . . . . . . . . . . . . .12-64
WIRING DIAGRAM (STARTING WITH THE 2007 MODEL) . . . . . . . . . . . . . . . . .13-65
EXPLANATION OF CONNECTORS, CABLE COLORS . . . . . . . . . . . . . . . . . . . . . .13-66
START/CHARGING SYSTEM (UP TO THE 2007 MODEL) . . . . . . . . . . . . . . . . . .13-67
START/CHARGING SYSTEM (STARTING WITH THE 2007 MODEL) . . . . . . . . . .13-68
ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-69
FLASHER, HORN, COOLING FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-70
LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-72
INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-74
GROUND CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-76
POSITIVE CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-77
CONNECTOR LIST 950 SUPERMOTO / SUPERMOTO R
CONNECTOR AA - AF1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-78
CONNECTOR AF2 - AH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-79
CONNECTOR AI - AJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-80
CONNECTOR AK - AL2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-81
CONNECTOR AL3 - AM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-82
CONNECTOR AO - AR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-83
CONNECTOR AS - AT3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-84
CONNECTOR AT4 - AX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-85
CONNECTOR AY - AZ, BB - BG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-86
CONNECTOR BI - BS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-87
CONNECTOR BV - BW, CD, CR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-88
CONNECTOR DI - DK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-89
NOTE:
THE LIGHT IS SWITCHED OFF DURING THE STARTING PROCESS "UP TO THE 2007 MODEL"
THE LIGHT IS NOT SWITCHED OFF DURING THE STARTING PROCESS "STARTING WITH THE
2007 MODEL"
13
13-4
13
WIRING DIAGRAMS
INDEX
990 ADVENTURE
WIRING DIAGRAM (2006/2007) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-90
WIRING DIAGRAM (2007) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-91
WIRING DIAGRAM (2007/2008) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-100
EXPLANATION OF CONNECTORS, CABLE COLORS . . . . . . . . . . . . . . . . . . . . . .13-92
START/CHARGING SYSTEM (2006/2007) . . . . . . . . . . . . . . . . . . . . . . . . . . .13-93
START/CHARGING SYSTEM (2007) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-94
START/CHARGING SYSTEM (2007/2008) . . . . . . . . . . . . . . . . . . . . . . . . . .13-104
EFI (-2006) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-95
EFI (2007-) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-106
FLASHER, HORN, COOLING FAN (-2006) . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-96
FLASHER, HORN, COOLING FAN (2007-) . . . . . . . . . . . . . . . . . . . . . . . . . . .13-108
LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-98
INSTRUMENTS (-2006) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-112
INSTRUMENTS (2007-) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-113
ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-101
GROUND CONNECTION (-2006) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-102
GROUND CONNECTION (2007-) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-116
POSITIVE CONNECTION (-2006) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-104
POSITIVE CONNECTION (2007-) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-118
CONNECTOR LIST 990 ADVENTURE
CONNECTOR AA - AE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-119
CONNECTOR AF - AI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-120
CONNECTOR AJ - AL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-121
CONNECTOR AM - AO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-122
CONNECTOR AP - AR4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-123
CONNECTOR AR5 - AT2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-124
CONNECTOR AT3 - AY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-125
CONNECTOR AZ, BA - BE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-126
CONNECTOR BF - BJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-127
CONNECTOR CA - CK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-128
CONNECTOR CL - CQ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-129
CONNECTOR CR - CX, DL-DM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-130
CONNECTOR DN-DP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-131
NOTE:
THE LIGHT IS SWITCHED OFF DURING THE STARTING PROCESS "UP TO THE 2007 MODEL"
THE LIGHT IS NOT SWITCHED OFF DURING THE STARTING PROCESS "STARTING WITH THE
2007 MODEL"
13-5
WIRING DIAGRAMS
INDEX
Repair manual KTM LC8
Art.-No. 3.206.056-E
950 SUPER ENDURO
WIRING DIAGRAM (UP TO THE 2007 MODEL) . . . . . . . . . . . . . . . . . . . . . . .12-117
WIRING DIAGRAM (STARTING WITH THE 2007 MODEL) . . . . . . . . . . . . . . . .12-118
EXPLANATION OF CONNECTORS, CABLE COLORS . . . . . . . . . . . . . . . . . . . . .13-119
START/CHARGING SYSTEM (UP TO THE 2007 MODEL) . . . . . . . . . . . . . . . . .13-120
START/CHARGING SYSTEM (STARTING WITH THE 2007 MODEL) . . . . . . . . .13-121
ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-122
FLASHER, HORN, COOLING FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-123
LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-125
INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-127
GROUND CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-129
POSITIVE CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-130
CONNECTOR LIST 950 SUPER ENDURO
CONNECTOR AA - AF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-131
CONNECTOR AH - AI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-132
CONNECTOR AJ - AK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-133
CONNECTOR AL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-134
CONNECTOR AM - AO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-135
CONNECTOR AR - AS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-136
CONNECTOR AT - AU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-137
CONNECTOR AV - AZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-138
CONNECTOR BA - BI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-139
CONNECTOR BJ - BT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-140
CONNECTOR BW, CD - CR, DI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-141
NOTE:
THE LIGHT IS SWITCHED OFF DURING THE STARTING PROCESS "UP TO THE 2007 MODEL"
THE LIGHT IS NOT SWITCHED OFF DURING THE STARTING PROCESS "STARTING WITH THE
2007 MODEL"
13
13-6
13-7
WIRING DIAGRAMS
INDEX
990 SUPERMOTO
Repair manual KTM LC8
Art.-No. 3.206.056-E
START/CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-156
EFI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-157
INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-158
13
n
tachometer
br-bl
3
bl-or
1 ye-bu
2
bu-wh
br
ye-bu
1
gn-re
br-re
1
10
br
2
right front flasher
ye-bl
7
19
left front flasher
gn-gr
re-wh
ye-br
ye
11
13
bl
12
pu
ye-bu
4
bu
3
9
gn-bl
6
5
14
15
1
2
ye-bu
pu
br
4
1
2
3
br
gn-wh
bl
1
2
head light flascher
gn-bl
2
1
C_BI/2
2
cooling fan
M
1 7
3
8
1
ye-bu
2
temperature switch
br 1
C_AU/2
2
2 4
9
6
C_AD/12
5
bu-bl
1
1
1
1
front
C_AS1/2
2
1
rear
C_AS/2
2
3
6
9
2 7
sidestand switch
gn
bl
neutral switch 2nd gear
3rd gear
2nd
3th
3
2
C_AR3/3
C_AM1/3
1
2
C_AL/2
C_AT2/2
N
C_AB/9
C_BB/9
8
clutch switch
horn
G
flasher relay
950-Adventure 03-04
wh
gn
bu
wh
bu
ye
gn-re
gn-br
gn
C_AN/4
C_AR2/2
C_BE/3
C_AG/3
C_AM2/3
handle bar switch
for multi-func.-digitalspeedometer
v
front
brake switch
br-bl bl-or
C_AK/2
multi-func.-digital-speedometer
3
C_AH3/2
speed sensor
headlight
2
C_AC/6
C_AA/20
C_AH2/2
C_AK1/2
C_BC/6
ye
C_BD/12
pu
pi
gr
br-pi
br
br
br
C_AH/2
pi
or
re
ye-br
bl
bl-or
or
wh
ye-br
ye-wh
wh
br-wh
or
bl-bu
or
bl-gn
bl-wh
or
0
br
or
1
br
1
C_AO/26
3 16 10
2
br
br-re 2
fuel pump relay
20
bu-gr 2
ye-bl 3
br 4
bl-bu1
M
ye-bu
bl-wh
ye-bl
re-wh
ye-re
re-bl
fuse box
ye
bl-or
2
C_AT/2
1
bl-bu
br
fuel level sensor
fuel pump
8 6 13
1
wiring diagram
EPC 1 EPC 2
C_AW1/2
1 2
re-bl
re-gn
C_AW/2
2
ye-re
or
aditional instruments
(roadbook;...)
br
pu-wh
ye-br
1
C_AF1/4
br-wh
re-gn
C_AL2/2
light switch
ye-br
pu-wh
10 15 10
or
or
ye-re
re-wh
re-wh
or
re
ye-re
M
re-wh
sterter motor
re-wh
1 2
2
C_BF/1
C_BA/1
1
2
600 11 092 000
3
3
2
wh
gn-wh 1
1
w
br
4
pu 2
3
1
bl
br
ye
2
C_AH1/2
C_AK2/2
oil pressure switch -
TPS
C_AR1/3
C_AU1/2
rear
brake switch
rear - 600 11 076 000
Pick up
C_AT/2
ye
pi
1
C_AI1/2
2
C_AI/2
2
or
1
2
C_BI1/2
start auxillary relay
re-wh
diode
4
ye
br
re-wh
diode
1
re
re-wh 3
2 1
gn-bl
C_AM/3
1
2
C_AL1/2
1
6
4 5
battery
C_AF/4
front - 600 11 075 000
octane selector
7 4 11 19 25 26 18
C_BH/6
C_AP/6
3
3
C_AE/4
4
ignition switch
br
30
A
start relay
re-wh
bu-re
bl-wh
br-bl
ye-br
or
br-bl
ye-bu
A
A
A
A
A
A
A
pi
bl
C_AV/2
ye-wh
re-wh
ye
br
br
1
ye-bl
gn-gr
2
br
3
oil pressure sensor
temperature sensor
generator
G
U
regulator-rectifier
C_AX/2
C_BJ/1
re-wh
re
5 10
5
5
5
bl
A
bu-wh
bu-gr
ye
C_AM3/3
2
C_AY/1
re-ye
ye
ignition coil
C_AT1/2
gr
E
ye
Q
or
C
bu
U
bl
or
ye-re
ye-wh
ye-bu
t°
start/stop switch
C_BF1/1
ye-bu
C_BA1/1
bu
gr
C_AR/3
br-bl
br
ye
gn-wh
C_AZ/4
C_BK/4
C_AJ/3
C_BG/3
1/9
left rear flasher
licence plate lamp
right rear flasher
p
gn-re
rear light/brakelight
high/low beam switch horn switch
flasher switch
13-8
Repair manual KTM LC8
Art.-No. 3.206.056-E
13-9
Aditional instruments (roadbook;...)
Battery
Clutch switch
Cooling fan
Diode
Flasher relay
Flasher switch
Front brake switch
Fuel level sensor
Fuel pump
Fuel pump relay
Fuse box
Gear sensor
Generator
Handle bar switch for multi-func.-digital-speedometer
Headlight
High / low beam switch
Horn
Horn switch
Ignition coil
Ignition switch
Left front flasher
Left rear flasher
Licence plate lamp
Light switch
Multi-func.-digital-speedometer
Neutral switch
Octane selector
Oil pressure sensor
Pick up
Rear brake switch
Rear light / brakelight
Regulator-rectifier
Right front flasher
Right rear flasher
Sidestand switch
Speed sensor
Start auxillary relay
Start relay
Start/stop switch
Starter motor
Tachometer
Temperature sensor
Temperature switch
Throttle position sensor (TPS)
Externe Instrumente
Batterie
Kupplungsschalter
Lüftermotor
Diode
Blinkerrelais
Blinkerschalter
vorderer Bremslichtschalter
Benzinstandgeber
Kraftstoffpumpe
Kraftstoffpumpenrelais
Sicherungskasten
Gangerkennung
Generator
Lenkerschalter für Multifunkt.Digitaltacho
Scheinwerfer
Auf-Abblendschalter
Hupe
Hornschalter
Zündspule
Zündschloss
linker vorderer Blinker
linker hinterer Blinker
Kennzeichenbeleuchtung
Lichtschalter
Multifunktionsdigitaltacho
Leerlaufschalter
Oktananpassung
Öldruckschalter
Impulsgeber
hinterer Bremslichtschalter
hinteres Begrenzungslicht / Bremslicht
Regelgleichrichter
rechter vorderer Blinker
Rechter hinterer Blinker
Seitenständerschalter
Geschwindigkeitssensor
Starterhilfsrelais
Startrelais
Start / stop schalter
Startermotor
Drehzahlmesser
Temperatursensor
Temperaturschalter
Vergaserpotentiometer
NOTE to the connector designations:
The connector designations are comprised of letters and numbers - e.g.: C_AA1/20
– The 1st position C stands for connector (connector).
– The 2nd and 3rd positions AA stand for the connector type.
– The 4th position numbers the same type of connector if the connector is used for different
applications.
– The 5th and 6th positions 20 specify the number of pins in the connector, in this case 20 poles.
The 5th position is not required for connectors with less than 10 pins.
Cable colours
bl: black
ye: yellow
bu: blue
gn: green
re: red
wh: white
br: brown
or: orange
pi: pink
gr: grey
pu: purple
b r - bl
1
3
bu
g n -re
br-re
13
1
10
n
multi-func.-digital-speedometer
tachometer
handle bar switch
for multi-func.-digitalspeedometer
le f t f ro n t f l a s h e r
1
br
2
y e - bu
pu
br
4
1
2
3
br
gn-wh
bl
1
2
wh
gn
bu
ye
head light flascher
gn-bl
1
2
3
8
1
y e - bu
2
1
1
2
sidestand switch
gn
bl
neutral switch 2nd gear
3 r d gear
2nd
3th
3
2
C_AR3/3
C_AM1/3
1
2
C_AL/2
C_AT2/2
f r ont
C_AS1/2
pu-wh
1
rear
C_AS/2
2
2
1
3
6
wh
9
2 7
1
N
C_AB/9
C_BB/9
bl-bu
8
clutch switch
h o rn
G
flasher relay
or
950-Adventure 05
c o o l i ng f an
M
C_BI/2
1 7
bu-bl
t e m p e r a tu re sw it ch
br 1
C_AU/2
2
2 4
9
6
5
C_AD/12
C_BD/12
wh
ye
gn-re
gn-br
bu
bu-re
pu
pi
gr
br-pi
br
C_AN/4
C_AR2/2
C_BE/3
C_AG/3
C_AM2/3
right front flasher
ye-bl
7
19
g n - gr
re-wh
y e- br
ye
11
12
pu
bl
y e - bu
4
3
9
2
gn-bl
6
5
14
15
b l - or
1 y e - bu
br
y e - bu
3
C_AK/2
v
front
brake switch
br-bl bl-or
2
bu-wh
C_AH3/2
speed sensor
headlight
2
C_AC/6
C_AA/20
C_AH2/2
C_AK1/2
C_BC/6
C_AH/2
pi
bl-wh
re
ye-br
br
ye
bl
or
bl-gn
re-ye
or
bl-or
or
0
or
1
ACC2
switched
carb heater 1
3 16 10
C_AO/26
2
20
br-re
ye-bl
b u - gr
carb heater 2
f u e l pum p
8 6 13
ye-re
or
re
ye-re
M
4
C_BH/6
re-wh
1 2
3
C_AE/4
30
A
start relay
2
C_BF/1
C_BA/1
1
front
rear
carb heater
battery
600 11 075 000
600 11 076 000
600 31 005 000
P i c k up
C_AT/2
3
3
2
br
wh
gn-wh 1
1
wh
4
pu 2
3
1
bl
br
ye
2
C_AH1/2
C_AK2/2
rear
brake switch
oil pressure switch
600 11 092 000
TPS
C_AR1/3
2
ye
pi
1
C_AI1/2
2
1
2
C_BI1/2
start auxillary relay
C_AI/2
2
or
re-wh
br
re-wh
diode
4
ye
C_AF/4
diode
1
re
re-wh 3
2 1
gn-bl
C_AM/3
1
2
C_AL1/2
1
6
4 5
ignition switch
br
C_AP/6
3
o c t a ne s ele c tor
4 11 19 25 26 18
7
f u se box
re-wh
re-wh
or
or
fuel level sensor
f ue l p um p r e l a y
1
bl-bu
ye-re
re-wh
ye-bl
bl-wh
y e - bu
ye
b l - or
1
2
2
3
4
1
1
2
wiring diagram
EPC 1 EPC 2
C_AW1/2
1 2
C_AW/2
2
C_AH4/2
re-gn
y e- br
1
ACC1
always ON
or
gn
bl-wh
br-wh
ye-br
or
br-bl
br
ye-br
C_AT/2
C_AF1/4
light switch
re-gn
C_AT1/2
bu-gr
carb body
pu-wh
A
A
A
A
C_AL2/2
M
Q
10 15 10
10 10
10 10 10
A
A
A
A
bu-wh
pi
bl
C_AV/2
ye
ye
br
ye-bu
re-wh
re-wh
re-wh
re
ye-wh
ye
wh
ye-br
br-wh
or
ignition coil
br-bl
br
ye-bu
or
ye-re
ye-wh
br
C_AM3/3
2
C_BF1/1
ye-bu
C_BA1/1
bu
1
ye-bl
g n - gr
2
br
3
o i l p r e ss u r e s e n s o r
temper ature s ensor
generator
G
U
regulator-rectifier
C_AX/2
C_BJ/1
starter motor
ye-wh
bl
bl-bu
gr
E
or
C
bu
U
ye
gr
C_AR/3
br-bl
br
bl
gn-wh
t°
start/stop switch
C_AY/1
C_AU1/2
C_AZ/4
C_BK/4
C_AJ/3
C_BG/3
1/9
left rear flasher
licence plate lamp
right rear flasher
p
g n -re
rear light/brakelight
high/low beam switch horn switch
flasher switch
13-10
temperature switch
Repair manual KTM LC8
Art.-No. 3.206.056-E
13-11
Aditional instruments (roadbook;...)
Battery
Clutch switch
Cooling fan
Diode
Flasher relay
Flasher switch
Front brake switch
Fuel level sensor
Fuel pump
Fuel pump relay
Fuse box
Gear sensor
Generator
Handle bar switch for multi-func.-digital-speedometer
Headlight
High / low beam switch
Horn
Horn switch
Ignition coil
Ignition switch
Left front flasher
Left rear flasher
Licence plate lamp
Light switch
Multi-func.-digital-speedometer
Neutral switch
Octane selector
Oil pressure sensor
Pick up
Rear brake switch
Rear light / brakelight
Regulator-rectifier
Right front flasher
Right rear flasher
Sidestand switch
Speed sensor
Start auxillary relay
Start relay
Start/stop switch
Starter motor
Tachometer
Temperature sensor
Temperature switch
Throttle position sensor (TPS)
Carb heater (Carburator heater element)
Externe Instrumente
Batterie
Kupplungsschalter
Lüftermotor
Diode
Blinkerrelais
Blinkerschalter
vorderer Bremslichtschalter
Benzinstandgeber
Kraftstoffpumpe
Kraftstoffpumpenrelais
Sicherungskasten
Gangerkennung
Generator
Lenkerschalter für Multifunkt.Digitaltacho
Scheinwerfer
Auf-Abblendschalter
Hupe
Hornschalter
Zündspule
Zündschloss
linker vorderer Blinker
linker hinterer Blinker
Kennzeichenbeleuchtung
Lichtschalter
Multifunktionsdigitaltacho
Leerlaufschalter
Oktananpassung
Öldruckschalter
Impulsgeber
hinterer Bremslichtschalter
hinteres Begrenzungslicht / Bremslicht
Regelgleichrichter
rechter vorderer Blinker
Rechter hinterer Blinker
Seitenständerschalter
Geschwindigkeitssensor
Starterhilfsrelais
Startrelais
Start / stop schalter
Startermotor
Drehzahlmesser
Temperatursensor
Temperaturschalter
Vergaserpotentiometer
Vergaserheizelement
NOTE to the connector designations:
The connector designations are comprised of letters and numbers - e.g.: C_AA1/20
– The 1st position C stands for connector (connector).
– The 2nd and 3rd positions AA stand for the connector type.
– The 4th position numbers the same type of connector if the connector is used for different
applications.
– The 5th and 6th positions 20 specify the number of pins in the connector, in this case 20 poles.
The 5th position is not required for connectors with less than 10 pins.
Cable colours
bl: black
ye: yellow
bu: blue
gn: green
re: red
wh: white
br: brown
or: orange
pi: pink
gr: grey
pu: purple
31
battery
r ed 4
M
brown 0.5
3
30
31
red 4
r e d 0. 5
C_BF1/1
4
3
2
1
start auxillary relay
C_AF/4
8
red 0.5
2
A
page 7/9
1
orange 0.5
brown 0.5
950-Adventure
starter motor
4
C_BA1/1
C_AE/4
orange 0.5
C_BB/9
C_AB/9
7
ignition switch
black-orange 0.5
fuse
10 A
yellow 0.5
start-relay
2
diode
C_AI/2
1
o r a nge 1
green-black 0.5
start/stop switch
3
sidestand switch
C_AM3/3
C_AR/2
1
yellow 0.5
start system
brown 0.5
pink 0.5
C_AM1/3
C_AR3/3
2
B
page 4/9
diode
C_AI1/2
1
3
N
3th
2nd
1
clutch switch
C_AT2/2
C_AL
2
yellow 0.5
30
brown 0.5
neutral switch (N) / 2nd gear / 3rd gear
2/9
31
30
13-12
pink 0.5
13-13
start switch
ignition switch
r-w r-w r-w
o
y-r
r
ON
cable
harness
or
cable
switch
blbu
blor
bl
START
OFF
unpushed
LOCKED
Art.-No. 3.206.056-E
kill switch
sidestand switch
cable
harness
re
or
cable
harness
br
pi
cable
switch
or
blwh
cable
switch
gn
bl
RUN
folded up
STOP
folded down
clutch switch
switch
position
pulled
Repair manual KTM LC8
unpulled
ye
br
br
31
fuel pump
clock
page 4/9
page 7/9
950-Adventure
red-black 0.5
yellow-red 0.5
1
10
A
brake-horn-flasher-system
2
10
A
9
f an
10
A
10
page 5,6,7/9
page 6/9
3
4
10
A
11
5
10
A
12
6
10
A
13
7
15
A
14
8
10
A
15
1
2
3
5
6
4
C_BH/6
page 5/9
start system
light
page 2/9
fuse box
orange 1
black-orange 0.5
16
yellow-red 1
yellow 1
battery
red 1
yellow-blue 1
red-white 1
red-white 1
yellow-red 1
r ed 1
yellow-red 1
orange 1
black-white 1
C_AP/6
yellow-red 1
o r a nge 1
orange 1
black-yellow 1
30
31
red-white 1
red-white 1
red-white 1
red-white 0.5
red-white 1
ignition switch
red-white 1
red-white 1
charging circuit
aditional instruments
(roadbook;...)
main fuse
30 A
C_AE/4
1 2
red-white 1
30
2
1
3
generator
G
31
3/9
U
regulator-rectifier
30
13-14
brown 1
C_AU1/2
C_BI1/2
13-15
ignition switch
r-w r-w r-w
ON
OFF
Repair manual KTM LC8
Art.-No. 3.206.056-E
LOCKED
o
y-r
r
30
31
31
C_BB/9
C_AB/9
battery
1
o r a nge 0.5
2
o r a nge 1
U
7
20
3
2
10
16
18
8
6
1
4
11
19
26
25
13
1
black 0.5
yellow 0.5
blue 0.5
2
1
o r a n g e 0. 5
brown-white 0.5
violet-white 0.5
EPC 1 EPC 2
C _ A W1 /2
1 2
C _ A W /2
2
r ed- gr een 0.5
yellow-white 0.5
yellow-blue 0.5
C_AT/2
C_AL1/2
ignition coil
brown 0.5
blue-white 0.5
pink 0.5
b l u e- gr ey 0.5
1 2
1
front
C_AS1/2
2
grey 0.5
r ear
C_AS/2
2
1
C_AM/3
C_AR1/2
3
throttle position sensor
yellow-brown 0.5
950-Adventure
o r a nge 0.5
black-orange 0.5
E
C
7
fuse
10 A
C_AO/26
pick up
2
3 th
N
ECU
neutral switch (N) / 2nd gear / 3rd gear
2 nd
C_AM1/3
C_AR3/3
1
black-brown 0.5
1
C_BF/1
C_BA/1
1
B
page 2/9
octane selector
C
page 7/9
fuel pump relay
brown 0.5
o r a nge 1
C_AF1/4
fuel pump
start/stop switch
brown 0.5
1
1
M
C_AT/2
2
4
2
3
ignition switch
brown 0.5
31
o r a nge 1
30
4/9
fuse
10 A
black-blue 0.5
30
13-16
13-17
ignition switch
r-w r-w r-w
o
y-r
ON
OFF
LOCKED
Art.-No. 3.206.056-E
start switch
cable
harness
or
cable
switch
blbu
blor
bl
START
unpushed
kill switch
cable
harness
re
or
cable
switch
or
blwh
RUN
Repair manual KTM LC8
STOP
r
31
E
page 7/9
D
page7/9
C_AH/2
4
1
C_AD/12
C_BD/12
7
flasher switch
G
v i ol et 0 .5
3
950-Adventure
rear flasher light`s
C_AZ/4
C_BG/4
2
1 2
1 2
4
C_AK1/2
violet 0.5
black 0.5
C_AH3/2
C_AH2/2
C_ A K / 2
fuse
10 A
ignition switch
brown 0.5
brown 0.5
yellow-blue 0.5
orange 0.5
8
horn
brown 1
ignition switch
black-white 1
o r a nge 1
2
1
2
temperature switch
C_AV/2
1
fuse
10 A
turn indicator system
horn switch
C_BD/12
C_AD/12
3
yellow-blue 0.5
r ed 1
grey 0.5
1
2
brown 0.5
brown-black 1
flasher relay
right front flasher
black 0.5
left-front-flasher
M
31
30
5/9
cooling fan
C_BI/2
30
13-18
C_AU/2
13-19
ignition switch
r-w r-w r-w
o
y-r
r
ON
OFF
LOCKED
Art.-No. 3.206.056-E
flasher switch
cable
harness
or
gr
br
cable
switch
gn- bu- bupi
br re bl
brpi
pu
bl
TURN L
TURN R
OFF
Repair manual KTM LC8
horn switch
cable
harness
gr
br
cable
switch
pi
brpi
HORN
OFF
31
0
1
2
head light flasher
HI
LO
low/high beam switch
C_BD/12
C_AD/12
light switch
2
5
6
9
3
yellow 1
F
page 7/9
white 0.5
fuse
10 A
C_AB/9
front
blue 1
g r een 1
brake switch
r ear
brake switch
1
2
C_BK/4
C_AZ/4
4
1
white 0.5
green-white 0.5
1
2
C_BG/3
C_AJ/3
1
white 0.5
3
2
3
rear light/brake ight
C_BC/6
C_AC/6
light-brake system
licence plate lamp
2
1
blue-yellow
C_AH1/2
ignition switch
ignition switch
C_BB/9
950-Adventure
9
6
yellow 1
yellow-brown 1
fuse
15 A
yellow-red 1
r ed 1
brown 0.5
head light
4
brown 0.5
30
brown 0.5
6/9
31
30
13-20
C_AK2/2
13-21
ignition switch
r-w r-w r-w
o
y-r
r
ON
OFF
LOCKED
light switch
high/low beam switch
cable
harness
yewh ye
br
cable
harness
bu
gn
yebr
cable
switch
yewh wh
cable
switch
wh ye
gnre
LIGHT OFF
LO
Art.-No. 3.206.056-E
P. LIGHT
HI
LIGHT
passing light
brake switch
cable
harness
gn- yewh bu
cable
harness
ye
cable
switch
bl
cable
switch
gnwh
bl
pushed
unpushed
Repair manual KTM LC8
reye
bl
P. HORN
OFF
bu
31
head light flasher
HI
LO
low/high beam switch
2
6
5
9
F
page 7/9
yellow 1
white 0.5
fuse
10 A
ignition switch
ignition switch
front
r ear
brake switch
blue 1
g r een 1
brake switch
950 Adventure
C_AB/9
3
6
9
yellow 1
yellow-brown 1
fuse
15 A
yellow-red 1
r ed 1
brown 0.5
C_BK/4
C_AZ/4
4
1
white 0.5
green-white 0.5
C_BC/6
2
C_BG/3
C_AJ/3
1
white 0.5
3
2
3
rear light/brake light
1
C_AC/6
light system USA
licence plate lamp
2
1
1
2
head light
4
brown 0.5
30
brown 0.5
6A/9
31
30
13-22
C_AH1/2
C_AK2/2
C_BD/12
C_AD/12
13-23
ignition switch
r-w r-w r-w
o
y-r
r
ON
OFF
LOCKED
light switch
high/low beam switch
cable
harness
yewh ye
br
cable
harness
bu
gn
yebr
cable
switch
yewh wh
cable
switch
wh ye
gnre
LIGHT OFF
LO
Art.-No. 3.206.056-E
P. LIGHT
HI
LIGHT
passing light
brake switch
cable
harness
gn- yewh bu
cable
harness
ye
cable
switch
bl
cable
switch
gnwh
bl
pushed
unpushed
Repair manual KTM LC8
reye
bl
P. HORN
OFF
bu
31
3
black-brown 0.5
1 2
yellow-brown 0.5
yellow 0.5
3
green-red 0.5
2
7 19
1 6
2 9
p
C_BJ/1
C _ AY /1
1
yellow-blue 0.5
oil pressure sensor
gree n-gr ey 0.5
yellow-black 0.5
green-black 0.5
950-Adventure
F
page 6/9
E
page 5/9
D
page 5/9
violett 0.5
handlebar switch
for multi-func.-digitalspeedometer
C_AN/4
1 4
blue 0.5
red-white 0.5
speed sensor
v
black-orange 0.5
C_AM2/3
C_AR2/3
3 5
black 0.5
C_AA/20
10 15 14 11 12 13 4
brown 0.5
fuse
5A
brown 0.5
brown 0.5
2
f u e l l e v el s e ns or
Q
C_AL2/2
C_AT1/2
1
instruments_tachometer
t e mperature sensor
2
A
page 2/9
t°
C_AX/2
1
ignition switch
fuse
10 A
r ed 1
3 2
C_AG/3
C_BE/3
1
n
tachometer
yellow-blue 0.5
blue-white 0.5
multi-func.-digital-speedometer
brown 0.5
30
31
7/9
C
page 4/9
30
13-24
13-25
ignition switch
r-w r-w r-w
ON
OFF
Repair manual KTM LC8
Art.-No. 3.206.056-E
LOCKED
o
y-r
r
left front flasher
headlight
right front flasher
fuel pump relay
handle bar switch
tachometer
M
fuel pump
ECU
battery
brown
regulator
ground connection
sidestand switch
temperature switch
30
A
950 Adventure
clutch switch
external instruments
external instruments
multi-func.-digital-speedometer
horn switch
s t a r t er m o t o r
start relay
rear flasher
8/9
rear light/brakelight
octane selector
f u e l l e v el se ns o r
t e mperature sensor
13-26
tachometer
front brake switch
flasher relay
speed sensor
rear brake switch
950 Adventure
multi-func.-digital-speedometer
Fan
A
A
A
10 15 10
fuel pump relay
A
A
A
A
A
battery
fuse box
yellow-red
10 10 10 10 10
o r ange
red
ignition switch
30
A
positve connection
black-orange
start/stop switch
light switch
M
yellow-black
black-white
horn
high/low beam switch
s t a r t er mo t o r
yellow
yellow-blue
s t a r t relay
red-white
red-white
Art.-No. 3.206.056-E
red-black
yellow-red
Repair manual KTM LC8
9/9
external instruments
external instruments
carb heaters
regulator
13-27
13-28
Connector AA
20-pole 1
11 1
1
Multifunctional digital
speedometer
Behind
the
functional
speedometer
20 10
multidigital
Connector AB
9-pole 2
3
1
9
2
Start/stop/light switch
On
the
connector
support
under
the
multifunctional digital
speedometer
4
Connector AC
6-pole 3
Front light
1
4
3
6
On
the
connector
support
under
the
multifunctional digital
speedometer
Connector AD
12-pole 4
3
1
7
12
Light/turn signal/horn
switch
On
the
connector
support
under
the
multifunctional digital
speedometer
Connector AE
4-pole 5
1
4 2
5
Starter relay
On the right side on the
battery case
Connector AF
4-pole 6
1
42
Auxiliary start relay
Connector AF
4-pole 7
Fuel pump
On
the
connector
support
under
the
multifunctional digital
speedometer
3
6
7
13-29
Connector AG
3-pole 1
Tachometer
1
3
On
the
connector
support
under
the
multifunctional digital
speedometer
1
2
Connector AH
2-pole 2
Turn signal relay
1 2
On
the
connector
support
under
the
multifunctional digital
speedometer
Connector AH1
2-pole 3
3
Rear brake light
switch
Art.-No. 3.206.056-E
Under the right rear side
cover
Connector AH2
2-pole 4
4
Left front turn signal
Under the right front
side cover
Connector AH3
2-pole 5
Repair manual KTM LC8
Right front turn signal
Under the left front side
cover
5
Connector AH4
2-pole 6
Temperature switch of
carburator heater
element
Behind the headlight
6
13-30
Connector AI
2-pole 1
2
1
Diode neutral switch
2
1
On
the
connector
support
under
the
multifunctional digital
speedometer
Connector AI1
2-pole 2
Diode side stand switch
On
the
connector
support under the multifunctional
digital
speedometer
Connector AJ
3-pole 3
1
2
3
3
Rear lighting
Under the right rear side
cover
Connector AK
2-pole 4
Rear brake light switch
1
2
4
Under the right rear side
cover
Connector AK1
2-pole 5
Right front turn signal
Under the left front side
cover
5
Connector AK2
2-pole 6
Left front turn signal
Under the right front
side cover
6
13-31
Connector AL
2-pole 1
1
Clutch switch
1
Behind the headlight
under the connector
support
2
Connector AL1
2-pole 2
2
Pick up
Between the water pipe
and the front cylinder
head
Connector AL2
2-pole 3
Fuel sender
Art.-No. 3.206.056-E
Between the left tank and
the frame
Connector AM
3-pole 4
1
3
Carburetor
potentiometer
3
4
Under the fuse box
Connector AM1
3-pole 5
Repair manual KTM LC8
Gear sensor
6
Connector AM2
3-pole 7
Speed sensor
Behind the headlight
under the connector
support
Connector AM3
3-pole 6
Side stand switch
links am Motor vor dem
Generatordeckel
7
5
13-32
Connector AN
4-pole 1
1
Tripmaster switch
1 2
4
Near
the
connector
support
under
the
multifunctional digital
speedometer
Connector AO
26-pole 2
20
14
8
ECU (control unit)
1
Under the fuse box
behind the steering
head
26
19
13
7
2
Connector AP
6-pole 3
Ignition lock
1
3
6
Under the fuse box
3
Connector AQ
1-pole
Connector for auxiliary
devices:
Kl 15 (ignition)
Kl 30 (battery)
Kl 31 (ground)
Behind the headlight
under the connector
support
Connector AR
3-pole 4
Side stand switch
3
1
4
Connector AR3
3-pole 5
5
Gear sensor
On the left side of the
engine in front of the
generator cover
Connector AR1
3-pole 6
Carburetor
potentiometer
Under the fuse box
6
13-33
Connector AR
3-pole 1
Speed sensor
3
1
Behind the headlight
under the connector
support
1
Connector AS
2-pole 2
Rear ignition coil
1
2
2
Behind the air filter box
Connector AS1
2-pole 3
Front ignition coil
Art.-No. 3.206.056-E
Behind the radiator
3
Connector AT
2-pole 4
Pick up
1
2
Between the water pipe
and the front cylinder
head
4
Connector AT1
2-pole 5
5
Repair manual KTM LC8
Fuel sender
Between the left tank
and the frame
Connector AT2
2-pole 6
Clutch switch
Behind the headlight
under the connector
support
6
13-34
Connector AU
2-pole 1
Radiator fan motor
21
1
On the right behind the
radiator next to the fan
Connector AU1
2-pole 2
Regulator
On the right side of the
battery case under the
starter relay
2
Connector AV
2-pole 3
1
2
Temperature switch for
the radiator fan
On the right behind the
radiator next to the
compensating tank
3
Connector AW
2-pole 4
EPC front cylinder
2
1
On the right side of the
frame
4
Connector AW1
2-pole 5
EPC rear cylinder
Behind the air filter box
5
13-35
Connector AX
2-pole 1
Temperature sensor for
the multifunctional
digital speedometer
1
2
On the left side of the
engine between the
cylinders
2
1
Connector AY
1-pole 2
Oil pressure switch
On the left side of the
frame under the air
filter box
Connector AZ
4-pole 3
Art.-No. 3.206.056-E
1
2
3
4
Rear turn signal
Connector BA
1-pole 4
Octane selector
Behind the air filter box
Repair manual KTM LC8
3
Under the right rear side
cover
4
13-36
Connector BB
9-pole 1
1
3
7
9
1
Start/stop/light switch
On
the
connector
support
under
the
multifunctional digital
speedometer
2
3
Connector BC
6-pole 2
Front light
3
6
1
On
the
connector
support
under
the
multifunctional digital
speedometer
Connector BD
12-pole 3
3
1
10
12
Light/turn signal/horn
switch
On
the
connector
support
under
the
multifunctional digital
speedometer
Connector BE
3-pole 4
1
3
Tachometer
4
On
the
connector
support
under
the
multifunctional digital
speedometer
Connector BF
1-pole 5
Octane selector
Behind the air filter box
Connector BG
3-pole 6
1
2
3
Rear lighting
Under the right rear side
cover
5
6
13-37
Connector BH
6-pole 1
Ignition lock
1
3
6
Under the fuse box
1
Connector BI
2-pole 2
Radiator fan motor
2 1
On the right behind the
radiator next to the fan
2
Connector BI1
2-pole 3
Regulator
On the right side of the
battery case under the
starter relay
Art.-No. 3.206.056-E
3
Connector BJ
1-pole 4
Oil pressure switch
On the left frame under
the air filter box
1
4
Repair manual KTM LC8
Connector BK
4-pole 5
1
1
2
3
Rear turn signal
Under the right rear side
cover
5
multi-func.-digital-speedometer
headlight
n
front
brake switch
speed sensor
15
16
9
3
4
5
2
7
8
1
br
left front flasher
right front flasher
br
gn-gr
wh
r e- br
br-bu
gn-bl
re-wh
or-ye
bl
pu
bu
br-bl
br
ye
ye-bu
bl-or
1
3
5
4
bl
or-ye
2
10
r e- br
wh
cooling fan
M
C_BI1/2
re-wh
or-ye
bl
pu
bu
r e- br
bu-br
11 gn-gr
3
br
12 wh
2
9
10 gn-bl
6
5
7
1
4
5
4
sensor
rollover
C_AP2/6
6
temperature switch
C_AV/2
1
C_CI/12
2
gn-gr 11
1
br
12
7
bu-br
gn-bl
C_AU1/2
2
9
pu
re-wh
6
bu
C_CC/12
p
C_AY/1
C_BJ/1
7 1
oil pressure sensor
1
2
L
L
rear
t°
3
2
1
gr
ye-bu
6
1 2
C_AX/2
4
2
ye -re
or
br
3
p
C_BZ2/3
1
1
1
2
t°
or
C_AH2/2
C_BH1/6
h o rn
p
C_BZ1/3
2 3
1
1
2
C_CM/2
t°
diode
G
flasher relay
or
1
8
C_AB/9
C_BB/9
bl-bu
2 3
p
C_BZ/3
1
wiring diagramm
lambda sensor`s
front
t°
C_CE/4
4
C_CA/4
3
C_CE1/4
2
diagnostic
connector
3
8
C_CA1/4
4 1
990 Super Duke 2005/06
pu
y e - br
6
wh
gn
2
1
bu
3
br
br
bl
or-ye
2
4
gn-wh
br-bl
1
bl-or
bu-re
12
6
C_BE/3
C_AH/2
LED red
for optional alarm system
tachometer
clutch switch
C_AK/2
10
C_BS/2
3
C_AC/6
v
C_AT1/2
C_AM5/3
C_AG/3
C_AR5/2
1
2
C_BC/6
C_AA/20
C_BV/2
C_AL1/2
2
1
2
bl-wh
2 4
or
br-bl
head light flascher
gn-bl
ye
re-gn
wh-bl
br-bl
wh
bu
bu-re
bl
1
bl
ye
gn
gn-re
gn-br
ye-br
or
9
or
pu
pi
gr
br-pi
br
wh-or
bl-wh
2 7
9
2
1
3
C_AR3/3
C_AM3/3
2
C_AL/2
Pick up
C_AT/2
1
sidestand switch
3
6
wh
wh
re-ye
ye
bu-bl
bl
re-br
or-bl
ye-bu
6
bu
fuse box
1
2
A
3
2nd
2
1
9
A
4
6
5
5 3
6
7
A
A
A
A
A
10 10 10 10 10
3
4
C_BH/6
C_AP/6
8
2
gn-bl
y e - br
gr
1 0 1 1 12 13 14 1 5 16
A
10 15 10
or-bl
or
ye-bl
C_AD/12
re
bu-bl
ye-bu
ye-re
re-wh
C_BD/12
ye
re
re-gn
5
7 13 14 3 24 23 11 12 4
C_AO/26
2 10 9 22 6 20 25 26 19 15 18 17
C_CR/1
2
8
f uel pump
M
3
2
C_CR1/1
9 14 16 34
alarm system
d u mmy p l u g
Connector for
optional
alarm system
fuel pump module
Q
C_AR4/3
C_AM4/3
1
A CC
starter motor
M
33 15 13 23 11 3
6 29 26
C_CO/34
7 21 12 4 22 5
main harness - 610.11.075.000
1
1
re-wh
br
ye-bu
manifold pressure sensor front
br
ye-re
bu
air temperature sensor
bl
bl
br-re
ye-wh
ye-bu
re-br
3
C_AR2/3
3th
bu-bl
br
br
1
fuel level sensor
bu-gr
br
br
bu-wh
wh
bu-br
0
C_AM2/3
N
1
4
3 2
C_AE1/4
1
30
A
start relay
2
1
C_BV1/2
C_BS1/2
battery
C_DK/18
C_DJ/18
front
exhaust air
val ve
2
14
2
10
6
16
8
4
12
15
7
3
11
5
9
13
1
bu-gr
2
1
or-wh
2
1
C_AH1/2
C_AK1/2
2
main relay
fuel pump relay
C_AR/3
2
C_AM/3
1
re-wh
re-wh
start auxillary relay
1
2
1
rear
C_CL/2
injector´s
front
C_CL1/2
3
2nd throttle
position sensor
rear
brake switch
re-gn
4
br
or
3
4
1
or-wh
ye-bl
3
2
bu-bl
2
4
re-bl
re-bl
3
ye-wh
re-wh
11.11..2004
rear
ye-bu
bu
bl
ye
ye-wh
bl-or
gn
wh
wh-re
bl-br
gn-wh
bu-wh
pi
bl-gr
bl-wh
or
C_CK/2
1
1
C_AS/2
1 2
C_AS1/2
2
1
1
2
3
2
bu-wh
4
4
2
bl
water temperature sensor
C_AP1/6
atmospheric pressure sensor
re-wh
bl
5
5
C_AI3/2
bu
ye-bl
gn-gr
bl
bl
or
ye-or
bl
bl
2
6
6
bl
ye-wh
br
7
7
or
bl
re-bl
bl
3
bl
8
8
or
or-bl
pi
re-wh
9
9
ye-br
bu
re-bl
pu
bl
re-wh
bu-re
bl
bl
re-wh
bl
10
10
bl
11
11
or
re-bl
bu
13
13
ignition switch
1
3
2
1
4
2
gn-wh 3
br
wh
pu
wh
bl
br
2
1
C_AR1/3
C_AM1/3
2
C_CE2/4
1
3
main throttle
position sensor
C_CA2/4
4
1
2
C_BI/2
2nd throttle
stepper motor
3
ye
light switch
pu
start/stop switch
C_CP/16
4
1
C_AE/4
G
3
1/8
left raer flasher
licence plate lamp
right rear flasher
2
C_AI2/2
1
2
C_AI1/2
1
2
C_AI/2
1
diode
generator
diode
3
U
diode
re-wh
regulator-rectifier
ISC
stepper motor
2
gn
gn
re-wh
or-wh
or
bl
pu
manifold pressure sensor rear
gn
gn
14
14
seat surveillance
for optional alarm system
wh-br
ignition coil`s
15
15
bl
16
bl
17
bl
18
17
wh-pu
gn-wh
C_CQ/16
ye-wh
C_AF2/4
or
gn-bl
C_AF1/4
C_AF/4
bu
bl-wh
E
or
ye-wh
re
bu
bl
ye-bu
ye-wh
pu
bu-bl
gn-gr
re-br
re-gn
ye-re
ye
ye-wh
ye-bl
re
br
ye-or
ye
pi
gn-bl
ye-br
gr
ye-re
C
bl
Antenna
12
12
wh-or
wh-bl
re-bl
bl-or
gn
wh
wh-re
bl-br
gn-wh
bu-wh
pi
bl-gr
bl-wh
wh-pu
wh-br
U
bu
18
re-bl
gn-re
bu-bl
C_AU/2
C_AU/2
bu
re
wh
gr
C_AZ/4
C_BK/4
C_AJ/3
C_BG/3
wh
gn
bl
gr
16
or
or
pu
ye
high/low beam switch horn switch
flasher switch
13-38
rear light/brakelight
3rd gear
neutral switch 2nd gear
br
Repair manual KTM LC8
Art.-No. 3.206.056-E
13-39
Aditional instruments (roadbook;...)
Battery
Clutch switch
Cooling fan
Diode
Flasher relay
Flasher switch
Front brake switch
Fuel level sensor
Fuel pump
Fuel pump relay
Fuse box
Gear sensor
Generator
Headlight
High / low beam switch
Horn
Horn switch
Ignition coil
Ignition switch
Left front flasher
Left rear flasher
Licence plate lamp
Light switch
Multi-func.-digital-speedometer
Oil pressure sensor
Pick up
Rear brake switch
Rear light / brakelight
Regulator-rectifier
Right front flasher
Right rear flasher
Sidestand switch
Speed sensor
Start auxillary relay
Start relay
Start/stop switch
Starter motor
Tachometer
Temperature sensor
Temperature switch
Fuel pump module
Power relais
Roll over sensor
Diagnostic connector
Water temperature sensor
Air temperature sensor
Front hego sensor
Rear hego sensor
Manifold pressure sensor front
Manifold pressure sensor rear
Atmospheric pressure sensor
ECU
Main throttle position sensor
2nd throttle position sensor
Exhaust air valve
Front injector
Rear injector
2nd throttle stepper motor
ISC stepper motor
Cable colours
bl: black
ye: yellow
bu: blue
gn: green
re: red
wh: white
br: brown
or: orange
pi: pink
gr: grey
pu: purple
Externe Instrumente
Batterie
Kupplungsschalter
Lüftermotor
Diode
Blinkerrelais
Blinkerschalter
vorderer Bremslichtschalter
Benzinstandgeber
Kraftstoffpumpe
Kraftstoffpumpenrelais
Sicherungskasten
Gangerkennung
Generator
Scheinwerfer
Auf-Abblendschalter
Hupe
Hornschalter
Zündspule
Zündschloss
linker vorderer Blinker
linker hinterer Blinker
Kennzeichenbeleuchtung
Lichtschalter
Multifunktionsdigitaltacho
Öldruckschalter
Impulsgeber
hinterer Bremslichtschalter
hinteres Begrenzungslicht / Bremslicht
Regelgleichrichter
rechter vorderer Blinker
Rechter hinterer Blinker
Seitenständerschalter
Geschwindigkeitssensor
Starterhilfsrelais
Startrelais
Start / stop schalter
Startermotor
Drehzahlmesser
Temperatursensor
Temperaturschalter
Kraftstoffpumpengruppe
Hauptrelais
Neigungssensor
Diagnosestecker
Wassertemperatursensor
Lufttemperatursensor
Lambdasensor vorne
Lambdasensor hinten
Ansaugkrümmerdrucksensor vorne
Ansaugkrümmerdrucksensor hinten
Außenluftdrucksensor
Steuergerät
Drosselklappenpositions-Hauptsensor
2. Drosselklappenpositionssensor
Ventil für Sekundär-Luft-System
vorderes Einspritzventil
hinteres Einspritzventil
2. Drosselklappenstellmotor
Leerlaufstellmotor
NOTE to the connector designations:
The connector designations are comprised of letters and numbers - e.g.: C_AA1/20
– The 1st position C stands for connector (connector).
– The 2nd and 3rd positions AA stand for the connector type.
– The 4th position numbers the same type of connector if the connector is used for
different applications.
– The 5th and 6th positions 20 specify the number of pins in the connector, in this
case 20 poles. The 5th position is not required for connectors with less than 10
pins.
30
A
M
starter motor
battery
start relay
re-wh
re-wh
re-wh
br
1
2
3
4
3
generator
G
U
regulator-rectifier
17
5
4
3
2
1
5
4
3
2
1
bl
bl
re-wh
start auxillary relay
7
6
8
8
6
9
7
10
9
11
10
12
13
14
15
16
11
C_DK/18
12
13
14
15
C_DJ/18
C_BI/2
C_AU/2
990 Super Duke 2005/06
re-wh
re-wh
gn
gn
17
16
C_AF2/4
ye-wh
1
2
7
1
clutch switch
C_AR2/3
C_AT1/2
3 th
2
1
N
3
C_AI1/2
diode
neutral switch (N) / 2nd gear / 3rd gear
2 nd
C_AM2/3
2
o r a nge 1
C_AL1/2
1
2
C_AI2/2
diode
1
ignition 9
fuse
10 A
ignition switch
re-bl
b a tte ry g e n e ra to r s ta rte r
3
4
2
1
8
C_BB/9
C_AB/9
start/stop switch
re-bl
18
or-bl
18
ye-wh
Dummy plug
ye
C o nnector for
optional
alarm system
ye-wh
re-wh
gn-bl
30
A
2/8
31
p a ge 6
30
13-40
C_AE1/4
F
E
D
1
-A 1
C _ D K /1 8
3
4
6
7
8
9
8
9
A L A -P 1
/3 . C 5
/3 . D 2
/3 . D 6
C onne c tor for
optiona l
a la rm s ys te m
pow-X 9
/3 . B 2
tlig-H 4
plig-S 2
10 11 12 13 14 15 16 17 18
a la rm s ys te m dummy plug
5
/3 . D 6
/3 . D 6
fla R -X 2 00
fla L -X 2 00
/2 . D 4
/3 . D 4
78,79
1
C _ A I /2
2
1
2
3
10A
-F 1
-S 2 0
s eat
s urve illa nc e
C _ B V /2
C _ B S /2
2
-X 4 3
990 S U P E R D U K E (R ) 07
74
C _ D J /1 8
-A 2 -P 1
lig-S 7
7
116
-X31
9
6
2
5
1
4
126,127
-X32
11bl
10 bl
85,86
C
3
9
-X33
12 bl
8
65,66
2
-X34
13 bl
65
1
-X35
14 bl
83,54
76,166
203
48
C _ A B /9
66
C _ B B /9
-X36
15 bl
3
6
-X37
16 bl
2
5
-X38
17 bl
51
B
73
4
-X39
Antenna
19 bl
75
55
1
-X40
20 bl
128,129
67,68
C _ B H /6
-X41
21bl
56
26
73
C _ A P /6
2
1
70
2
2
2
10A
1
10A
1
1
2
1
3
C _ E B /4
-K 5
129
AC C
B a t-P 1
/3 . A 6
3
1
fue l
pump
M
C _ A R /3
C _ A M/3
2
-M2
/3 . B 2
4
4
5
1
3
-K 3
-M1
s ta rte r
motor
C _ E B /4
207
light re la y
2
ba tte ry, ge ne ra tor, s ta rte r
fue l pump re la y
4
2
10A
10A
1
71
-F 5 -F 6 -F 7 -F 8
224
-X 1 s plic e
1,2
diode
52
-V 2
25
25
s ta rt/s top s witc h
M
-K 1
4
2
4
C _ A E /4
3
1
C _ E B /4
3
6
2
30
A
s ta rt re la y
powe r re la y
114
-S 2
68
ignition s witc h
23,24
74,75
6
5
69
113
113
114
fuel-A2
5
4
208
A
-S 1
4
1
-G 1
-K 4
1
72
128
67
3
53
51
for optional alarm system
39,35
-X42
22 bl
2
115
2
4
G N D -X 2
ba tte ry
4
/2 . C 3
24
23
7
2
1
2
1
3
7
gn
-K 2
1 15 , 1 16
C _ E B /4
7
s ta rt a ux illa ry
re la y
5
1
213
C_BI/2
Art.-No. 3.206.056-E
224
130
/2.E5
182
/3.A5
lig-X4
27
/2.B5
STR-A3
200
C_AU/2
7,8
Repair manual KTM LC8
-A 1 -X 1 0
G
ge ne ra tor
/2 . C 1
3
-N 1
/2 . C 2
611. 11. 075 . 10 0
610. 41. 012. 000
8
ma in ha rne s s -
G N D -X 8
53, 55, 56, 207, 208, 213
re -wh
U
re gula tor-re c tifie r
re -wh
gn
gn
8
3 P.
P a ge : 1
F
E
D
C
B
A
13-41
F
E
D
C
B
1
-A1
73
1
4
C_DK/18
C_DJ/18
6
-A2-P1
5
3
2
3
1
2
74
-X31 116
-X32 126,127
11bl
6
7
2
3
lig-S7
4
8
9
ALA-P1
8
7
6
pow-X9
/3.B2
tlig-H4
plig-S2
/3.C5
/3.D2
/3.D6
2
3
990 Superduke
2007-2008
Connector for
optional
alarm system
9 10 11 12 13 14 15 16 17 18
/3.D4
5
78,79
alarm system dummy plug
5
4
/3.D6
/3.D6
flaR-X200
flaL-X200
/2.D4
1
9
C_AB/9
1
C_AI/2
66
C_BB/9
2
-X43
67,68
C_AP/6
-X35
14 bl
85,86
48
-X36
8
-X33
12 bl
65
15 bl
83,54
65,66
51
-X37
16 bl
C_BV/2
C_BS/2
1
51
-S20
seat
surveillance
2
10A
-F1
2
1
10A
2
1
2
1
3
C_EB/4
-K5
129
ACC
Bat-P1
/3.A6
3
1
fuel
pump
M
C_AR/3
C_AM/3
2
-M2
/3.B2
-X1 splice
4
4
5
1
3
-K3
-M1
starter
motor
C_EB/4
207
1,2
light relay
2
battery, generator, starter
fuel pump relay
4
10A
2
1
10A
2
1
10A
2
1
70
-F5 -F6 -F7 -F8
69
113
113
26
73
71
114
C_BH/6
25
25
diode
224
-V2
23,24
74,75
start/stop switch
M
-K1
4
2
4
C_AE/4
3
1
C_EB/4
3
6
2
30
A
start relay
power relay
114
-S2
68
ignition switch
5
6
4
208
75
-X40 55
-X41 56
21bl
5
-K4
1
-G1
4 GND-X2
battery
4
/2.C3
24
23
7
2
1
1
2
3
7
gn
-K2
115,116
C_AU/2
C_EB/4
7
start auxillary
relay
5
A
-S1
4
1
3
2
115
72
67
128
fuel-A2
C_BI/2
2
213
76,166
-X39
203
-X38
17 bl
128,129
Antenna
19 bl
9
-X34
13 bl
10 bl
224
130
/2.E5
182
/3.A5
lig-X4
27
/2.B5
STR-A3
200
53
52
for optional alarm system
39,35
-X42
22 bl
20 bl
7,8
1
-A1-X10
G
generator
/2.C1
3
-N1
/2.C2
8
611.11.075.100
610.41.012.000
main harness -
GND-X8
53,55,56,207,208,213
re-wh
re-wh
U
regulator-rectifier
gn
gn
8
3 P.
Page:1
F
E
D
C
B
A
13-42
F
E
D
C
B
1
-A1
73
1
4
C_DK/18
C_DJ/18
6
-A2-P1
5
3
6
7
2
3
lig-S7
4
8
9
ALA-P1
8
7
6
pow-X9
/3.B2
tlig-H4
plig-S2
/3.C5
/3.D2
/3.D6
Connector for
optional
alarm system
9 10 11 12 13 14 15 16 17 18
/3.D4
5
alarm system dummy plug
5
4
/3.D6
/3.D6
flaR-X200
flaL-X200
/2.D4
1
C_AB/9
C_BB/9
78,79
1
C_AI/2
2
-X43
2
3
C_BV/2
C_BS/2
1
51
-S20
seat
surveillance
2
10A
-F1
2
1
10A
2
1
2
1
3
C_EB/4
-K5
129
ACC
Bat-P1
/3.A6
3
1
fuel
pump
M
C_AR/3
C_AM/3
2
-M2
/3.B2
4
4
5
1
3
-K3
-M1
starter
motor
C_EB/4
207
light relay
2
battery, generator, starter
fuel pump relay
4
10A
2
1
10A
2
1
10A
2
1
70
-F5 -F6 -F7 -F8
-X1 splice
1,2
diode
66
990 Superduke R 2008
2
3
1
2
9
C_AP/6
74
-X31 116
-X32 126,127
11bl
67,68
C_BH/6
-X35
14 bl
85,86
48
-X36
8
-X33
12 bl
65
15 bl
83,54
65,66
51
-X37
16 bl
69
113
113
26
73
71
114
-V2
25
25
start/stop switch
M
-K1
4
2
4
C_AE/4
3
1
C_EB/4
3
6
2
30
A
start relay
power relay
114
-S2
23,24
74,75
6
68
ignition switch
224
75
-X40 55
-X41 56
21bl
5
5
A
-S1
4
4
208
3
1
-G1
-K4
1
2
4 GND-X2
battery
4
/2.C3
24
23
7
2
1
2
1
3
7
gn
-K2
115,116
C_AU/2
C_EB/4
7
start auxillary
relay
5
1
2
115
72
67
128
fuel-A2
C_BI/2
Art.-No. 3.206.056-E
213
76,166
-X39
203
-X38
17 bl
128,129
Antenna
19 bl
9
-X34
13 bl
10 bl
224
130
/2.E5
182
/3.A5
lig-X4
27
/2.B5
STR-A3
200
53
52
for optional alarm system
39,35
-X42
22 bl
20 bl
7,8
Repair manual KTM LC8
-A1-X10
G
generator
/2.C1
3
-N1
/2.C2
8
611.11.175.000
610.41.012.000
main harness -
GND-X8
53,55,56,207,208,213
re-wh
re-wh
U
regulator-rectifier
gn
gn
8
3 P.
Page:1
F
E
D
C
B
A
13-43
31
4
5
bu
s en so r
rollover
C_AP2/6
bl
ye-re
6
wh-bl
br
3
L
L
rear
t°
2
1
p
C_BZ1/3
3
2
1
C_AX/2
2
3
p
C_BZ/3
1
1
2
C_CM/2
t°
1
2
pu
3
bl
p
C_BZ2/3
2
3
4
2
1
or
br
or-wh
g n -re
15
fuse
10 A
7
1
3
2
C_AR3/3
C_AM3/3
sidestand switch
P i c k up
C_AT/2
C_AL/2
1
ye-wh
manifold pressure sensor rear
atmospheric pressure sensor
990 Super Duke 2005/06
lambda sensor´s
f r ont
t°
C_CE/4
2
C_CE1/4
4 1
bl
C_CA/4
3
wh-or
C_CA1/4
re-gn
or
4 1 2
bl
t°
ye-bl
gn-gr
bu
2
bl
bl
1
water temperature sensor
manifold pressure sensor front
ye
re-br
or
re
C_AL1/2
bu
air temperature sensor
bu
main relay
ye-bu
C_AT1/2
bu-bl
bl
bl
bl
re-wh
2
C_AI/2
1
7 13 14 3 24 23 11 12 4
C_AO/26
2 10 9 22 6 20 25 26 19 15 18 17
1
8
ECU
2
1
9 14 16 34
C_AM2/3
1
6
ye-re 4
br
or
C_AR2/3
I
page 6/9
H
6/8
G
6 /8
C
6/8
gr
ye-br 2
gn-bl 3
N
3th
2nd
C_AP1/6
C_AF/4
pi
1
33 15 13 23 11 3
C_BH1/6
bl
bl
or
6 29 26
C_CO/34
7 21 12 4 22 5
7
2
ye-or
diagnostic
c o nn e c to r
C_AB/9
C_BB/9
start/stop switch
or
ignition switch
bu
3rd gear
diode
or
bu-gr
br
br
bu-wh
wh
bu-br
18
1
f r ont
C_AS1/2
2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
or
C_DJ/18
rear
C_AS/2
2
C_DK/18
14
10
4
8
11
bl-wh 9
o r 13
b l - gr 5
pi
bu-wh 3
gn-wh 7
b l - b r 15
wh-re 12
wh
gn
b l - o r 16
bu
ye
2
exhaust
air valve
C_CK/2
1
2
ye-wh 6
bl
9
C_CQ/16
C_AR/3
1
f r ont
C_CL1/2
2
bu-bl
or
pu
ye
bu
re
gr
gr
wh
gn
pu
bu
2
3
2
5
4
1
rear
C_CL/2
2
C_AR1/3
1
4
2 1
C_CA2/4
C_CE2/4
fuel pumprelay
3
2
C_AM4/3
C_AR4/3
2
M
fuel pump
4
1 3
C_AE/4
1
B
6/8
Q
f u e l pum p unit
3/8
ISC
stepper motor
s e c on d
throttle stepper motor
3
3
3
2
TPS
C_AM1/3
C_AF1/4
1
13
fuse
10 A
2nd TPS
C_AM/3
1
g n - re
bl
wh
airbox harness
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
fuse
10 A
1
or
C_CP/16
610.41.012.000
1
wh-pu
ignition switch
alarm system dummy plug
re-bl
or
ignition coil
bu
or-bl
or
Connector for
optional
alarm system
wh-br
bu
re-wh
or
wh
ye
br
gr
bu-bl
wh
clutch switch
E
gn
pu
re-wh
or-wh
bu
bl
ye-bu
ye-wh
pu
bu-bl
gn-gr
re-br
re-gn
ye-re
ye
ye-wh
ye-bl
re
br
ye-or
ye
pi
gn-bl
ye-br
gr
ye-re
C
bu
2nd gear neutral switch
wh-or
wh-bl
re-bl
bl-or
gn
wh
wh-re
bl-br
gn-wh
bu-wh
pi
bl-gr
bl-wh
wh-pu
wh-br
U
gn-re
or
injector´s
bu-bl
bl
or
bu-gr
ye-bl
pu
bu-bl
or-wh
bl
re
gr
br-re
31
30
fuel level sensor
30
13-44
F
E
D
2
-X 1 1 s plic e
-B 2
6
4
1
rollove r
s e n s or - B 7
-B 1 5
fue -P 1
1
he go s e ns or
re a r
t°
-B 1 6
1
p
C _ D P /3
2
164
-B 4
a tmos phe ric
pre s s ure
s e ns or
3
/3 . B 2
1
C _ A R /3
C _ A M/3
137
3
1
p
C _ D P /3
2
C _ A R /2
-X 1 0 1
205, 209, 210
205, 206
1
p
C _ D P /3
2
-B 1 8
G N D -P 1
1 68 , 2 04
ma nifold
pre s s ure
s e ns o r r e a r
-B 1 7
3
2
2
3
49
3
/1 . D 2
/3 . B 2
2
pic k up
C _ A T /2
C _ A L /2
1
1
ECU
4
2
3
C _ A O /2 6
4
/3 . D 4
G N D -S 5
-A 2
-L 3
-A 2 -P 1
G N D -H 4
214, 215, 33
/3 . B 6
49, 176, 177, 178
1 56, 157, 158
-X 1 3 s plic e
-X 1 7 s plic e
206, 223
-X 2 s plic e
G N D -X 2 4
1
C _ A M/2
53, 55, 56, 207, 208, 211, 212, 213
ma nifold
pre s s ure
s e ns or front
3
/1 . C 7
-X 8 s plic e
2
990 S U P E R D U K E (R ) 07
he go s e ns or
front
t°
L
2
C _ C E /4
3
C _ C E /4
4
C _ C A /4
1
C _ C A /4
2
G N D -X 8
2
1 42, 146, 147, 150 , 152, 15 5, 159, 1 62, 225
-X 6 s plic e
3
L
/1 . E 8
1 32, 13 3, 134, 135, 13 6, 137
4
1 64 , 1 65
-X 7 s plic e
C _ A P /6
5
138
1 33, 139, 50, 141
-X 1 5 s plic e
1 20, 12 1, 122, 123, 12 4, 125
1 17, 11 8, 119 , 120
-X 1 0 s plic e
160
1 15 , 1 16
161
50
-X 1 6 s plic e
a ir te mp.
s e n s or
t°
C _ C M/2
1
225
159
-A 1 -X 1 0
165
C
145
/1 . D 7
149
B
147
1
140
117
/3 . B 2
154
te m-P 1
152
211
122
212
153
175
148
156
134
C _ A L /2
151
201
121
174
C _ A T /2
136
3
139
155
150
173
162
2
167
1
132
C _ E C /3
5
6
7
8
175
173
171
154
172
149
170
7
6
5
4
3
2
1
C _ D O /8
C _ D N /8
1
2
3
4
C _ C O /3 4
5
8
6
214
7
8
215
5
/3 . B 2
6
2. 1
2. 2
2. 3
2. 4
2. 5
2. 6
2. 7
2. 8
2. 9
2. 10
2. 11
2 . 12
2. 13
2. 14
2. 15
2. 16
-A 2 -P 1
3 20
3 16
3 11
3 09
3 07
3 06
3 03
ignition
c oil
front
1
7
-L 1
T A C -P 1
2
1
C _ C L /2
inje c tion
re a r
2
1
C _ A R /3
C _ A M/3
ignition
c oil
re a r
1
-L 2
/3 . B 2
C _ A S /2
2
-Y 3
3 00, 30 1, 302
C _ C L /2
1
-B 1 3
1
-M5
M I L -P 1
1
2
1
3
4
3
8
ma in ha rne s s 611. 11. 075 . 20 0
610. 41. 012. 000
307
1
M
-M6
C _ C E /4
C _ C A /4
2
319
3 P.
P a ge : 2
2 nd throttle
s te ppe r motor
C _ C K /2
/3 . B 2
2
-Y 1
-Y 2
purge va lve
e x ha us t a ir
va lve
2
2
1
C _ A M/3
C _ A R /3
C _ A E /4
3
M
8
2 nd throttle
pos ition s e ns or
IS C
s te ppe r motor
4
-B 1 4
C _ D U /2
-Y 4
3
ma in throttle
pos ition s e ns or
3 16, 317, 318
7
inje c tion
front
2
3 13
/3 . B 2
C _ A S /2
2
313, 314, 315
3 19
3 12
3 10
3 08
3 05
3 04
3 00
-X 3 1 0 s plic e
-X 3 0 9 s plic e
/3 . F 2
-X 3 0 8 s plic e
1 93
1 25
1 94
1 86
1 89
1 85
1 84
C L U -A 2
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34
1 95
1 35
1 87
1 67
1 88
1 70
1 83
1 46
1 81
1 79, 180, 181
-X 1 8 s plic e
/3 . A 8
1 7 8 N e u-P 1
G N D -X 3
E C U
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
174
N
176
3 th
168
-A 3 S ta rte r I nte rloc k U nit
141
126
2 nd
169
-S 1 1
151
-B 1 1
145
STR-A3
/1.E7
140
R
138
-B 3
163
6
179
200
158
157
186
222
184
180
185
169
187
4
189
1
191
C _ A P /6
188
-X 5 0
192
t°
190
-B 9 t°
148
A
194
ge a r pos ition
s witc h
193
s ide s ta nd
s e ns or
196
fue l le ve l
s e ns or
195
C _ B H /6
199
6
197
5
198
dia gnos tic
c onne c tor
142
-X307
C_CQ/16
4
160
9 8 7 6 5 4 3 2 1
16 15 14 13 12 11 10
153
wa te r te mp.
s e n s or
171
309
3
163
317
2
172
305
199
fuel-A2
182
306
177
/1.E4
183
314
196
304
C_CP/16
123
310
1
190
Art.-No. 3.206.056-E
118
315
197
320
124
301
198
308
318
312
119
303
302
311
Repair manual KTM LC8
F
E
D
C
B
A
13-45
F
E
D
2
159
-B2
6
4
1
rollover
sensor -B7
C_AP/6
5
-B15
t°
1
t°
fue-P1
-B16
1
p
C_DP/3
2
164
1
-B4
atmospheric
pressure
sensor
3
/3.B2
137
3
1
p
C_DP/3
2
2
C_AR/2
205,209,210
3
3
205,206
1
p
C_DP/3
2
-B18
GND-P1
168,204
manifold
pressure
sensor rear
-B17
-X101
2
49
3
/1.D2
/3.B2
2
pick up
C_AT/2
C_AL/2
1
/3.D4
GND-S5
-A2
1
4
/3.B6
2 3 4 5
C_AO/26
ECU
-L3
-A2-P1
GND-H4
214,215,33
49,176,177,178
156,157,158
-X13 splice
-X17 splice
206,223
-X2 splice
GND-X2 4
1
C_AM/2
53,55,56,207,208,211,212,213
manifold
pressure
sensor front
3
/1.C7
-X8 splice
2
990 Superduke
2007-2008
hego sensor
rear
L
2
C_CE/4
3
C_CE/4
4
C_CA/4
1
C_CA/4
2
GND-X8
2
142,146,147,150,152,155,159,162,225
-X6 splice
hego sensor
front
L
3
4
164,165
-X7 splice
/1.E8
132,133,134,135,136,137
-X15 splice
133,139,50,141
-X16 splice
120,121,122,123,124,125
117,118,119,120
-X10 splice
115,116
-X11 splice
-A1-X10
air temp.
sensor
t°
C_CM/2
1
225
160
50
1
140
161
138
C
145
/1.D7
165
B
154
/3.B2
152
175
148
212
153
211
122
201
121
tem-P1
149
156
134
117
147
155
150
C_AR/3
151
C_AM/3
163
C_AT/2
136
174
C_AL/2
139
173
162
3
167
2
138
1
132
C_EC/3
6
7
175
173
171
154
172
149
170
7
6
5
4
3
2
1
C_DO/8
C_DN/8
1
2 3 4 5
C_CO/34
8
6
214
7
5
/3.B2
/3.A8
178 Neu-P1
GND-X3
195
135
187
167
188
170
183
146
181
6
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
2.11
2.12
2.13
2.14
2.15
2.16
-A2-P1
320
316
311
309
307
306
303
ignition
coil
front
1
7
-L1
TAC-P1
2
1
C_CL/2
injection
rear
2
1
C_AR/3
C_AM/3
ignition
coil
rear
-L2
1
/3.B2
C_AS/2
2
-Y3
300,301,302
C_CL/2
1
-B13
1
-M5
MIL-P1
1
1
3
4
3
main harness -
8
611.11.075.100
610.41.012.000
307
1
M
-M6
C_CE/4
C_CA/4
2
319
3 P.
Page:2
2nd throttle
stepper motor
C_CK/2
/3.B2
2
2
-Y1
-Y2
purge valve
exhaust air
valve
2
2
1
C_AM/3
C_AR/3
C_AE/4
3
M
8
2nd throttle
position sensor
ISC
stepper motor
4
-B14
C_DU/2
-Y4
3
main throttle
position sensor
316,317,318
7
injection
front
2
313
/3.B2
C_AS/2
2
313,314,315
319
312
310
308
305
304
300
-X310 splice
-X309 splice
/3.F2
-X308 splice
193
125
194
186
189
185
184
CLU-A2
179,180,181
-X18 splice
8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34
215
E C U
8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
174
N
126
3th
151
2nd
168
-A3 Starter Interlock Unit
187
R
169
-S11
145
STR-A3
/1.E7
140
-B11
163
-B3
171
6
141
176
200
179
157
158
222
186
180
184
169
185
4
189
1
191
C_AP/6
188
A
192
C_BH/6
190
-X50
194
t°
196
-B9 t°
148
6
195
5
193
4
197
gear position
switch
198
3
199
sidestand
sensor
142
-X307
C_CQ/16
2
160
9 87 65 43 2 1
16 15 14 13 12 11 10
153
fuel level
sensor
172
305
199
fuel-A2
182
314
196
306
177
/1.E4
183
309
C_CP/16
123
310
diagnostic
connector
190
1
118
304
317
315
197
320
124
301
198
308
318
312
119
303
302
311
water temp.
sensor
F
E
D
C
B
A
13-46
F
E
D
2
159
-B2
6
4
1
rollover
sensor -B7
C_AP/6
5
-B15
t°
1
t°
fue-P1
-B16
1
p
C_DP/3
2
164
-B4
atmospheric
pressure
sensor
3
/3.B2
1
C_AR/3
C_AM/3
137
3
1
p
C_DP/3
2
C_AR/2
205,209,210
3
205,206
1
p
C_DP/3
2
-B18
GND-P1
168,204
manifold
pressure
sensor rear
-B17
-X101
2
3
2
49
3
/1.D2
/3.B2
2
pick up
C_AT/2
C_AL/2
1
1
4
/3.B6
2 3 4 5
C_AO/26
ECU
-L3
/3.D4
GND-S5
-A2
-A2-P1
GND-H4
214,215,33
49,176,177,178
156,157,158
-X13 splice
-X17 splice
206,223
-X2 splice
GND-X2 4
1
C_AM/2
53,55,56,207,208,211,212,213
manifold
pressure
sensor front
3
/1.C7
-X8 splice
2
990 Superduke R 2008
hego sensor
rear
L
2
C_CE/4
3
C_CA/4
4
C_CE/4
1
C_CA/4
2
GND-X8
2
142,146,147,150,152,155,159,162,225
-X6 splice
hego sensor
front
L
3
4
164,165
-X7 splice
/1.E8
132,133,134,135,136,137
-X15 splice
133,139,50,141
-X16 splice
120,121,122,124,125,123
117,120,119,118
-X10 splice
115,116
-X11 splice
-A1-X10
air temp.
sensor
t°
C_CM/2
1
225
160
50
1
140
161
138
C
145
/1.D7
165
B
154
/3.B2
152
175
148
212
153
211
122
201
121
tem-P1
149
156
134
117
147
155
150
C_AT/2
139
174
C_AL/2
151
3
136
2
167
1
132
C_EC/3
6
7
175
173
171
154
172
149
170
7
6
5
4
3
2
1
C_DO/8
C_DN/8
1
2 3 4 5
C_CO/34
8
6
214
7
5
/3.B2
/3.A8
178 Neu-P1
GND-X3
195
135
187
167
188
170
183
146
181
6
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
2.11
2.12
2.13
2.14
2.15
2.16
-A2-P1
313,314,315
319
312
310
308
305
304
300
320
316
311
309
307
306
303
2
TAC-P1
1
7
ignition coil
front
C_EP/3
C_EO/3
3
/3.B2
2
1
C_CL/2
3
3
4
-B14
1
M
/3.B2
3
2
C_EO/3
1
ignition coil
rear
C_EP/3
-L5
MIL-P1
/3.B2
1
C_DU/2
1
2
M
-M6
C_CE/4
C_CA/4
2nd throttle
stepper motor
3
4
3
2
1
C_CK/2
8
611.11.175.000
610.41.012.000
main harness -
3 P.
Page:2
-Y1
-Y2
purge valve
exhaust air
valve
2
2
-M5
1
C_AM/3
C_AR/3
C_AE/4
2
8
2nd throttle
position sensor
ISC
-Y4
stepper motor
injection
rear
2
1
C_AR/3
C_AM/3
-L6
-Y3
300,301,302
C_CL/2
1
-B13
main throttle
position sensor
316,317,318
7
injection
front
2
313
-X310 splice
-X309 splice
/3.F2
-X308 splice
193
125
194
186
189
185
184
CLU-A2
179,180,181
-X18 splice
8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34
215
E C U
8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
174
N
126
3th
168
-A3 Starter Interlock Unit
151
2nd
169
-S11
145
STR-A3
/1.E7
140
-B11
187
R
138
-B3
163
6
141
176
200
179
157
158
222
186
180
184
169
185
4
189
1
191
C_AP/6
188
-X50
192
t°
190
-B9 t°
148
A
194
gear position
switch
193
sidestand
sensor
196
fuel level
sensor
195
C_BH/6
197
6
198
5
199
diagnostic
connector
142
C_CP/16
-X307
C_CQ/16
water temp.
sensor
163
317
315
4
160
9 87 65 43 2 1
16 15 14 13 12 11 10
153
173
162
309
3
171
301
2
172
306
199
fuel-A2
182
320
177
/1.E4
183
305
197
314
196
304
1
123
308
Art.-No. 3.206.056-E
118
303
302
311
318
312
198
307
119
310
124
319
190
Repair manual KTM LC8
F
E
D
C
B
A
13-47
31
E
6/8
D
6/8
1
or-bl
orange 0.5
C_AH2/2
4
7
C_AD/12
C_BD/12
1
flasher switch
G
3
1
2
3
right front flasher
br
left front flasher
brown 0.5
990 Super Duke
rear flasher light`s
C_BK/4
C_AZ/4
1
7
C_CC/12
C_CI/12
pu
2
bl
1
diode
C_AI3/2
2
8
horn switch
C_BD/12
C_AD/12
3
yellow-blue 0.5
r ed 1
horn
12
4
re
2
1
2
temperature switch
C_AV/2
1
fuse
10 A
ignition switch
br
turn signal , horn , fan
11
fuse
10 A
ignition switch
br
3
gr
flasher relay
bl-wh
red-white 1
br-bl
red-white 1
M
31
30
4/8
cooling fan
C_BI1/2
30
13-48
C_AU1/2
13-49
ignition switch
r-w r-w r-w
flasher switch
o
ON
y-r
r
cable
harness
or
gr
br
cable
switch
gn- bu- bupi
br re bl
brpi
pu
bl
TURN L
OFF
TURN R
LOCKED
OFF
Art.-No. 3.206.056-E
start switch
cable
harness
or
cable
switch
blbu
blor
bl
START
horn switch
cable
harness
gr
br
cable
switch
pi
brpi
HORN
unpushed
OFF
stop switch
cable
harness
Repair manual KTM LC8
cable
switch
RUN
STOP
or
-bl
or
bl
bl
- bu
clutch switch
switch
position
pulled
unpulled
ye
br
31
head light flasher
HI
LO
low/high beam switch
2
1
0
light switch
C_BD/12
C_AD/12
2
6
5
9
3
F
6/8
white 0.5
fuse
10 A
ignition switch
C_BB/9
11
3
r ed 1
front
yellow-brown 1
blue 1
g r een 1
brake switch
r ear
brake switch
990 Super Duke
9
6
10
yellow-red 1
yellow 1
ignition switch
fuse
15 A
C_AB/9
2
yellow 1
yellow-brown 1
licence plate lamp
green-white 0.5
1
3
1
2
white 0.5
C_BG/3
C_AJ/3
6
2
rear light/brakelight
C_BC/6
C_AC/6
light-brake system
1
2
blue-yellow
2
1
head light
3
4
brown 1
C_AH/2
C_AH1/2
C_AK/2
C_AK1/2
30
brown 0.5
5/8
31
30
13-50
13-51
light switch
ignition switch
r-w r-w r-w
o
y-r
r
ON
cable
harness
yewh ye
br
cable
switch
yewh wh
reye
LIGHT OFF
OFF
P. LIGHT
LOCKED
LIGHT
high/low beam switch
Art.-No. 3.206.056-E
brake switch
cable
harness
gn- yewh bu
cable
harness
bu
gn
yebr
cable
switch
bl
cable
switch
wh ye
gnre
bl
pushed
LO
unpushed
HI
Repair manual KTM LC8
passing light
cable
harness
ye
cable
switch
gnwh
bl
P. HORN
OFF
bu
31
bu-br
white 0.5
F
5/8
7
1 6
2 9
p
C _ AY /1
C_BJ/1
oil pressure sensor
gree n-gr ey 0.5
green-black 0.5
990 Super Duke 2005/06
D E
4/8
violett 0.5
I G H B
3/8
3 5
blue 0.5
red-white 0.5
speed sensor
v
black-brown 0.5
C_AM5/3
C_AR5/3
2
or.ye
black-orange 0.5
1 3
4
black 0.5
8 12
re-br
C_AA/20
10 15 16
brown 0.5
14
ignition switch
11
r ed 1
A
2/8
3 2
C_AG/3
C_BE/3
1
n
tachometer
instruments-tachometer
fuse
10 A
3
ye-bu
6
brown 0.5
fuse
10 A
ye-bu
multi-func.-digital-speedometer
blue-white 0.5
30
C
3/8
6/8
31
30
13-52
F
E
D
C
B
1
C_ED/32
-S8
-H7
-B12 t°
C_AH/2
94
109
110
96
95
1 10
97
98
1 11
92
93
89
90
99
1 01
1 00
1 05
1 03
1 08
1 02
1 81
221
91
107
81
82
166
78
220
1 11
1 12
108,112
-X304 splice
C L U -A 2
1 81
203
1 61
178
1 92
204
203
T A C -P 1
te m-P 1
N e u-P 1
M I L -P 1
G N D -P 1
A L A -P 1
46,54
-S 7
7 8, 79
201
plig-S 2
219
80, 81
127
129
84, 85
1 91
1 61
178
2 02
1 92
204
129
1 91
B a t-P 1
127
-A 2 -P 1
8
C _ A D /1 2
1
38
HI
79
2
4
P . light
7
/1 . B 2
2
5
L
3
R
48
lig-S 7
be a m horn fla s he r s witc h
LO
C _ B D /1 2
80
990 S U P E R D U K E (R ) 07
/2 . A 6
/1 . B 3
1 04, 10 5, 106 , 109
87, 89
92
104
93
94, 95
96
90, 91
97
98
99
100
1 01
1 02
103
/2 . D 3
/1 . E 3
/2 . B 2
/2 . D 7
/1 . D 5
/2 . E 7
/2 . B 1
/2 . B 6
/2 . E 8
201
fue -P 1
46
6
84
3
C _ B J /1
2
G N D -H 4
1
C _ A Y /1
1
209, 210, 223
fla s he r
re la y
G -K 6
C _ A H /2
lig-X 4
1
C _ A I /2
diode
2
27
-X 4 s plic e
-X 1 2 s plic e
/1 . E 6
-V 1
1
1
10A
2
10A
10A
2
-F 2 -F 3 -F 4
2
1
4
5
1
C _ B L /2
M
/1 . B 5
/1 . E 2
/1 . E 2
G N D -S 5
AC C
2
33
130
t
C _ A V /2
1
32
1
-S 5
7 6, 166
85, 86
83, 54
tlig-H 4
fla L -X 2 00
fla R -X 2 00
6
37
te mpe ra ture
s witc h
-X 9 s plic e
/1 . B 3
34, 39, 40
-M3
/2 . C 4
C _ C D /2
2
1
c ooling
fa n
2
10A
-F 9
6
1
a ditiona l c urre nt
c onne c tion A C C 1
-X 2 1 C _ C R /1 -X 2 2 C _ C R /1
-H 5
216
5
ins trume nts -ta c home te r
9
/2 . C 4
1
2. 1
C _ E H /1
-X 5 1
-S 2 1
28
47
2
1
2
29
34
front brake
switch
flasher
right front
ambient temp.
sensor
multi-func.-digital-speedometer
headlight
C_CW/2
31 32
20 21 22 23 24 25 26 27 28 29 30
17 18 19
10 11 12 13 14 15 16
9
8
7
6
5
4
3
2
1
-P1
G
-B8
speed
sensor
high
low
C_CX/2
C_CX/2
6
5
4
3
3
C_AM/3
C_AK/2
2
87
107
-X303 splice
3
2
1
2.1 2.2 2.3
2.10 2.11 2.12
2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9
C_BE/3
C_CI/4
2
1
9 10 11 12
8
7
6
5
4
3
2
C_AG/3
-X302
C_CC/4
-X301
1
218
106
42
82
209
83
86
77
ho r n
1
1
7
1
2
a ditiona l c urre nt
c onne c tion A C C 2
-X 2 3 C _ C R /1 -X 2 4 C _ C R /1
60
59
58
57
1
C _ A H /2
C _ A K /2
2
re a r bra k e
s witc h
7
-X 2 0 1 s plic e
-S 6
131
oil pre s s ure
s witc h
43
217
4
40
30
31
64
131
32
41
3
47,48
2
1
C_AC/6
C_CW/2
C_BC/6
C_CX/2
pos.
clutch
switch
flasher
left front
-H201
-H6
-S9
45
2
2.4 2.3 2.2 2.1
1
C_AT/2
36
31
pow-X9 35,39
/1.E3
C_CW/2
2
1
C_AL/2
35
A
1
6 2 , 63 , 6 1
/2 . B 6
2 22
210
63
59
62
57
7 6, 77
216, 217, 218, 219, 220, 221, 223
-X 3 s plic e
3 6, 42
61
58
G N D -X 3
8
611. 11. 075 . 10 0
610. 41. 012. 000
8
ma in ha rne s s -
C_DI/2
C_AR/3
Art.-No. 3.206.056-E
C_CV/4
C_CX/2
C_CX/2
321
202
44
1
2
1
45
43,41
44
38
-X200
C_BY/4
37
1
2
3
4
1
2
1
C_CW/2
C_BG/3
1
2
-H8
-H4
-H9
2
3
1
2
C_AJ/3
C_CW/2
flasher
right rear
rear light/
brake light
-H200
licence plate
lamp
3 P.
P a ge : 3
flasher
left rear
Repair manual KTM LC8
F
E
D
C
B
A
13-53
F
E
D
C
1
C_AH/2
94
109
110
96
95
110
97
98
111
92
93
89
90
99
101
100
105
103
322
108
102
181
221
91
107
81
82
166
78
220
111
112
87
108,112
-X304 splice
/2.A6
103
C_BE/3
107
181
191
161
178
192
204
203
TAC-P1
tem-P1
Neu-P1
MIL-P1
GND-P1
ALA-P1
-S7
plig-S2
78,79
46,54
219
201
80,81
127
129
84,85
191
161
178
202
192
204
129
Bat-P1
203
127
-A2-P1
1
38
8
HI
2
2
80
4
P.light
7
/1.B2
5
lig-S7
L
beam horn flasher switch
LO
C_BD/12
C_AD/12
79
-X303 splice
3
990 Superduke
2007-2008
CLU-A2
/1.B3
104,106,109,105,322
87,89
92
104
93
94,95
96
90,91
97
98
99
100
101
102
/2.D3
/1.E3
/2.B2
/2.D7
/1.D5
/2.E7
/2.B1
/2.B6
/2.E8
201
R
48
46
6
84
3
2
1
2
GND-H4
1
flasher
relay
G -K6
C_AH/2
209,210,223
1
C_AI/2
diode
2
27
-X4 splice
-X12 splice
lig-X4
-V1
10A
2
10A
10A
2
1
-F2 -F3 -F4
1
2
1
4
5
10A
-F9
1
C_BL/2
M
/1.B5
/1.E2
/1.E2
GND-S5
ACC
6
33
t
C_AV/2
1
32
-S5
76,166
85,86
83,54
tlig-H4
flaL-X200
flaR-X200
6
37
temperature
switch
2
130
1
1
-H5
216
aditional current
connection ACC1
-X21 C_CR/1 -X22 C_CR/1
-X9 splice
/1.B3
34,39,40
-M3
/2.C4
C_CD/2
2
1
cooling
fan
2
instruments-tachometer
9
/2.C4
1
C_AY/1
C_BJ/1
2.1
1
/1.E6
29
47
P
C_EH/1
-X51
-S21
28
34
front brake
switch
flasher
right front
ambient temp.
sensor
-S8
-H7
-B12 t°
-P1
B
C_ED/32
C_AM/3
multi-func.-digital-speedometer
headlight
G
-B8
speed
sensor
high
C_CW/2
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
9
8
7
6
5
4
3
2
1
3
C_CX/2
C_CX/2
6
5
4
2
321
202
30
31
64
131
32
C_AK/2
3
C_AG/3
2
C_AL/2
2.1 2.2 2.3
2.10 2.11 2.12
2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9
3
1
9 10 11 12
8
7
6
5
4
3
2
-X302
C_CC/4
-X301
1
218
C_CI/4
fue-P1
82
209
83
86
77
horn
1
7
2
60
59
58
57
1
C_AH/2
C_AK/2
P
2
7
-X201 splice
-S6
rear brake
switch
1
1
aditional current
connection ACC2
-X23 C_CR/1 -X24 C_CR/1
131
oil pressure
switch
40
2
2
low
pos.
flasher
left front
clutch
switch
43
31
pow-X9 35,39
/1.E3
217
5
2.4 2.3 2.2 2.1
1
1
36
106
42
47,48
2
1
C_AC/6
C_CW/2
C_BC/6
C_CX/2
35
4
62,63,61
/2.B6
222
210
63
59
62
57
76,77
216,217,218,219,220,221,223
-X3 splice
36,42
61
58
GND-X3
8
8
611.11.075.100
610.41.012.000
main harness -
C_DI/2
41
3
45
2
C_CV/4
C_CX/2
C_CX/2
C_CW/2
2
1
C_AT/2
-H201
-H6
-S9
44
1
2
1
45
43,41
44
38
-X200
C_BY/4
37
1
2
3
4
1
2
1
C_CW/2
C_BG/3
1
2
-H8
-H4
-H9
2
3
1
2
C_AJ/3
C_CW/2
flasher
right rear
rear light/
brake light
-H200
licence plate
lamp
3 P.
Page:3
flasher
left rear
A
1
F
E
D
C
B
A
13-54
C_AR/3
F
E
D
C
1
C_AH/2
94
109
110
96
95
110
97
98
111
92
93
89
90
99
101
100
105
103
322
108
102
181
221
91
107
81
82
166
78
220
111
112
87
108,112
-X304 splice
107
CLU-A2
181
191
161
178
192
204
203
TAC-P1
tem-P1
Neu-P1
MIL-P1
GND-P1
ALA-P1
-S7
plig-S2
78,79
46,54
219
201
80,81
127
129
84,85
191
161
178
202
192
204
129
-A2-P1
203
201
127
fue-P1
Bat-P1
1
38
8
HI
79
2
4
P.light
7
/1.B2
2
5
lig-S7
L
beam horn flasher switch
LO
C_BD/12
C_AD/12
80
-X303 splice
3
990 Superduke R 2008
/2.A6
/1.B3
104,106,109,105,322
87,89
92
104
93
94,95
96
90,91
97
98
99
100
101
102
103
/2.D3
/1.E3
/2.B2
/2.D7
/1.D5
/2.E7
/2.B1
/2.B6
/2.E8
2
1
R
48
46
6
84
3
2
GND-H4
1
flasher
relay
G -K6
C_AH/2
209,210,223
1
C_AI/2
diode
2
27
-X4 splice
-X12 splice
lig-X4
-V1
10A
10A
2
1
10A
2
1
-F2 -F3 -F4
2
1
4
5
10A
-F9
1
C_BL/2
M
/1.B5
/1.E2
/1.E2
GND-S5
ACC
2
33
130
1
t
C_AV/2
-S5
1
76,166
85,86
83,54
tlig-H4
flaL-X200
flaR-X200
6
37
temperature
switch
-X9 splice
/1.B3
34,39,40
-M3
/2.C4
C_CD/2
2
1
cooling
fan
2
instruments-tachometer
9
/2.C4
1
C_AY/1
C_BJ/1
2.1
1
/1.E6
6
32
-H5
1
aditional current
connection ACC1
-X21 C_CR/1 -X22 C_CR/1
216
5
29
47
P
C_EH/1
-X51
-S21
28
34
front brake
switch
flasher
right front
ambient temp.
sensor
-S8
-H7
-B12 t°
-P1
B
C_ED/32
C_AM/3
multi-func.-digital-speedometer
headlight
G
-B8
speed
sensor
high
C_CW/2
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
9
8
7
6
5
4
3
2
1
3
C_CX/2
C_CX/2
6
5
4
3
2
30
31
64
131
32
C_AK/2
3
C_AG/3
2
C_AL/2
2.1 2.2 2.3
2.10 2.11 2.12
2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9
C_BE/3
C_CI/4
1
9 10 11 12
8
7
6
5
4
3
2
-X302
C_CC/4
-X301
1
218
321
202
106
42
82
209
83
86
77
horn
1
7
2
60
59
58
57
1
C_AH/2
C_AK/2
P
2
7
-X201 splice
-S6
rear brake
switch
1
1
aditional current
connection ACC2
-X23 C_CR/1 -X24 C_CR/1
131
oil pressure
switch
40
2
2
low
pos.
flasher
left front
clutch
switch
43
31
pow-X9 35,39
/1.E3
217
4
2.4 2.3 2.2 2.1
1
1
36
41
3
47,48
2
45
2
1
C_AC/6
C_CW/2
C_BC/6
C_CX/2
35
A
1
62,63,61
/2.B6
222
210
63
59
62
57
76,77
216,217,218,219,220,221,223
-X3 splice
36,42
61
58
GND-X3
8
8
611.11.175.000
610.41.012.000
main harness -
C_DI/2
C_AR/3
Art.-No. 3.206.056-E
C_CV/4
C_CX/2
C_CX/2
C_CW/2
2
1
C_AT/2
-H201
-H6
-S9
44
1
2
1
45
43,41
44
38
-X200
C_BY/4
37
1
2
3
4
1
2
1
C_CW/2
C_BG/3
1
2
-H8
-H4
-H9
2
3
1
2
C_AJ/3
C_CW/2
flasher
right rear
rear light/
brake light
-H200
licence plate
lamp
3 P.
Page:3
flasher
left rear
Repair manual KTM LC8
F
E
D
C
B
A
13-55
headlight
tachometer
LED red
Alarm sytem
M
ECU
ECU
battery
temperature switch
30
A
990 Super Duke
clutch switch
right-left front flasher
multi-func.-digital-speedometer
horn switch
s t a r t er m o t o r
start relay
bl
brown
bl
alarmsystem
ground connection
regulator
7/8
rear light/brakelight
rear flasher
main relay
diagnostic connector
fu e l pump module
accesory
13-56
rear brake switch
tachometer
front brake switch
flasher relay
or
multi-func.-digital-speedometer
I
3/8
990 Super Duke
speed sensor
ye-bu
bl -o r
start/stop switch
A
A
9
5
6
7
A
A
A
A
A
8
10 11 12 13 14 15 16
A
4
10 10 10 10 10
3
fuel pump relay
re-bl
30
A
bl
bl
battery
positive connection
fan
fuse box
2
10 15 10
1
ignition switch
ye-bu
horn
ye
bl-wh
light switch
M
ye-bl
high/low beam switch
s t a r t er mo t o r
ye
re
s t a r t relay
gn-re
Art.-No. 3.206.056-E
re-wh
Repair manual KTM LC8
power relay
alarm system
accesory
regulator
8/8
13-57
13-58
Connector AA
20-pole 1
11 1
Multifunctional digital
speedometer
Behind
the
functional
speedometer
multidigital
20 10
1
Connector AB
9-pole 2
1
3
9
Start/stop/light switch
Behind
mask
the
headlight
3
2
Connector AC
6-pole 3
Front lighting
1
4
3
6
Behind
mask
the
headlight
Connector AD
12-pole 4
1
3
7
12
Turn signal, horn, high
beam switch
Behind
mask
the
Connector AE
4-pole 5
1
4 2
4
headlight
Idle speed control motor
5
On the throttle body
Connector AE1
4-pole 6
Start relay/main fuse
On the left next to the
battery case
6
13-59
Connector AF
4-pole 1
Main relay
1
Under the seat
42
3
Connector AF1
4-pole 2
Fuel pump relay
Under the seat
Connector AF2
4-pole 3
Auxiliary starter relay
Art.-No. 3.206.056-E
Under the seat
Connector AG
3-pole 4
Speedometer
1
3
Behind
mask
the
5
headlight
4
Connector AH
2-pole 5
Repair manual KTM LC8
Front brake light switch
1 2
Behind
mask
the
headlight
6
Connector AH1
2-pole 6
Rear brake light switch
In front of the fuse box
Connector AH2
2-pole 7
Turn signal relay
Behind
mask
the
headlight
7
2
1
13-60
Connector AI, AI1, AI2
2-pole 1
2
1
Diodes
Under the seat
Connector AI3
2-pole 2
1
Diode
Behind
mask
the
headlight
2
Connector AJ
3-pole 3
1
2
3
Rear lighting
Under the seat
3
Connector AK
2-pole 4
4
Front brake light switch
1
2
Behind
mask
the
headlight
Connector AK1
2-pole 5
Rear brake light switch
In front of the fuse box
5
Connector AL
2-pole 6
Pick up
1
2
In front of the 2nd
cylinder over the battery
case
6
Connector AL1
2-pole 7
Clutch switch
Behind
mask
the
headlight
7
13-61
Connector AM
3-pole 1
1
3
Throttle sensor for the
2nd throttle
1
On the throttle body
2
Connector AM1
3-pole 2
Throttle sensor
On the throttle body
Connector AM2
3-pole 3
Gear sensor
Art.-No. 3.206.056-E
On the left next to the
battery case
3
4
Connector AM3
3-pole 4
Side stand
On the left next to the
battery case
Connector AM4
3-pole 5
Fuel pump
Repair manual KTM LC8
In front of the fuse box
5
Connector AM5
3-pole 6
Speed sensor
Behind
mask
the
headlight
6
13-62
Connector AO
26-pole 1
20
14
8
1
ECU
Behind
head
26
19
13
the
steering
7
1
Connector AP
6-pole 2
Ignition switch
1
3
6
Behind
head
the
steering
2
Connector AP1
6-pole 3
Diagnosis connector
Behind the fuse box
3
Connector AP2
6-pole 4
Rollover sensor
Behind
mask
the
headlight
4
Connector AR
3-pole 5
3
1
Throttle sensor for the
2nd throttle
On the throttle body
Connector AR1
3-pole 6
Throttle sensor
On the throttle body
6
5
13-63
Connector AR2
3-pole 1
3
1
2
Gear sensor
On the left next to the
battery case
1
Connector AR3
3-pole 2
Side stand
On the left next to the
battery case
Connector AR4
3-pole 3
Fuel pump
Art.-No. 3.206.056-E
In front of the fuse box
Connector AR5
3-pole 4
Speed sensor
Behind
mask
the
3
4
headlight
Repair manual KTM LC8
Connector AS
2-pole 5
1
2
Rear ignition coil
Behind the air filter box
5
Connector AS1
2-pole 6
Front ignition coil
Behind the radiator
6
13-64
Connector AT
2-pole 1
Pick up
1
2
In front of the 2nd
cylinder over the battery
case
1
Connector AT1
2-pole 2
2
Clutch switch
Behind
mask
the
headlight
Connector AU
2-pole 3
Regulator output
21
On the left next to the
battery case
3
Connector AU1
2-pole 4
4
Fan motor
Behind the radiator
Connector AV
2-pole 5
1
2
Temperature switch
On the right side of the
radiator
5
Connector AX
2-pole 6
1
2
Coolant temperature
sensor
On the left between the
cylinders
6
13-65
Connector AY
1-pole 1
Oil pressure switch
1
On the outer left side of
the frame
Connector AZ
4-pole 2
1
2
3
4
Rear blinker
Under the seat
2
Art.-No. 3.206.056-E
Connector BB
9-pole 3
1
3
7
9
Start/stop/light switch
Behind
mask
the
headlight
4
3
Connector BC
6-pole 4
Front lighting
1
3
6
Behind
mask
the
headlight
Connector BD
12-pole 5
Repair manual KTM LC8
1
10
3
Turn signal, horn, high
beam switch
Behind
mask
the
headlight
12
5
13-66
Connector BE
3-pole 1
1
3
Speedometer
Behind
mask
the
headlight
1
Connector BG
3-pole 2
Rear lighting
1
2
3
Under the seat
2
Connector BH
6-pole 3
Ignition switch
1
3
6
Behind
head
the
3
steering
Connector BH1
6-pole 4
Diagnosis connector
Behind the fuse box
4
Connector BI
2-pole 5
Regulator output
2 1
On the left next to the
battery case
5
Connector BI1
2-pole 6
Fan motor
Behind the radiator
6
13-67
Connector BJ
1-pole 1
Oil pressure switch
1
On the outer left side of
the frame
1
Connector BK
4-pole 2
1
1
2
3
Rear turn signal
Under the seat
3
2
Connector BS
2-pole
Alarm LED
1
2
Instrument panel (only
for alarm systems)
Connector BS1
Art.-No. 3.206.056-E
Seat switch 3
Under the seat (only for
alarm systems)
Connector BV
2-pole 4
Alarm-LED
2
1
Instrument panel (only
for alarm systems)
Connector BV1
Seat switch
Repair manual KTM LC8
Under the seat (only for
alarm systems)
4
13-68
Connector BZ
3-pole 1
Pressure sensor for rear
cylinder
1
On the left side of the
frame
3
1
Connector BZ1
3-pole 2
Manifold air pressure
sensor for front cylinder
On the right side of the
frame
Connector BZ2
3-pole 3
2
3
Ambiant air pressure
sensor
Behind
mask
the
headlight
Connector CA
4-pole 4
Rear lambda probe
1
2
3
4
On the left next to the
battery case
4
Connector CA1
4-pole 5
Front lambda probe
On the right side of the
frame
5
Connector CA2
4-pole 6
Control motor for the
2nd throttle
On the throttle body
6
13-69
Connector CC
12-pole 1
Front wiring harness
3
1
Behind
mask
7
the
1
headlight
12
Connector CE
4-pole 2
2
Rear lambda probe
1
2
3
4
On the left next to the
battery case
Connector CE1
4-pole 3
Front lambda probe
3
Art.-No. 3.206.056-E
On the right side of the
frame
Connector CE2
4-pole 4
Control motor for 2nd
throttle
On the throttle body
4
Connector CI
12-pole 5
Repair manual KTM LC8
1
3
Front wiring harness
Behind
mask
7
the
5
headlight
12
Connector CK
2-pole 6
2 1
Secondary air system
valve
Behind the air filter box
6
13-70
Connector CL
2-pole 1
Rear injection valve
1
2
On the throttle body
1
Connector CL1
2-pole 2
Front injection valve
On the throttle body
2
Connector CM
2-pole 3
Air temperature sensor
2
3
On the top of the air
filter box
1
Connector CO
34-pole 4
26
18
10
1
ECU
Behind the steering head
34
25
17
9
4
Connector CP
16-pole 5
4
1
Wiring harness EFI
On the right side of the
frame
6
16
5
Connector CQ
16-pole 6
1
4
Wiring harness EFI
On the right side of the
frame
16
13-71
Connector CR
1-pole 1
Connector for
attachments:
Kl 15 (ignition)
Kl 31 (ground)
1
Under the seat next to
the fuse box
Connector DJ
20-pole 2
2 1
18 17 16 15 14 13
6 5
Connector for the alarm
system control unit
Under the seat
Connector DK
20-pole 3
Art.-No. 3.206.056-E
Repair manual KTM LC8
13 14 15 16 17 18
1 2 3 4 5 6
Connector
(without alarm system)
Under the seat
3
2
front
brake switch
C_AA/20
v
C_BV/2
speed sensor
clutch switch
2
7
2
1
bu-re
left front flasher
br
gn-gr
re-br
br-bl
ye-bl
gn-bl
re-wh
ye-or
bl
pu
bu
ye-bu
1
2
gn-wh
1
2
1
3
2
br
bl
pu
br
br
br
br
1
1
C_BL1/2
M
cooling fan
M
cooling fan
C_CD1/2
2
C_BL/2
C_CD/2
2
temperature switch
C_AV/2
1
2
wh
C_AY/1
C_BJ/1
oil pressure sensor
p
7 1
2 4
9
6
C_AD/12
C_BD/12
ye
5
950 SUPERMOTO 2005/06/07
wh
gn
bu
br
bl-or
ye-or
2
1
br-bl
3
ye
C_CR/1
bl-or
C_AM3/3
br
15
1
19
6
10
9
3
4
5
right front flasher
C_AH1/2
LED red
for optional alarm system
C_BS/2
16
C_AL3/2
multi-func.-digital-speedometer
headlight
positionlight
C_AK1/2
C_AR3/2
1
C_DI/2
C_BW/3
2
C_AT3/2
C_CR1/1
bl-wh
ye-re
bl-wh
head light flascher
gn-bl
ye
gn-re
gn-br
gn
bu-bl
bu
bu-re
ye-br
or
gn-gr
pu
bl
ye-bu
2
1
1
3
2
N
t°
C_AX/2
1
1
8
C_AB/9
C_BB/9
2
2 7
front
C_AS1/2
1
2
r ear
0
9
1
C_AW1/2
2
3
C_AR2/3
C_AM2/3
2
ye-br
3 16 10
br-wh
C_AO/26
20
2
sidestand switch
3
6
EPC 1 EPC 2
C_AW/2
2 1
1
C_AS/2
2
1
temperature sensor
horn
G
flasher relay
neutral switch 2nd gear
3rd gear
2nd
C_AR1/3
C_AM1/3
1
3th
fuel lev el sensor
Q
C_AL1/2
C_AT1/2
2
gr
ye-bu
2
1
bl-or
bl-or
or
wiring diagramm
3
8
pi
gr
br-pi
br
br
br-bl
br-bl
re-br
gr
C_CR2/1
br-bl
C_AI3/2
ye-br
br
C_AH3/2
br
bl-gn
or
or-wh
bl-wh
or
bl-bu
or
or
1
pi
bl
re
wh
wh
re-ye
ye
ye-wh
re-gn
aditional
current
connection
ACC1
2
pu-wh
C_CR3/1
C_BC/6
5
C_AC/6
13
ignition switch
or
or
A
A
A
A
8
re-wh
re-wh
9
2
1
A
2
1
br
re
fuse box
temperature switch
for carburetorheating
C_AK2/2
C_AH2/2
1
A
A
10 10 10 10 10
A
10 15 10
16
7 19 11 4 25 26 18
M
2 1
C_AT2/2
C_AL2/2
fuel pump
heaterelement heaterelement
M
2
Pick up
C_AT/2
C_AL/2
1
2 1
TPS
C_AR/3
C_AM/3
3
bu
C_AL4/2
C_AT4/2
main harness - 625.11.075.000
8
1
4
starter motor
4
1
30
A
3 2
C_AF3/4
re-bu
aditional
current
connection
ACC2
ye-bu
diode
or
bl
re-gn
or
ye
br
or
re-bl
re-wh
ye-bu
ye
or-bl
bu
bl-wh
bl
br
re-wh
re-bl
re-wh
ye-wh
br-bl
or
pu-wh
ye-bu
re-ye
br-bl
bu-bl
ye-wh
ye-br
bu
or
re-gn
ye
ye-bl
br-wh
ignition coil
bu-gr
re
gr
E
pi
bl-or
ye-or
C
bl
start relay
re-wh
light switch
re-wh
start/stop switch
br
high/low beam switch horn switch
flasher switch
ye-bu
or-wh
ye
or
re-bu
ye-bl
br
bu- gr
bu-bl
or
re
re-bu
re-wh
4
1
2
3
4
3
2
1
3
2
4
1
C_DJ/18
C_DK/18
20.02 .2005
alarm system
dummy plug
Connector for
optional
alarm system
battery
re-wh
bl
re-wh
re-wh
r ear
brake switch
start auxillary relay
fuel pump relay
light system relay
gn
1
br
bl
wh
gn-wh
br
wh
pu
2
1
C_BV1/2
C_BS1/2
seat surv eillance
for optional alarm system
2
3
3
2
1
4
2
1
3
or-wh
C_AF2/4
C_AF1/4
C_AF/4
2
1
3
or
ye-or
gn-wh
or-wh
4
4
bl
5
5
pu
C_AK/2
G
C_AI2/2
1/8
left rear flasher
licence plate lamp
right rear flasher
1 2
2
C_AI1/2
1
2
C_AI/2
1
diode
diode
generator
diode
3
U
regulator-rectifier
ye
ye-bl
U
C_AH/2
bu-re
6
6
bl
7
7
bl
8
8
bl
1
1
bl
9
9
bl
10
Antenna
11
11
10
bl
12
12
bl
13
13
bl
bl
C_AU/2
br
14
14
ye
or
C_AZ/4
C_BK/4
gn-bl
C_AJ/3
C_BG/3
C_BI/2
br
15
15
bl
16
16
bl
17
17
bl
bl
2
2
ye-bu
bl
18
18
ye
pi
re-bl
13-72
rear light/brakelight
front
brake switch
speed sensor
C_AK1/2
C_AH1/2
1
2
left front flasher
re-wh
br
gn-gr
re-br
br-bl
ye-bl
gn-bl
ye-bu
1
2
gn-wh
bl
2
1
pu
br
ye-re
1
C_BJ/1
C_AY/1
2
1
bl-or
ye-bu
2
1
M
cooling fan
cooling fan
3th
3
N
8 1
t°
C_AX/2
1
C_BB/9
C_AB/9
2
2 7
rear
9
1
2
EPC 1 EPC 2
2
3
C_AR2/3
C_AM2/3
sidestand switch
3
6
wh
C_AW1/2
2 1
C_AW/2
1
1
C_AS/2
2
wiring diagramm
front
C_AS1/2
1
2
temperature sensor
horn
G
flasher relay
neutral switch 2nd gear
3rd gear
2nd
C_AM1/3
M
1
fuel level sensor
Q
C_AL1/2
C_AR1/3
C_BL1/2
2
1
C_AT1/2
2
C_AI3/2
ye-bu
gr
bl-or
or
1
3
8
C_CD1/2
oil pressure sensor
p
7 1
2 4
9
6
C_AD/12
C_BD/12
5
2
C_BL/2
C_CD/2
2
temperature switch
C_AV/2
1
2
950 Supermoto (R) 2007
950 Supermoto R 2008
br
wh
gn
br
bu
2
br
br
1
3
br
bl-or
ye-or
2
1
br-bl
3
ye
C_CR/1
ye-or
bl
pu
bu
bu-re
C_AL3/2
C_CR1/1
bl-or
C_AM3/3
br
2
7
15
1
19
6
10
9
3
4
5
right front flasher
clutch switch
LED red
for optional alarm system
C_BV/2
16
C_AT3/2
multi-func.-digital-speedometer
headlight
positionlight
v
C_AA/20
C_BS/2
C_AR3/2
1
2
C_BW/3
C_DI/2
wh
bl-wh
br
bl-wh
ye
br-bl
C_CR2/1
br-bl
head light flascher
gn-bl
ye
gn-re
gn-br
gn
bu
bu-re
pu
gn-gr
ye-br
or
bu-bl
bl
br-pi
gr
pi
br
bl-bu
or
br-bl
bl-wh
or
aditional
current
connection
ACC1
re-gn
wh
re-ye
ye
0
2
ye-br
3 16 10
br-wh
C_AO/26
20
5
C_AC/6
C_BC/6
8
1
4
bl-or
C_CR3/1
gr
br-bl
re-br
ye-br
br
C_AH3/2
br
bl-gn
diode
or
13
ignition switch
2
9
1
A
10
2
1
br
re
fuse box
temperature switch
for carburetorheating
C_AK2/2
C_AH2/2
1
A
A
10
re-wh
7 19 11 4 25 26 18
8
A
A
10 10
A
10
A
15 10
A
10
16
re-wh
or-bl
br
or
or-wh
or
1
2 1
C_AT2/2
C_AL2/2
M
starter motor
M
2
2 1
TPS
C_AR/3
C_AM/3
3
bu
C_AL4/2
C_AT4/2
main harness - 625.11.075.100
Pick up
C_AT/2
C_AL/2
1
heaterelement heaterelement
fuel pump
4
3 2
C_AF3/4
1
30
A
start relay
br
light switch
or
or
bu
ye-wh
ye-br
bu
re-gn
pi
pu-wh
or
ye
ye-bu
bl
re-gn
or
ye-bu
or
re-bl
re-wh
re-wh
ye-wh
br
re-wh
ye-bl
bl-wh
ye
re-bl
re-ye
br-bl
bu-bl
ye-bu
ye-wh
bl
re
or
pu-wh
bl
ye-bl
br-wh
ignition coil
pi
bu-gr
re
gr
E
2
re-wh
start/stop switch
re-wh
high/low beam switch horn switch
flasher switch
re-bu
re-bl
4
br
ye-bu
or-wh
ye
or
re-bu
ye-bl
4
1
2
3
4
3
2
1
bu-gr
bu-bl
2
3
or
re
br
re-wh 1
C_DJ/18
C_DK/18
6.6.2007
alarm system
dummy plug
Connector for
optional
alarm system
battery
re-wh
re-wh
rear
brake switch
start auxillary relay
fuel pump relay
light system relay
gn
1
2
wh
gn-wh
br
2
1
C_BV1/2
C_BS1/2
wh
pu
br
bl
seat surveillance
for optional alarm system
3
aditional
current
connection
ACC2
4
4
ye
C_AF2/4
C_AF1/4
5
5
Art.-No. 3.206.056-E
or
ye-or
bl
bl
bl
2
1
1
C_AK/2
C_AF/4
2
1
bl
6
6
ye-or
C
re-wh
or-wh
bl
3
gn-wh
or-wh
C_AH/2
bu-re
7
7
bl
U
pu
bl
bl
2
bl
8
8
bl
9
9
Antenna
10
bl
11
11
bl
bl
C_AU/2
3
2
1
4
2
1
3
13
13
G
1/8
left rear flasher
licence plate lamp
right rear flasher
2
C_AI2/2
1
2
C_AI1/2
1
2
C_AI/2
1
diode
diode
generator
diode
3
U
regulator-rectifier
ye
C_AZ/4
or
C_BK/4
C_AJ/3
gn-bl
ye
C_BG/3
C_BI/2
br
14
14
br
15
15
bl
16
16
bl
17
17
bl
12
12
10
ye-bu
bl
18
18
ye
pi
Repair manual KTM LC8
13-73
rear light/brakelight
13-74
Aditional instruments (roadbook;...)
Battery
Carb heater (Carburator heater element)
Clutch switch
Cooling fan
Diode
Flasher relay
Flasher switch
Front brake switch
Fuel level sensor
Fuel pump
Fuel pump relay
Fuse box
Gear sensor
Generator
Headlight
High / low beam switch
Horn
Horn switch
Ignition coil
Ignition switch
Left front flasher
Left rear flasher
Licence plate lamp
Light switch
Multi-func.-digital-speedometer
Neutral switch
Oil pressure sensor
Pick up
Rear brake switch
Rear light / brakelight
Regulator-rectifier
Right front flasher
Right rear flasher
Sidestand switch
Speed sensor
Start auxillary relay
Start relay
Start/stop switch
Starter motor
Temperature sensor
Temperature switch
Throttle position sensor (TPS)
Externe Instrumente
Batterie
Vergaserheizelement
Kupplungsschalter
Lüftermotor
Diode
Blinkerrelais
Blinkerschalter
vorderer Bremslichtschalter
Benzinstandgeber
Kraftstoffpumpe
Kraftstoffpumpenrelais
Sicherungskasten
Gangerkennung
Generator
Scheinwerfer
Auf-Abblendschalter
Hupe
Hornschalter
Zündspule
Zündschloss
linker vorderer Blinker
linker hinterer Blinker
Kennzeichenbeleuchtung
Lichtschalter
Multifunktionsdigitaltacho
Leerlaufschalter
Öldruckschalter
Impulsgeber
hinterer Bremslichtschalter
hinteres Begrenzungslicht / Bremslicht
Regelgleichrichter
rechter vorderer Blinker
Rechter hinterer Blinker
Seitenständerschalter
Geschwindigkeitssensor
Starterhilfsrelais
Startrelais
Start / stop schalter
Startermotor
Temperatursensor
Temperaturschalter
Vergaserpotentiometer
NOTE to the connector designations:
The connector designations are comprised of letters and numbers - e.g.: C_AA1/20
– The 1st position C stands for connector (connector).
– The 2nd and 3rd positions AA stand for the connector type.
– The 4th position numbers the same type of connector if the connector is used for different
applications.
– The 5th and 6th positions 20 specify the number of pins in the connector, in this case 20
poles. The 5th position is not required for connectors with less than 10 pins.
Cable colours
bl: black
ye: yellow
bu: blue
gn: green
re: red
wh: white
br: brown
or: orange
pi: pink
gr: grey
pu: purple
30
A
M
battery
start relay
red-white 1
br
brown 0.5
4
red-white 1
1
A
H-p age 6/8
f us e bo x
F-pag e6/8
U
red-white 1
red-white 1
red-white 1
red-blue 0.5
starter motor
8
7
8
7
2
1
2
1
bl
bl
start auxillary relay
4
3
4
3
6
9
9
5
10
10
6
11
5
12
13
14
15
16
17
18
1
4
2
3
light system relay
3
2
4
1
Connector for
optional
alarm system
11
C_DK/18
12
13
14
15
16
17
18
Dummy plug
C_DJ/18
950 SUPERMOTO 2005/06/07
E-page3/8
D-pa ge 4/8
C-page 5/8
B-page 5/8
A-page3/8
9
G
generator
G- pag e 6 /8
A
A
A
A
A
A
8
3
10 10 10 10 1 0
A
1 0 15 1 0
16
or
or-bl
re-bu
re-wh
ye
3
or
ye-bu
re-wh
or
bl-wh
re-wh
re-wh
ye-bl
2
re-wh
re-wh
C_AR1/3
3th
1
2
C_AI1/2
diode
5
N
3
green-black 0.5
pink 0.5
neutral switch (N) / 2nd gear / 3rd gear
2nd
C _AM1/3
C_AL3/2
1
C_AT3/2
2
2
1
C_AI2/2
C_AI/2
4
C_AC/6
C_BC/6
ignition switch
diode
1
2
diode
clutch switch
yellow 0.5
7
re-wh
start system
2
1
8
C_BB/9
C_AB/9
start/stop switch
orange-white 0.5
regulator-rectifier
or
re-bl
1
re-wh
re-ye
orange 0.5
orange-white 0.5
30
C_AF/4
C_AF2/4
red 0.5
Art.-No. 3.206.056-E
brown 0.5
Repair manual KTM LC8
2/8
31
I-page6/8
J-page3/8
30
13-75
red-white 1
C_AF3/4
30
A
M
battery
start relay
re-bu
br
4
red-white 1
3
brown 0.5
re-wh
or
red-white 1
3
9
H-page6/8
fuse box
F-page6/8
U
red-white 1
red-white 1
red-white 1
red-blue 0.5
starter motor
bl
bl
start auxillary relay
1
5
1
6
5
6
2
7
7
2
8
8
4
9
9
3
10
10
4
11
3
12
13
14
15
16
17
18
11
C_DK/18
12
13
14
15
16
17
C_DJ/18
3
2
4
1
1
4
2
3
light system relay
950 Supermoto (R) 2007
950 Supermoto R 2008
E-page3/8
D-page 4/8
1
A
G
generator
G-page 6/8
A
A
A
A
10 10 10 10 10
A
C-page 5/8
B-page 5/8
A-page3/8
8
A
A
10 15 10
16
or
ye-bu
re-wh
or
bl-wh
2
re-wh
ye-bl
1
re-wh
re-wh
8
C_AR1/3
3th
1
2
C_AI1/2
diode
5
N
3
green-black 0.5
pink 0.5
neutral switch (N) / 2nd gear / 3rd gear
2nd
C_AM1/3
C_AT3/2
1
C_AL3/2
2
2
1
C_AI2/2
C_AI/2
4
C_AC/6
C_BC/6
ignition switch
diode
1
2
diode
clutch switch
yellow 0.5
7
re-wh
start system
2
1
C_BB/9
C_AB/9
start/stop switch
orange 0.5
18
brown 0.5
regulator-rectifier
or
re-bl
re-wh
ye
or-bl
re-wh
re-ye
red 0.5
Connector for
optional
alarm system
brown 0.5
Dummy plug
C_AF/4
C_AF2/4
orange-white 0.5
orange-white 0.5
30
2/8
31
I-page6/8
J-page3/8
30
13-76
red-white 1
C_AF3/4
alarm system dummy plug
31
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
or 0.5
1
K-page6/8
yellow-orange 0.5
C_DJ/18
Connector for
optional
alarm system
C_DK/18
C_BB/9
C_AB/9
2
red 0.5
yellow-blue 0.5
violet-white 0.5
brown-white 0.5
red-green 0.5
brown 0.5
2
3
20
7
yellow-brown 0.5
black-brown 0.5
18
grey 0.5
pink 0.5
8
10
blue-grey 0.5
1
16
yellow 0.5
black 0.5
11
4
blue 0.5
yellow-white 0.5
2
1
2
1
front
C_AS1/2
2
2
1
1
rear
C_AS/2
2
3th
2
N
J-page2/8
ECU
neutral switch (N) / 2nd gear / 3rd gear
2nd
C_AM1/3
C_AR1/3
2
3
C_AR2/3
1
C_AM2/3
C_AR/3
1
sidestand switch
C_AM/3
3
throttle position sensor
EPC 1 EPC 2
C_AW1/2
2 1
C_AW/2
1
C_AL/2
C_AT/2
pick up
yellow-orange 0.5
19
26
25
13
orange-black 0.5
950 Supermoto (R) 2007
950 Supermoto R 2008
orange 1
U
C
E
7
brown 0.5
ignition switch
C_AO/26
A-page2/8
ignition coil
start/stop switch
fuel pump relay
brown 0.5
30
C_AF1/4
fuel pump
Art.-No. 3.206.056-E
1
black-blue 0.5
M
C_AL2/2
C_AT2/2
2
1
4
2
3
30
3/8
31
E-page2/8
yellow-black 1
brown 0.5
Repair manual KTM LC8
13-77
orange 0.5
31
M-page6/8
L-page6/8
2
1
C_AH3/2
4
7
C_AD/12
C_BD/12
1
flasher switch
G
violet 0.5
black 0.5
violet 0.5
2
black 0.5
3
right front flasher
brown 0.5
left front flasher
950 Supermoto (R) 2007
950 Supermoto R 2008
rear flasher light`s
C_BK/4
C_AZ/4
1
1
8
horn switch
C_BD/12
C_AD/12
3
horn
brown 1
C_AV/2
1
D-page2/8
black-white 1
2
1
2
1
2
temperature switch
turn indicator system
diode
C_AI3/2
2
yellow-blue 0.5
C-page2/8
grey 0.5
flasher relay
brown 0.5
brown-black 1
black-orange 0.5
brown 0.5
C_CD/2
C_CD1/2
M
31
30
4/8
cooling fan
M
cooling fan
C_BL/2
C_BL2/1
30
13-78
13-79
start switch
cable
harness
or
cable
switch
blbu
Stop switch
blor
bl
START
cable
harness
re
or
cable
switch
or
blwh
RUN
STOP
unpushed
ignition switch
bl-or r-w
re
clutch switch
r-w
switch
position
ON
ye
br
pulled
unpulled
Art.-No. 3.206.056-E
OFF
LOCKED
flasher switch
or
gr
cable
switch
gn- bu- bupi
b r re b l
TURN L
Repair manual KTM LC8
horn switch
cable
harness
TURN R
OFF
pu
bl
br
cable
harness
gr
br
brpi
cable
switch
pi
brpi
HORN
OFF
31
0
1
2
head light flasher
HI
LO
low/high beam switch
2
5
6
9
9
6
N-page6/8
yellow 1
C_BB/9
C_AB/9
white 0.5
blue 1
green 1
rear brake switch
front brake switch
950 Supermoto (R) 2007
950 Supermoto R 2008
C_BD/12
C_AD/12
3
yellow 1
yellow-brown 1
light switch
C-page2/8
brown 0.5
C_AK1/2
2
1
4
green-white 0.5
2
1
C_BG/3
C_AJ/3
3
white 0.5
2
rear light/brakelight
1
C_DI/2
positionlight
light-brake system
headlight
C_BK/4
C_AZ/4
1
1
2
blue-yellow
C_AH1/2
C_AH/2
C_AK/2
B-page2/8
1
3
C_BW/3
2
headlight
brown 0.5
30
brown 0.5
5/8
31
30
13-80
13-81
light switch
high/low beam switch
cable
harness
yewh ye
br
cable
switch
yewh wh
r eye
cable
harness
bu
gn
yebr
cable
switch
wh ye
gnre
LIGHT OFF
LO
P. LIGHT
HI
Art.-No. 3.206.056-E
LIGHT
brake switch
cable
harness
cable
switch
pushed
Repair manual KTM LC8
unpushed
gn- yewh bu
bl
bl
31
3
yellow-orange 0.5
1
speed sensor
v
2
black-brown 0.5
C_AM3/3
C_AR3/3
black-orange 0.5
1
yellow-black 0.5
19
3 5
7
M-page4/8
L-page4/8
9 4
2
N-page5/8
1 6
brown 0.5
temperature sensor
brown-black 0.5
950 Supermoto (R) 2007
950 Supermoto R 2008
t°
C_AX/2
2
10 15 16
violett 0.5
C_AA/20
multi-func.-digital-speedometer
blue 0.5
p
1
C_BJ/1
C_AY/1
1
fuel level sensor
Q
C_AL2/2
C_AT2/2
2
brown 0.5
instruments-tachometer
oil pressure sensor
green-grey 0.5
red-brown 0.5
green-black 0.5
yellow-orange 0.5
K-page3/8
C_CR3/1
red-black 0.5
red-white 0.5
H-page2/8
C_CR2/1
aditional
current
connection
ACC2
F-page2/8
black 0.5
G-page2/8
C_CR/1
C_CR1/1
yellow-red 0.5
I-page2/8
aditional
current
connection
ACC1
30
brown 0.5
6/8
31
30
13-82
Repair manual KTM LC8
Art.-No. 3.206.056-E
13-83
left front flasher
positionlight
headlight
right front flasher
LED for alarmsystem
ACC1
ACC2
M
ECU
C_AF3/4
regulator
temperature sensor
temperature switch
30
A
950 Supermoto (R) 2007
950 Supermoto R 2008
clutch switch
carburetorheating
fuellevelsensor
right-left front flasher
multi-func.-digital-speedometer
horn switch
starter motor
battery
ground connection
brown
start relay
7/8
alarmsystem
rear light/brakelight
main relay
rear flasher
fuel pump module
13-84
front brake switch
flasher relay
diode
A
Fan
8
A
9
1
A
fuel pump relay
A
A
A
A
10 10 10 10 10
A
10 15 10
16
30
A
battery
positive connection
fuse box
rear brake switch
950 Supermoto (R) 2007
950 Supermoto R 2008
multi-func.-digital-speedometer
yellow-blue
ignition switch
yellow
yellow-blue
horn
red-white
C_AF3/4
yellow-black
black-white
light switch
M
red-white
high/low beam switch
starter motor
start relay
red-black
regulator
green
green
alarmsystem
ACC1
ACC2
carburetorheating
8/8
start auxillary relay
C_AF/4
Art.-No. 3.206.056-E
yellow
black-orange
Orange
red-yellow
Repair manual KTM LC8
13-85
13-86
Connector AA
20-pole 1
11 1
1
Multifunctional digital
speedometer
Behind
the
functional
speedometer
20 10
multi
digital
Connector AB
9-pole 2
1
3
9
2
Start/stop/light switch
Behind
the
functional
speedometer
multi
digital
4
3
Connector AC
6-pole 3
Ignition switch
1
4
3
6
Behind
the
functional
speedometer
multi
digital
Connector AD
12-pole 4
1
3
7
12
Light/turn signal/horn
switch
Behind
the
functional
speedometer
multi
digital
Connector AF
4-pole 5
1
Auxiliary starter relay
Under the seat
42
6
Connector AF1
4-pole 6
Fuel pump relay
Under the seat
5
13-87
Connector AF2
4-pole 1
1
Lighting relay
Under the seat
42
1
Connector AF3
2-pole 2
Start relay
Under the seat
2
Connector AH
2-pole 3
Rear brake light switch
Art.-No. 3.206.056-E
1 2
On the right side of the
frame
3
Connector AH1
2-pole 4
Front brake light switch
4
Behind the headlight
5
Connector AH2
2-pole 5
Repair manual KTM LC8
Temperature switch for
carburetor heater
Behind the headlight
Connector AH3
2-pole 6
Turn signal relay
Behind the headlight
6
13-88
Connector AI
2-pole
2
1
Neutral switch diode
Under the seat, next to
the battery
Connector AI1
2-pole
Diode for side stand
switch
Under the seat, next to
the battery
Connector AI2
2-pole
Diode for side stand
switch
Under the seat, next to
the battery
Connector AI3
2-pole 1
Diode for turn signal
control
Behind the headlight
mask next to the turn
signal relay
Connector AJ
3-pole 2
Rear lighting system
1
2
3
Under the seat in the
back of the storage
compartment
1
2
13-89
Connector AK
2-pole 1
Rear brake light switch
1
2
On the right side of the
frame
1
Connector AK1
2-pole 2
Front brake light switch
2
Behind the headlight
3
Connector AK2
2-pole 3
Temperature switch for
carburetor heater
Art.-No. 3.206.056-E
Behind the headlight
Connector AL
2-pole 4
Pick up
1
2
4
On the left between the
oil
tank
and
the
generator cover
Connector AL1
2-pole 5
Repair manual KTM LC8
Fuel sender
On the front left next to
the radiator
Connector AL2
2-pole 6
Fuel pump
On the front left next to
the radiator
5
6
13-90
Connector AL3
2-pole 1
Clutch switch
1
Behind the headlight
1
6
2
Connector AL4
2-pole 2
Carburetor heater
Behind the steering
head and the ECU
3
2
Connector AM
3-pole 3
Throttle sensor
1
3
Behind the steering
head and the ECU
Connector AM1
3-pole 4
Gear sensor
On the left between the
oil
tank
and
the
generator cover
Connector AM2
3-pole 5
Side stand switch
On the left between the
oil
tank
and
the
generator cover
Connector AM3
3-pole 6
Speed sensor
Behind the headlight
4
5
13-91
Connector AO
26-pole
20
14
8
1
ECU 1
Behind
head
26
19
13
the
1
steering
7
Connector AR
3-pole 2
3
1
Throttle sensor
Behind the steering
head and the ECU
Connector AR1
3-pole 3
Gear sensor
Art.-No. 3.206.056-E
On the left between the
oil
tank
and
the
generator cover
2
4
3
Connector AR2
3-pole 4
Side stand switch
On the left between the
oil
tank
and
the
generator cover
Connector AR3
3-pole 5
Speed sensor
Repair manual KTM LC8
Behind the headlight
5
13-92
Connector AS
2-pole 1
1
2
Rear ignition coil
1
Behind the air filter box
Connector AS1
2-pole 2
Front ignition coil
Behind the radiator
2
Connector AT
2-pole 3
Pick up
1
2
On the left between the
oil
tank
and
the
generator cover
3
Connector AT1
2-pole 4
Fuel sender
On the front left next to
the radiator
5
4
Connector AT2
2-pole 5
Fuel pump
On the front left next to
the radiator
Connector AT3
2-pole 6
Clutch switch
Behind the headlight
6
13-93
Connector AT4
2-pole 1
Carburetor heater
1
2
Behind the steering
head and the ECU
1
Connector AU
2-pole 2
2
Controller outlet
21
Under the seat next to
the battery case
Connector AV
2-pole 3
Temperature switch
1
2
On the left side of the
radiator
Art.-No. 3.206.056-E
3
Connector AW
2-pole 4
Front EPC
2
1
On the right side of the
frame
4
Connector AW1
2-pole 5
EPC rear
Repair manual KTM LC8
Behind the air filter box
5
Connector AX
2-pole 6
1
2
Coolant temperature
sensor
On the left between the
cylinders
6
13-94
Connector AY
1-pole 1
Oil pressure switch
On the left side of the
frame under the air
filter box
1
Connector AZ
4-pole 2
Rear turn signal
1
2
3
4
Under the seat in the
back of the storage
compartment
2
Connector BB
9-pole 3
1
3
7
9
3
Start/stop/light switch
4
On
the
connector
support
under
the
multifunctional digital
speedometer
Connector BC
6-pole 4
Ignition switch
3
6
1
On
the
connector
support
under
the
multifunctional digital
speedometer
Connector BD
12-pole 5
3
1
10
12
Turn signal/horn/high
beam switch
On
the
connector
support
under
the
multifunctional digital
speedometer
Connector BG
3-pole 6
1
2
3
Rear lighting system
Under the seat in the
back of the storage
compartment
5
6
13-95
Connector BI
2-pole 1
1
Controller outlet
2 1
Under the seat next to
the battery case
Connector BJ
1-pole 2
Oil pressure switch
1
On the left side of the
frame under the air
filter box
Connector BK
4-pole 3
Art.-No. 3.206.056-E
1
1
2
3
3
Rear turn signal
Under the seat in the
back of the storage
compartment
Connector BL/BL1
2-pole 4
4
Radiator fan
1
2
2
Behind the left radiator
Connector BS
2-pole 5
Alarm LED
Repair manual KTM LC8
1
2
Instrument panel
alarm system only)
(for
5
Connector BS1
2-pole 6
Seat switch
Under the seat
alarm system only)
(for
6
13-96
Connector BV
2-pole
Alarm LED
Instrument panel
alarm system only)
2
1
(for
Connector BV1
2-pole
Seat switch
Under the seat
alarm system only)
(for
Connector BW
3-pole 1
1
Headlight
Behind the headlight
1
3
Connector CD/CD1
2-pole 2
Radiator fan
1
2
2
Behind the left radiator
Connector
CR/CR1/CR2/CR3
1-pole
Connector for
attachments:
Ground 3
Continuous positive
polarity 4
Positive ignition 5
Behind the headlight
4
3
3
5
13-97
Connector DI
2-pole
1
Parking light 1
On the headlight
Connector DJ
18-pole
2 1
18 17 16 15 14 13
6 5
Connector for the alarm
ECU 2
Under the seat
Connector DK
18-pole 3
Art.-No. 3.206.056-E
Repair manual KTM LC8
13 14 15 16 17 18
1 2 3 4 5 6
Dummy plug
(without alarm system)
Under the seat
3
2
tachometer
clutch switch
15
16
14
2
7
8
13
1
12
6
10
9
3
4
5
11
v
n
front
brake switch
speed sensor
left fron t flas her
right fron t flasher
1
2
adition al
curr ent
conn ec ti on
ACC1
C_AM5/3
ye
gn
ye-br
2
6
br
pu
2
1
5
4
sen sor
rollover
C_AP2/6
6
temp er atur e switch
cool ing fan
M
C_BI1/2
C_ AU 1/ 2
2
1
C_AV/2
2
990 Adventure S 2006/07
p
C_ AY/1
C_BJ/1
7 1
diag nos tic
connector
2
L
L
t°
3
2
p
C_DP2/3
3
or
br
lbu
2
1
1
1
6
4
t°
gr
ye- bu
2
1
C_AX/2
or
p
C_DP1/3
3 2
1
1
2
C_ CM /2
t°
horn
G
flas her relay
or
1
8
C_AB/9
C_BB/9
bl-bu
C_AH2/2
C_BH1/6
3 2
p
C_DP/3
1
wiring diagramm
rear
lam bd a s en sor `s
front
t°
C_CA/4
1
C_CE/4
4
3
C_CA1/4
3
8
C_CE1/4
4 1
2
oil p res su re switch
990 Adventure 2006/07
wh
bu
3
1
br
br
ye-re
br
re-bl
4
br
1
2
1
C_CR/1
bl
C_CR2/1
C_CR1/1
br
ye-br
ye
gn-r e
br
or- ye
C_CR3/1
gn-r e
br
gn- gr
wh
ye
re-br
br- bu
gn-bl
re- wh
or
bl
pu
bu
ye-br
br-bl
bl-or
4
3
2
1
1
wh
ye
C_AG/3
adition al
curr ent
conn ec ti on
ACC2
C_AA/20
C_AT1/2
multi-func.-digital-speedometer
headlight
C_AL1/2
C_AN/4
C_CX1/2
C_BC/6
handle bar switch
for multi-func.-digitalspeedometer
C_BE/3
C_AR5/3
C_CW1/2
C_CW/2
bl-or
bl-wh
br-bl
head light flascher
gn-bl
bu
re-gn
2
or
br-bl
br-bl
2 4
wh-bl
br
ye-re
bu
9
bl
3
bl
ye
gn
bu-re
pu
gn-re
gn-br
ye-br
or
gr-gn
6
re-br
C_AD/12
wh-or
bu-bl
bl
br-pi
br
pi
gr
or
ye-bu
water temperature sensor
C_AP1/6
C_BD/12
bl
5
bl
ye- bu
bu
gn- w h
re
bu-bl
2
manifold pressure sensor front
1
2 7
2
1
0
9
2
1
3
C_AR3/3
C_ AM 3/ 3
2
Pick up
C_AT/2
C_AL/2
1
sid estan d s ens or
bl
ye-bl
bu
air temperature sensor
bl
bl
bl-wh
or
3
6
wh
wh
re-ye
ye
ye- bu
ye-wh
br
pu-br
C_BF/1
C_ BA /1
2nd
3
C_AR2/3
2
1
gn-bl
ye-br
gr
A
8
A
10
A
10
A
10
A
10
A
15 10
A
10
16
re- wh
5
C_ BH /6
C_AP/6
ye-bl
bl
re
pi
ye
br
ye-bu
1
A
10
9
2
7 13 14 3 24 23 11 12 4
ye-bl
C_AO/26
2 10 9 22 6 20 25 26 19 15 18 17
re-br
C_AL2/2
C_AT2/2
2
8
9 14 16 34
M
3 2
lbu
to ABS harness
gr
33 15 13 23 11 3
4
C_AE1/4
7 21 12
6 29 26
C_CO/34
4 22 5
1
30
A
star t relay
ABS connector
fuel level sen sor
light relay
C_AF3/4
starter m otor
main harness - 601.11.075.000
21 1
gn
gn
3
ye-wh
ye-br
bu
3rd gear
2nd gear
neutral switch
ye-bu
C_AM2/3
re-wh
1
3
gr
re
bl-wh
ye-re
re-gn
3th
1
2
re
2
bu-gr
br
br
bu-wh
wh
bu-br
re-bu
4
Q
2
1
re-wh
N
br
1
C_AT3/2
re-bl
bu
front
fuel pump
M
3
2
2
exhaust air
valve
C_CK/2
1
14
2
10
6
16
8
4
12
15
7
3
11
5
9
13
2
1
4
2
3
3
4
2
1
bu- bl
or -w h
bu- gr
or
br
or -w h
2
2
1
C_ AH /2
C_AK/2
ye- bu
re- gn
power rel ay
fuel pum p relay
2
C_A M /3
C_AR/3
1
2
1
rear
C_CL/2
injec tor´s
front
C_CL1/2
3
2nd th rottle
pos ition s ens or
1
re- wh
re- wh
start auxillary r elay
rear
brake switch
4
ye- wh
ye-bl
1
re-bl
3
re-bl
re- bu
07.12.2005
rear
1
bu
bl
pu- re
re-bl
or -gn
gn
bu- or
wh -r e
br-gr
gn- w h
bu- pi
ye- gn
bl-gr
ye-or
or
fuel p um p m odu le
Q
C_AR4/3
C_ AM 4/ 3
battery
C_AS/2
2
1
C_AS1/2
2
re-wh
or
re-bu
ignition coil`s
gn
bu-bl
C_AF1/4
ign iti on swi tch
C_CQ/16
lig ht swi tch
wh-pu
C_AF2/4
or
start/s top switch
3
bl
br
3
2
1
4
2
1
gn- w h 3
br
wh
pu
wh
2
1
C_AR1/3
C_ AM 1/ 3
2
C_CE2/4
1
3
mai n thr ottle
pos ition s ens or
C_CA2/4
4
1
2
2nd th rottle
stepp er m otor
ye
hi gh /l ow b eam switch horn swi tch
flash er switch
pu
bu-w h
C_CP/16
C_AF/4
gn-wh
bu
bl
gn-gr
atmospheric pressure sensor
bl
2
4
1
gn
3
1/9
left r aer fl ash er
lic en ce p late lamp
right rear flasher
2
C_AI2/2
1
2
C_AI1/2
1
2
C_AI/2
1
diode
diode
ISC
stepp er m otor
C_AE/4
G
gen erator
diode
3
U
regu lator-rectifier
ye-wh
or-wh
or
bl
pu
manifold pressure sensor rear
re-wh
wh-br
C_AC/6
C_CX/2
br-bl
br
or
gn-bl
re-bl
E
bu
fuse box
br
br-bl
bu
bl
ye-bu
ye-wh
pu
bu-bl
gn-gr
re-br
re-gn
ye-re
pu-re
re-bl
ye-bl
re
pu-br
or
ye
pi
gn-bl
ye-br
gr
lbu
C
C_AL3/2
wh-or
wh-bl
or-bl
or-gn
gn
bu-or
wh-re
br-gr
gn-wh
bu-pi
ye-gn
bl-gr
ye-or
wh-pu
wh-br
U
fuel level sensor
or
gn-re
bu-bl
C_AU/2
bu
re
wh
gr
C_AZ/4
C_AJ/3
wh
gn
bl
gr
br
or
or-bl
or
pu
ye
ye-wh
2
13-98
rear light/brakelight
octane selector
tachometer
additional
cur rent
connection
AC C 1
n
front
brake switch
C_CR/1
C_CR/1
speed sensor
v
14
2
7
8
13
1
12
6
10
9
3
4
5
11
15
16
left front flasher
right front flasher
C_AI/2
2
1
4
3
2
1
1
2
3
ye-bu
ye-br
ye
gn - re
br
or-ye
1
2
1
gn
ye-br
2
6
1
c oo l i n g f an
M
C_BI1/2
C_AU1/2
2
5
4
s e n sor
rollover
C_AP2/6
6
t em p e r a t u r e s w i t c h
C_AV/2
1
2
head light flascher
ye
p
2 4
9
C_BJ/1
C_AY/1
1
6
4
2
L
L
rear
lambda sensor`s
front
t°
3
t°
C_CA/4
C_CE/4
1
2
C_AX/2
t°
C_CA1/4
4 1
3
br-pi
C_CE1/4
2
8
3
di a g n o s t i c
co n n e ct o r
4 1
bu-bl
7 1
oil pressure switch
6
C_AD/12
C_BD/12
wh
5
990 Adventure (S) 2007
br
pu
2
wh
bu
3
1
br
br
ye-re
br
4
br
bl
1
2
br
ye
C_EE/1 C_CR/1
C_EE/1 C_CR/1
C_CR2/1
re -b l
br - bl
b l-o r
gn-wh
C_CR3/1
gn -r e
br
gn-g r
wh
ye
re-br
br - bu
gn- bl
re-wh
or
bl
pu
bu
ye-br
br -b l
b l-o r
additional
cur r ent
connection
ACC2
C_AT1/2
multi-func.-digital-speedometer
headlight
handlamp
socket
clutch switch
C_AA/20
C_AG/3
C_CX1/2
C_AL1/2
C_AM5/3
C_AN/4
C_AC/6
handle bar switch
for multi-func.-digitalspeedometer
C_BE/3
C_AR5/3
C_CW1/2
C_CW/2
ye-bu
bl-wh
1
br-bl
br
br-bl
ye-re
bu
or
br
C_AI/2
2
1
3
2
p
C_DP2/3
1
1
2
C_CM/2
t°
gr
ye-bu
ye-bu
C_AH1/2
8 1
2
3 2
p
C_DP1/3
1
3
C_AR3/3
C_AM3/3
1
s i d e st a n d s e n s o r
horn
G
fl as h er r elay
wir in g diag ra mm
lbu
2
1
ye-or
or
C_BB/9
C_AB/9
3 2
p
C_DP/3
1
2 7
1
1
1
3
6
2
C_AL/2
Pick up
C_AT/2
2
C_DF/2
0
9
PVC
2
light switch
wh
gn-bl
ye
gn-re
gn-br
gr-gn
bu-re
pu
or
re-bl
bl-wh
or
ye-wh
re-ye
wh
ye
br
bl
br
pu-br
C_BF/1
C_BA/1
2nd
3
C_AR2/3
2
1
gn- bl
ye-br
gr
A
A
8
A
10
A
10 10
A
10
A
15 10
A
10
16
re-wh
5
C_BH/6
C_AP/6
9
1
A
10
2
ignition switch
ye-bl
gn
or
ye
C_AM2/3
bu
re-gn
bl
br
water temperature sensor
wh-or
ye-bu
ye-br
or
wh-bl
bl
C_BH1/6
bl
ye-bl
bl
bl-wh
pi
gr
C_AP1/6
or
re-br
air temperature sensor
re
re-gn
3
bl
gn
fuse box
start/stop switch
gr
ye-bl
high/low beam switch horn switch
flasher switch
7 13 14 3 24 23 11 12 4
C_AO/26
21 1
2 10 9 22 6 20 25 26 19 15 18 17 8
re-br
re
l igh t r el ay
C_EB3/4
starter motor
1
C_BV/2
C_BS/2
alarm LED
2
2
C_EG/14
C_EF/14
1
M
f uel l e v e l s ens or
ABS connector
to ABS harness
C_AT2/2
bu-wh
bu
bl
bu
atmospheric pressure sensor
C_AL2/2
re-wh
ye-re
4
Q
rt-bu
1
2
C_AT3/2
re-wh
1
gn
3
2
1
2
C_AL3/2
br
bl
re
or
ye-wh
diode
pi
re
gn-gr
bl
bl
bu-bl
manifold pressure sensor front
8
9 14 16 34 31 32 33 15 13 23 11 3
main harness -
C_CO/34
2
4 22 5
6
1
8
7
6 29 26
f ront
8
1
6
7
1 5
2
bu 1 4
2
bl
pu-re 1 0
re-bl 6
or-gn 1 6
8
gn
bu-or 4
wh-re 12
br-gr 15
gn-wh 7
bu- pi 3
ye-gn 11
bl-gr 5
ye-or 9
13
or
2
ex haus t air
v al v e
C_CK/2
1
2
C_AK/2
2
2
1
C_AH/2
ye-bu
2
3
p owe r r e la y
fuel pum p re lay
2
C_AM/3
C_AR/3
1
2
rear
C_CL/2
i n j e c tor ´ s
front
C_CL1/2
3
1
2nd throttle
p o s i ti on s en s or
1
re-wh
re-wh
start auxillary relay
rear
brake switch
2
1
or-wh
re-gn
4
or
br
01.10.2006
rear
C_AS/2
2
1
2
C_AS1/2
4
C_DN/8
2
3
bu-gr
Connector for
optional
alarm system
1
S t a r t e r I n t e r l oc k U n i t
3
or-gn
C_BV/2
C_BS/2
9 10 11 12 13 14
C_DO/8
4
or-wh
3
1
bu- bl
ye-bl
4
2
1
or-gn
re-bl
re-bl
3
re-bu
seat
surveillance
gn
battery
alarm system dummy plug
5
601.11.075.200
601.11.042.060
610.41.012.000
7 21 12
3 2
3
4
4
C_AE1/4
30
A
start relay
or
ye-br
re-bl
ye-bu
bu
C_EB1/4
bl-bu
bu
manifold pressure sensor rear
ye
3rd gear
2nd gear
neutral switch
pu
wh-br
or
bu
bl
pu
C_BC/6
C_CX/2
br-bl
br
rt-bu
or
3th
or
gn-bl
N
br
bu
re-wh
ye-rt
re-wh
bl
re-bu
Antenna
ignition coil`s
br
C_EB2/4
or
2
C_AR4/3
re-bl
E
3
3
2
1
4
2
1
gn-wh 3
wh
br
pu
wh
bl
br
2
C_AI/2
d i od e
1
2
C_AR1/3
C_AM1/3
1
2 1
C_CE2/4
3
2
4 1
gn
3
3
G
generator
U
regulator-rectifier
ISC
s te p p e r mo to r
C_AE/4
fuel level sensor
m ain t h rott le
p o s i ti on s en s or
C_CA2/4
4
1
2
C_BI/2
2nd throttle
st e p pe r mo t o r
ye
Art.-No. 3.206.056-E
C_CP/16
or
br-bu
or-bl
for optional alarm system
C_CQ/16
C_EB/4
gn-wh
bu
lbu
br
br-bl
bu
bl
ye-bu
ye-wh
pu
bu-bl
gn-gr
re-br
re-gn
ye-re
pu-re
re-bl
ye-bl
re
pu-br
or
ye
pi
gn-bl
ye-br
gr
lbu
pi-bu
C
bl
or-bl
pi-bu
wh-pu
bu-bl
bu-bl
pi
br
br
or
br
bu-gr
br
br
bu-wh
wh
bu-br
re-bl
bu-br
wh-or
wh-bl
or-bl
or-gn
gn
bu-or
wh-re
br-gr
gn-wh
bu-pi
ye-gn
bl-gr
ye-or
wh-pu
wh-br
U
bu
bu
C_AM4/3
pu
C_AU/2
or
wh
re
C_AZ/4
fuel pump
or-wh
M
Q
gr
C_AJ/3
wh
gn
bl
gr
bu
or
fuel pump module
pu
octane selector
Repair manual KTM LC8
1/9
left raer flasher
li c e nc e pl a t e la m p
right rear flasher
13-99
rear light/brakelight
tachometer
additional
current
connection
ACC1
n
front
brake switch
C_CR/1
C_CR/1
speed sensor
v
14
2
7
8
13
1
12
6
10
9
3
4
5
11
15
16
left front flasher
right front flasher
C_AI/2
4
3
2
1
1
2
ye-bu
ye-br
ye
gn-re
br
or-ye
1
2
1
1
2
2
br
ye
1
pu
gn
2
wh
1
cooling fan
M
C_BI1/2
C_AU1/2
2
5
4
sensor
rollover
C_AP2/6
6
temperature switch
C_AV/2
1
2
990 Adventure (S)
2007-2008
ye-br
bu
3
6
br
br
ye-re
br
4
br
br
bl
C_EE/1 C_CR/1
C_EE/1 C_CR/1
C_CR2/1
re-bl
br-bl
bl-or
gn-wh
C_CR3/1
gn-re
br
gn-gr
wh
ye
re-br
br-bu
gn-bl
re-wh
or
bl
pu
bu
ye-br
br-bl
bl-or
additional
current
connection
ACC2
C_AT1/2
multi-func.-digital-speedometer
headlight
C_AL1/2
3
C_CX1/2
head light flascher
ye
wh
C_BJ/1
C_AY/1
7 1
1
6
4
L
L
rear
lambda sensor`s
front
t°
3
t°
C_CE/4
2
C_CA/4
4 1
1
2
C_AX/2
t°
C_CE1/4
2
3
C_CA1/4
4 1
8
3
diagnostic
connector
oil pressure switch
p
2 4
9
6
5
C_AD/12
C_BD/12
gn-bl
C_AG/3
C_AM5/3
C_AN/4
C_AC/6
handlamp
socket
clutch switch
C_AA/20
handle bar switch
for multi-func.-digitalspeedometer
C_BE/3
C_AR5/3
C_CW1/2
C_CW/2
gn-re
gn-br
ye
bu-re
pu
2
bl-wh
1
br-bl
br
br-bl
ye-re
bu
atmospheric pressure sensor
2
3
p
C_DP2/3
1
1
2
C_CM/2
t°
gr
ye-bu
2
1
2
3 2
p
C_DP1/3
1
3
C_AR3/3
C_AM3/3
1
sidestand sensor
horn
G
flasher relay
wiring diagramm
or
br
lbu
C_AI/2
ye-bu
ye-or
1
or
2
C_AB/9
C_BB/9
bl-bu
8 1
3 2
p
C_DP/3
1
2 7
1
1
6
9
2
C_AL/2
Pick up
C_AT/2
2
C_DF/2
PVC
3
wh
ye-bu
manifold pressure sensor front
or
re-bl
ye-wh
re-ye
wh
ye
bl-wh
or
0
C_BF/1
C_BA/1
A
3
2
1
A
A
A
8
10
15 10
re-wh
10
16
ye
1
bl
gn-bl
ye-br
gr
ye-bu
bu
re-gn
ye-bl
5
C_BH/6
C_AP/6
A
A
A
10
10 10
re
re-wh
gn
gr-gn
wh-bl
1
re-gn
1
A
10
9
2
ye-bl
gn
fuse box
ye-br
or
or
2
gr
bu-bl
bl
C_BH1/6
bl
bl
re-bl
ye-re
br
C_AM2/3
ignition switch
C_AR2/3
7 13 14 3 24 23 11 12 4
C_AO/26
21 1
2 10 9 22 6 20 25 26 19 15 18 17 8
re-br
light relay
C_EB3/4
starter motor
C_BV/2
C_BS/2
1
alarm LED
2
2
C_EG/14
C_EF/14
1
M
fuel level sensor
ABS connector
to ABS harness
C_AT2/2
light switch
C_AL2/2
br-pi
water temperature sensor
wh-or
8
9 14 16 34 31 32 33 15 13 23 11 3
main harness -
C_CO/34
2
4 22 5
6 29 26
601.11.075.200
601.11.042.060
610.41.012.000
7 21 12
bu
4
5
3 2
6
7
1
8
pu
battery
1
front
C_AS1/2
2
or-gn
2
exhaust air
valve
C_CK/2
1
bu14
2
bl
pu-re 10
re-bl 6
or-gn 16
8
gn
bu-or 4
wh-re 12
br-gr 15
gn-wh 7
bu-pi 3
ye-gn 11
bl-gr 5
ye-or 9
13
or
6.6.2007
rear
C_AS/2
2
1
1 5
2
7
6
8
4
C_DN/8
2
1
3
re-gn
C_EB2/4
C_AK/2
1
C_AH/2
2
2
3
power relay
fuel pump relay
1
2
1
rear
C_CL/2
3
injector´s
front
C_CL1/2
2
2
C_AM/3
C_AR/3
2nd throttle
position sensor
1
re-wh
re-wh
start auxillary relay
rear
brake switch
2
1
4
3
2
3
4
1
2
ye-bu
or-wh
br
or
ye-bl
bu-gr
or-wh
bu-bl
re-bl
or-gn 4
re-bl
re-bu
Connector for
optional
alarm system
Starter Interlock Unit
C_DO/8
3
1
C_BS/2
C_BV/2
seat
surveillance
9 10 11 12 13 14
rt-bu
alarm system dummy plug
3
4
C_AE1/4
30
A
start relay
br
start/stop switch
octane selector
C_AT3/2
pi
gr
br
C_AP1/6
or
re-br
air temperature sensor
bu
ye-bl
bl
C_AH1/2
bl
gn-gr
re-wh
3
bu
re-wh
ye-rt
high/low beam switch horn switch
flasher switch
bu-bl
re
bl
bl
bl
br
1
2
re
2
C_AL3/2
re-wh
1
gn
3
2
1
4
Q
bl
re
or
ye-wh
diode
pi
bu
C_AR4/3
ye-br
re-bl
ye-bu
3rd gear
2nd gear
neutral switch
or
ye
or
or
bu
bl
pu
manifold pressure sensor rear
C_BC/6
C_CX/2
br
pu-br
br-bl
br
bu
gn-bl
2nd
3th
N
re-bu
ignition coil`s
or-bl
pi-bu
br
br
Antenna
or
gn
or
br-bu
or-bl
pi
or
bl
wh-br
br
bu
wh-pu
for optional alarm system
C_CQ/16
C_EB1/4
C_EB/4
gn-wh
or
bl-wh
E
2
C_AR1/3
C_AM1/3
1
2 1
C_CE2/4
3
4 1
3
3
G
generator
U
regulator-rectifier
ISC
stepper motor
2
C_AE/4
fuel level sensor
main throttle
position sensor
C_CA2/4
4
1
4
2
1
3
wh 2
gn-wh 3
br
pu
wh
bl
br
2
C_AI/2
diode
1
2
1
C_BI/2
2nd throttle
stepper motor
3
ye
bu-wh
C_CP/16
br
bl
lbu
br
br-bl
bu
bl
ye-bu
ye-wh
pu
bu-bl
gn-gr
re-br
re-gn
ye-re
pu-re
re-bl
ye-bl
re
pu-br
or
ye
pi
gn-bl
ye-br
gr
lbu
pi-bu
C
bu
bu-bl
or
C_AU/2
bu
re
C_AM4/3
pu
C_AZ/4
fuel pump
or-wh
Q
C_AJ/3
wh
or
M
wh
gr
rt-bu
bu-gr
br
br
bu-wh
wh
bu-br
re-bl
bu-br
wh-or
wh-bl
or-bl
or-gn
gn
bu-or
wh-re
br-gr
gn-wh
bu-pi
ye-gn
bl-gr
ye-or
wh-pu
wh-br
U
gn
gn
bl
gr
bu
bu-bl
fuel pump module
pu
2
1/9
left raer flasher
licence plate lamp
right rear flasher
13-100
rear light/brakelight
Repair manual KTM LC8
Art.-No. 3.206.056-E
13-101
2nd throttle position sensor
2nd throttle stepper motor
ABS connector to ABS harness
Aditional current connection
Air temperature sensor
Atmospheric pressure sensor
Battery
Clutch switch
Cooling fan
Diagnostic connector
Diode
ECU
Exhaust air valve
Flasher relay
Flasher switch
Front brake switch
Front injector
Front lambda sensor
Fuel level sensor
Fuel pump module
Fuel pump relay
Fuse box
Gear sensor
Generator
Handle bar switch for multi-func.-digital-speedometer
Headlight
High / low beam switch
Horn
Horn switch
Ignition coil
Ignition switch
ISC stepper motor
Left front flasher
Left rear flasher
Licence plate lamp
Light relay
Light switch
Main throttle position sensor
Manifold pressure sensor front
Manifold pressure sensor rear
Multi-func.-digital-speedometer
Neutral switch
Octane selector
Oil pressure sensor
Pick up
Power relais
Rear brake switch
Rear injector
Rear lambda sensor
Rear light / brakelight
Regulator-rectifier
Right front flasher
Right rear flasher
Roll over sensor
Sidestand sensor
Speed sensor
Start auxillary relay
Start relay
Start/stop switch
Starter motor
Tachometer
Temperature switch
Water temperature sensor
2. Drosselklappenpositionssensor
2. Drosselklappenstellmotor
ABS-Steckverbindung zum ABS-Kabelstrang
Stromversorgung für Zusatzgeräte
Lufttemperatursensor
Außenluftdrucksensor
Batterie
Kupplungsschalter
Lüftermotor
Diagnosestecker
Diode
Steuergerät
Ventil für Sekundär-Luft-System
Blinkerrelais
Blinkerschalter
vorderer Bremslichtschaltero
vorderes Einspritzventil
Lambdasensor vorne
Benzinstandgeber
Kraftstoffpumpengruppe
Kraftstoffpumpenrelais
Sicherungskasten
Gangerkennung
Generator
Lenkerschalter für Multifunkt.Digitaltacho
Scheinwerfer
Auf-Abblendschalter
Hupe
Hornschalter
Zündspule
Zündschloss
Leerlaufstellmotor
linker vorderer Blinker
linker hinterer Blinker
Kennzeichenbeleuchtung
Beleuchtungsrelais
Lichtschalter
Drosselklappenpositions-Hauptsensor
Ansaugkrümmerdrucksensor vorne
Ansaugkrümmerdrucksensor hinten
Multifunktionsdigitaltacho
Leerlaufschalter
Oktananpassung
Öldruckschalter
Impulsgeber
Hauptrelais
hinterer Bremslichtschalter
hinteres Einspritzventil
Lambdasensor hinten
hinteres Begrenzungslicht / Bremslicht
Regelgleichrichter
rechter vorderer Blinker
Rechter hinterer Blinker
Neigungssensor
Seitenständerschalter
Geschwindigkeitssensor
Starterhilfsrelais
Startrelais
Start / stop schalter
Startermotor
Drehzahlmesser
Temperaturschalter
Wassertemperatursensor
Cable colours
bl: black
ye: yellow
bu: blue
gn: green
re: red
wh: white
br: brown
or: orange
pi: pink
gr: grey
pu: purple
NOTE to the connector designations:
The connector designations are comprised of letters and numbers - e.g.: C_AA1/20
– The 1st position C stands for connector (connector).
– The 2nd and 3rd positions AA stand for the connector type.
– The 4th position numbers the same type of connector if the connector is used for different
applications.
– The 5th and 6th positions 20 specify the number of pins in the connector, in this case 20 poles.
The 5th position is not required for connectors with less than 10 pins.
red-white 1
30
A
M
F-page7/9
G-page7/9
H-page7/9
J-page3/9
fus e box
generator
G
U
s t ar t a ux i l l ar y r e l ay
3
2
4
1
battery
start relay
8
C_BB/9
C_AB/9
1
2
brown 0.5
red -black 0.5
2
clutch switch
C_AT3/2
C_ AL 3/2
1
yellow-white 0.5
R-page3/9
7
re-wh
starter motor
2
C_AI1/2
diode
1
4
5
1
2
C_AI1/2
diode
C_ AC/6
C_ BC/6
31
I-page3/9
I-page6/9
30
2/9
green-black 0.5
ignition switch
b a tte ry , g e n e ra to r, s ta r te r
1
4
2
3
light system relay
990 Adventure (S) 2006/07
E-page3/9
D-page 5/9
C-page 5/9
B-page 6/9
A-page3/9
8
1
A
A
A
A
10
9
10 10
A
10
A
10
A
15 10
A
10
16
3
re-wh
gn
red-white 1
4
brown 0.5
br
bl-ye
re-bu
re-wh
ye
re-wh
gn
gn
ye-bu
3
gn
bl-wh
re-wh
re-wh
re-gn
2
re-bl
1
re-wh
re-wh
red-white 1
red-blue 0.5
regulator-rectifier
red-white 1
re-ye
red-white 1
C_AF/4
C_AF2/4
start/stop switch
red 0.5
30
13-102
red-white 1
red-white 1
30
A
M
J-page3/9
H-page7/9
G-pag e7/9
1
A
fu se bo x
generator
G
U
red-white 1
start auxillary relay
3
2
4
1
1
4
2
3
l igh t sys tem r elay
990 Adventure (S) 2007
E- pa ge 3/ 9
D-page 5/9
C-page 5/9
B-page 6/9
A-page3/9
A
F -pag e7 /9
A
A
A
A
A
8
9
10 10 10 10 10
A
10 15 10
16
3
re-wh
gn
battery
start relay
red-white 1
br
brown 0.5
4
bl-ye
re-bu
re-wh
ye
re-wh
C_AU/2
ye-bu
3
gn
bl-wh
re-wh
re-wh
re-gn
2
re-wh
re-wh
1
C_BI/2
gn
gn
red-white 1
red-blue 0.5
starter motor
regulator-rectifier
re-bl
30
C_AF/4
C_AF2/4
re-ye
red-white 1
Art.-No. 3.206.056-E
8
C_BB/9
C_AB/9
1
R - p a g e 3 /9
7
re-wh
St a rt s y st em
2
start/stop switch
red 0.5
Repair manual KTM LC8
SA R - p a g e 3 / 9
4
C_AC/6
C_BC/6
5
igni tion switch
2/9
31
30
13-103
red -black 0.5
red-white 1
30
A
M
battery
start relay
red-white 1
br
brown 0.5
4
red-white 1
A
J-page3/9
H-page7/9
G-page7/9
1
A
fuse box
generator
G
U
start auxillary relay
3
2
4
1
1
4
2
3
light system relay
990 Adventure (S)
2007-2008
E-page3/9
D-page 5/9
C-page 5/9
B-page 6/9
A-page3/9
9
F-page7/9
A
A
A
A
A
8
3
10 10 10 10 10
A
10 15 10
16
bl-ye
re-bu
re-wh
ye
re-wh
C_AU/2
ye-bu
3
gn
bl-wh
re-wh
re-wh
re-gn
2
re-wh
re-wh
1
re-wh
gn
re-bl
C_BI/2
gn
gn
red-white 1
red-blue 0.5
starter motor
regulator-rectifier
red-white 1
re-ye
red-white 1
C_AF/4
C_AF2/4
8
C_BB/9
C_AB/9
1
R-page3/9
7
re-wh
Startsystem
2
start/stop switch
red 0.5
30
SAR-page3/9
4
C_AC/6
C_BC/6
5
ignition switch
2/9
31
30
13-104
red -black 0.5
red-white 1
4
ye-re
5
bu
31
sensor
rollover
C_AP2 /6
bl
6
re-gn
or
wh-bl
ye
L
L
rear
lambda sensor´s
f ront
t°
t°
C_CE/4
3
C_CE1 /4
2
2
3
1
3
2
p
C_DP1 /3
1
octane selector
br
1
2
C_CM/2
t°
3
p
C_DP/3
1
2
bl
atmospheric pressure sensor
990 Adventure
p
C_DP2 /3
ye-bl
gn-gr
bu
2
bl
bl
1
C_AX/2
t°
I-page 2/9
water temperature sensor
manifold pressure sensor front
br
4 1
wh-or
C_CA/4
3
bl
C_CA1 /4
4 1 2
bl
re
2
bu
air temperature sensor
bu
1
bu-bl
br
br-pu
re-br
or
bl
bl
br-bl
2
ye-bu
21
1
3
C_AR3 /3
C_AM3/3
2
Pick up
C_AT/2
C_ AL /2
1
or
br
or-wh
gn-re
sidestand sensor
3
4
2
1
bl
C_ AL 1/ 2
C_BF/1
manifold pressure sensor rear
C_BA/1
pu
power relay
ye-wh
C_AF/4
bu
pi
C_AT1/2
Q-page7/ 9
C_AI/2
2
1
7 13 14 3 2 4 2 3 11 12
4
2 10 9 2 2
C_AO/ 26
6 2 0 2 5 2 6 19 15 18 17
1
or
EFI
2
8
1
2
3
9 14 16 3 4
P
6/8
O
6/8
K
6/8
gr
ye-br
gn-bl
bu-gr
br
br
bu-wh
wh
bu-br
C_AR2/3
C_AM2/3
lbu
br
or
6
4
1
N
3th
2nd
C_AP1/6
diode
3 3 15 13 2 3 11 3
C_BH1/6
7 21 12 4 2 2
3rd gear
neutral switch
diagnostic
connector
5
6 29 26
C_CO/ 34
f ront
gr
lbu
1
1
2
or-bl
C_CW/2
14
8
5
ye-or 9
or 13
bl-gr
ye-gn 11
bu-pi 3
gn-wh 7
br-gr 15
wh-re 12
bu-or 4
gn
or-gn 16
bu
2
exhaust
air valve
C_ CK/2
1
6
2
pu-re 10
re-bl
bl
C_CQ/16
610.41.012.000
airbox harness
rear
C_AS/2
2
1
C_ AS1/ 2
2
J-page2/9
R-page3/9
or
E-page2/9
wh-br
clutch switch
E
wh-pu
30
or-wh
bu
bl
ye-bu
ye-wh
pu
bu-bl
gn-gr
re-br
re-gn
ye-re
pu-re
re-bl
ye-bl
re
br-pu
or
ye
pi
gn-bl
ye-br
gr
lbu
C
or
1
bl
wh
3
f ront
1
rear
C_ CL /2
2
1
C_ CL 1/ 2
2
bu-bl
or
pu
ye
bu
re
gr
gr
wh
gn
pu
bu
gn-re
2
C_AM/3
C_AR/3
2nd TPS
4
2
C_AR1 /3
1
4
2 1
C_CA2 /4
C_CE2 /4
fuel pumprelay
4 1 3
C_ AE/4
2
3
2
C_AM4/3
C_AR4 /3
M
Q
fuel pump unit
f uel pump
3/9
ISC
stepper m ot or
second
throt tl e st epper m ot or
3
3
3
2
TPS
C_AM1/3
C_AF1 /4
1
bu
C_CX/2
or
wh
ye
bu
or
bl
or-wh
bu
A-page2/9
bu-gr
ye-bl
pu
bu-bl
bl
re
gr
br
bu-bl
wh
gr
2nd gear
wh-or
wh-bl
or-bl
or-gn
gn
bu-or
wh-re
br-gr
gn-wh
bu-pi
ye-gn
bl-gr
ye-or
wh-pu
wh-br
U
gn-re
or
bu-bl
injector´s
gn
pu
Art.-No. 3.206.056-E
30
31
fuel level sensor
Repair manual KTM LC8
13-105
C_CP/16
ignition coil
5
6
4
bl
31
sensor
rollover
C_AP2/6
ye-re
bu
1
2
C_AL1/2
C_AT1/2
bl
3
L
L
rear
lambda sensor´s
front
t°
t°
C_CE/4
2
C_CE1/4
4 1
wh-or
C_CA/4
3
bl
C_CA1/4
4 1 2
wh-bl
2
1
ye-bl
gn-gr
3
bu
1
atmospheric pressure sensor
2
3
p
C_DP1/3
1
octane selector
br
1
2
C_CM/2
t°
2
3
p
2
3
4
2
gn-re
or
br
or-wh
1
3
2
C_AR3/3
C_AM3/3
sidestand sensor
Pick up
C_AT/2
C_AL/2
1
br-bl
2
1
1
C_DP/3
PVC
C_DF/2
990 Adventure (S)
2007-2008
p
C_DP2/3
2
bl
bl
C_AX/2
t°
bu
br
br
water temperature sensor
manifold pressure sensor front
clutch switch
bu-bl
ye
re-gn
or
re
bl
br
br-pu
re-br
or
bl
I-page 7/9
C_BF/1
bu
air temperature sensor
C_BA/1
or
bl
re-bl
ye-wh
C_AF/4
bl
ye-bu
bu
pi
C_AI/2
21 1
7 13 14 3 24 23 11 12 4
2 10 9 22
C_AO/26
6 20 25 26 19 15 18 17 8
1
or-bl
2
EFI
1
C_AR2/3
lbu
br
or
C_AM2/3
P
6/8
O
6/8
K
6/8
gr
ye-br 2
gn-bl 3
4
1
6
ASP-page7/9
SAR-page2/9
N
3th
C_BH1/6
2
8
9 14 16 34
33 15 13 23 11
3
diagnostic
connector
6 29 26
C_CO/34
7 21 12 4 22 5
or-gn
front
C_AS1/2
1
1 5
2
7
6
8
4
2
3
ye
C_DN/8
C_DO/8
Starter Interlock Unit
gn-bl
1
6
2
14
8
5
gr
lbu
1
bl
wh
exhaust
air valve
1
610.41.012.000
front
C_CL1/2
2
bu-bl
or
pu
ye
bu
re
gr
gr
wh
gn
pu
bu
gn-re
2
C_AM/3
C_AR/3
3
2nd TPS
1
2
2
ye-or 9
or 13
bl-gr
ye-gn 11
bu-pi 3
gn-wh 7
br-gr 15
wh-re 12
bu-or 4
gn
or-gn 16
bu
C_CK/2
1
bl
pu-re 10
re-bl
J-page2/9
airbox harness
rear
C_AS/2
2
br
or-bl
1
R-page3/9
Q-page7/9
ignition coil
2nd
C_AP1/6
pi-bu
or
pi
wh-pu
br-bu
or
power relay
E
pu
manifold pressure sensor rear
or-wh
br-bl
bu
bl
ye-bu
ye-wh
pu
bu-bl
gn-gr
re-br
re-gn
ye-re
pu-re
re-bl
ye-bl
re
br-pu
or
ye
pi
gn-bl
ye-br
gr
lbu
pi-bu
C
or
diode
C_CQ/16
E-page2/9
C_CP/16
bu
wh-br
bu
C_CW/2
or
2
4
1
rear
C_CL/2
TPS
4
2 1
fuel pumprelay
3
2
C_AM4/3
C_AR4/3
M
fuel pump
2
Q
fuel pump unit
4 1 3
C_AE/4
3/9
ISC
stepper motor
second
throttle stepper motor
C_CE2/4
C_CA2/4
3
2
C_AR1/3
1
3
3
2
C_AM1/3
C_AF1/4
1
bu
C_CX/2
bl
or
or-wh
A-page2/9
ye-bl
wh
ye
bl
re
gr
bu-gr
pu
bu-bl
bu
neutral switch
2nd gear
3rd gear
bu-gr
br
br
bu-wh
wh
bu-br
re-bl
bu-br
wh-or
wh-bl
or-bl
or-gn
gn
bu-or
wh-re
br-gr
gn-wh
bu-pi
ye-gn
bl-gr
ye-or
wh-pu
wh-br
U
gn-re
bu-bl
injector´s
wh
br
gr
bu-bl
gn
pu
30
31
fuel level sensor
30
13-106
31
M-page6/9
L-page6/9
2
1
C_AH3/2
4
7
C_AD/12
C_BD/12
1
flasher switch
G
fl as he r re la y
v i ol et 0. 5
bl ac k 0.5
Yellow-blue 0.5
2
violet 0.5
2
3
black 0.5
rear flasher light`s
C_BK/4
C_ AZ/4
1
right front flasher
left front flasher
2 1
C_ CW 1/2
C_CX1/2
990 Adventure
1
C_CX/2
C_ CW /2
8
horn
brown 1
C_ AV/2
1
D-page2/9
black-white 1
2
1
2
temperature switch
turn signal, horn, fan
horn switch
C_BD/12
C_AD/12
3
yellow-blue 0.5
C-page2/9
brown-black 1
30
brown 0.5
grey 0.5
Art.-No. 3.206.056-E
30
M
5/9
31
cooling fan
C_BI1/2
Repair manual KTM LC8
13-107
C_AU1/2
brown 0.5
brown 0.5
orange 0.5
31
M-page6/9
L-page6/9
2
1
1
C_AH1/2
C_AI/2
4
7
C_AD/12
C_BD/12
1
flasher switch
G
2
violet 0.5
2
3
black 0.5
rear flasher light`s
C_BK/4
C_AZ/4
1
right front flasher
left front flasher
2 1
C_CW1/2
C_CX1/2
990 Adventure (S)
2007-2008
violet 0.5
black 0.5
1
C_CX/2
C_CW/2
8
horn
brown 1
turn signal, horn, fan
horn switch
C_BD/12
C_AD/12
3
yellow-blue 0.5
grey 0.5
ye-or
orange 0.5
C-page2/9
2
1
2
temperature switch
C_AV/2
1
D-page2/9
black-white 1
2
brown 0.5
brown-black 1
diode
flasher relay
Yellow-blue 0.5
30
M
5/9
31
cooling fan
C_BI1/2
30
13-108
C_AU1/2
brown 0.5
brown 0.5
13-109
ignition switch
clutch switch
o
r-w r-w r-w
y-r
r
ON
switch
position
ye
br
pulled
unpulled
OFF
LOCKED
kill switch
start switch
cable
harness
or
cable
switch
blbu
blor
bl
START
Art.-No. 3.206.056-E
flasher switch
Repair manual KTM LC8
cable
switch
or
blwh
horn switch
or
gr
cable
switch
gn- bu- bupi
b r re b l
OFF
or
STOP
cable
harness
TURN R
re
RUN
unpushed
TURN L
cable
harness
pu
bl
br
cable
harness
gr
br
brpi
cable
switch
pi
brpi
HORN
OFF
0
1
31
head light flasher
HI
LO
low/high beam switch
2
2
5
6
9
white 0.5
C-page2/9
yellow 1
C_AB/9
C_BB/9
rear
front
brake switch
yellow-brown 1
green 1
brake switch
990 Adventure
9
6
3
1
2
blue-yellow
2
C_AH1/2
B-page2/9
yellow 1
yellow-brown 1
light switch
C_BD/12
C_AD/12
1
licence plate lamp
green-white 0.5
1
3
1
2
white 0.5
C_BG/3
C_ AJ/3
6
2
rear light/brakelight
C_ BC/6
C_ AC/6
light-brake system
N-page7/9
head light
3
4
brown 1
30
brown 0.5
6/9
31
30
13-110
C_AK1/2
13-111
light switch
high/low beam switch
cable
harness
bu
gn
yebr
cable
switch
wh ye
gnre
cable
harness
yewh ye
br
cable
switch
yewh wh
LIGHT OFF
LO
P. LIGHT
HI
LIGHT
brake switch
cable
harness
cable
switch
Repair manual KTM LC8
Art.-No. 3.206.056-E
pushed
unpushed
gn- yewh bu
bl
bl
r eye
31
3
or.ye
blue-brown 0.5
white 0.5
brown 0.5
brown 0.5
red-brown 0.5
violett 0.5
L-page4/9
1
fuel l ev e l s ens or
Q
C_ AL 2/2
C_AT2/2
2
green-grey 0.5
green-black 0.5
red-green 0.5
y e l l ow 0.5
yellow-brown 0.5
990 Adventure
O P
3/8
2 9 11
p
C_BJ/1
C_AY/1
I-page2/9
H-page2/9
G-page2/9
brown 0.5
C_CR/1
3 2
C_AG/3
C_BE/3
1
n
tachometer
instruments-tachometer
oil pressure switch
1
2
3
4
handle bar switch
for multi-func.-digitals pe ed om et er
C_AN/4
F-page2/9
red-white 0.5
speed sensor
v
2
black 0.5
M-page4/9
black-orange 0.5
C_AM5/3
C_ AR5/3
black-brown 0.5
1
blue 0.5
N-page5/9
7 13 1 6
red-black 0.5
3 5
yellow-red 0.5
8 12 14 4
yellow-blue 0.5
C_CR2/1
aditional
current
connection
ACC2
C_AA/20
10 15 16
C_CR1/1
aditional
current
connection
ACC1
C_CR3/1
C-page2/9
brown 0.5
Q-page3/9
ye-bu
multi-func.-digital-speedometer
blue-white 0.5
30
7/9
31
K-page
3/9
30
13-112
brown 0.5
31
additional
current
connection
ACC1
handlamp
socket
C_AI/2
blue-brown 0.5
white 0.5
2 9 11
brown 0.5
red-brown 0.5
2
1
fuel level sensor
Q
C_AL2/2
C_AT2/2
2
green-grey 0.5
1
3
yellow 0.5
red-green 0.5
p
or
C_BJ/1
C_AY/1
1
C_BS/2
C_BV/2
H-page2/9
aditional
current
connection
ACC2
G-page2/9
ASP-page 3/9
additional
current
connection
ACC1
instruments-tachometer
Alarm System
2
alarm LED
oil pressure switch
I-page3/9
handle bar switch
for multi-func.-digitalspeedometer
yellow-brown 0.5 4
green-black 0.5
990 Adventure (S)
2007-2008
O P
3/8
1 6
brown 0.5
red-white 0.5
speed sensor
v
2
3
C_AM5/3
C_AR5/3
7 13
6
handlamp
socket
C_AI/2
7
8
or-bl
C_CR2/1
F-page2/9
or.ye
C_CR/1
3 5
red-black 0.5
black-brown 0.5
C_EE/1 C_CR/1
9
yellow-red 0.5
black-orange 0.5
C_EE/1 C_CR/1
C_CR/1
14 13 12 11 10
C_CR3/1
rt-bl
C_EE/1 C_CR/1
C_CR/1
8 12 14 4
violett 0.5
L-page4/9
pu
C_EE/1 C_CR/1
1
10 15 16
black 0.5
M-page4/9
ye-re
bl
5
4
2
1
C_EF/14
C_EG/14
2
3
C_AG/3
C_BE/3
1
n
tachometer
3
alarm system dummy plug
br
C_AA/20
blue 0.5
N-page5/9
Antenna
C_CR/1
C_AN/4
brown 0.5
Connector for
optional
alarm system
bu
brown 0.5
Q-page3/9
brown 0.5
multi-func.-digital-speedometer
ye-bu
30
K-page
3/9
2
31
7/9
C-page2/9
1
C_BS/2
C_BV/2
seat
surveillance
bu
yellow-blue 0.5
30
for optional alarm system
Art.-No. 3.206.056-E
blue-white 0.5
br
Repair manual KTM LC8
13-113
battery
30
31
2
2 1
or
1
re
C_EA/1
or
2
br
re-gn
2
1
C_AM5/3
C_ AR5/3
on main harness
2
C_ DL /2 6
4 1
990 Adventure
re
lbu
1
bl
to s p eed s ens or c o nne c tor
br
C_ AL 3/2
ye-or
bl-or
C_AT3/2
or
3
18 11
3
7
5
6
8
4
A B S c o n t r ol l i g h t
1
C_DN/8
C_ DO/8
ye-or
25
A
bl-or
re-gn
40
A
br
lbu
on main harness
br
2
23 12 14
bu-wh
ABS fuse box
br
wh
7 19
bl-wh
gr
AB S h a rne s s - 601.1 1 .079 . 000
ABS
gr-bl
16 5
1
2
C_ DM1/2
front wheel
revolution sensor
gr
t o A B S c o n n e c to r
bl
re
gr-bl
br
ye-bl
ye-bl
A
B
1
2
C_ DM/2
rear wheel
revolution sensor
wh
bu-wh
gn
gn
S
wh-bl
30
4/9
31
30
13-114
left flasher
right flasher
headlight
m ai n r el ay
tachometer
ACC1
ACC2
starter motor
M
battery
ECU
fuel pump
regulator
ground connection
ECU
temperature switch
30
A
start relay
Art.-No. 3.206.056-E
990 Adventure
clutch switch
handlebar switch
right-left front flasher
multi-func.-digital-speedometer
horn switch
Repair manual KTM LC8
8/9
rear light/brakelight
rear flasher
octane selector
diagnostic connector
fuel level sensor
13-115
left flasher
right flasher
headlight
main relay
tachometer
ACC1
ACC2
clutch switch
starter motor
990 Adventure (S)
2007-2008
handlebar switch
right-left front flasher
multi-func.-digital-speedometer
horn switch
M
battery
ECU
alarm LED
regulator
ground connection
ECU
starter interlock
fuel pump
temperature switch
30
A
start relay
alarm system
8/9
seat
surveillance
rear light/brakelight
rear flasher
octane selector
diagnostic connector
fuel level sensor
13-116
rear brake switch
tachometer
front brake switch
fl as he r re la y
horn
990 Adventure
multi-func.-digital-speedometer
ye-bu
ye
fan
A
10
A
A
A
10
10
A
15 10
fuel pump relay
fus e box
C_ AF3/4
A
A
A
10
ye-re
re-bl
re-wh
10 10
3
30
A
start relay
gr
battery
power relay
positive connection
ignition switch
1
light relay
ye
light switch
ye-bl
M
ye-bu
high/low beam switch
starter motor
bl-wh
gn-re
Art.-No. 3.206.056-E
re-wh
Repair manual KTM LC8
accesory
accesory
ABS
regulator
9/9
13-117
rear brake switch
tachometer
front brake switch
fl as he r re la y
990 Adventure
multi-func.-digital-speedometer
ye-bu
fan
A
10
A
A
A
10
10
A
15 10
fuel pump relay
fus e box
C_ AF3/4
A
A
A
10
ye-re
re-bl
re-wh
10 10
3
30
A
start relay
gr
battery
power relay
positive connection
ignition switch
1
ye
horn
ye
light relay
ye-bu
light switch
bl-wh
gn-re
high/low beam switch
ye-bl
M
re-wh
starter motor
accesory
accesory
ABS
regulator
9/9
13-118
13-119
Connector AA
20-pole 1
11 1
Multifunctional digital
speedometer
Behind
the
functional
speedometer
1
multi
digital
20 10
Connector AB
9-pole 2
3
1
9
2
Start/stop/light switch
On
the
connector
support
under
the
multifunctional digital
speedometer
4
Connector AC
6-pole 3
Front light
Art.-No. 3.206.056-E
1
4
3
6
On
the
connector
support
under
the
multifunctional digital
speedometer
Connector AD
12-pole 4
1
3
7
12
Light/turn signal/horn
switch
On
the
connector
support
under
the
multifunctional digital
speedometer
Repair manual KTM LC8
Connector AE
4-pole 5
1
4 2
Idle speed control motor
5
On the throttle body
Connector AE1
4-pole 6
Start relay
On the right side of the
battery case
3
6
13-120
Connector AF
4-pole 1
Main relay
1
Connector AF1
4-pole 2
42
1
Fuel pump relay
2
Connector AF2
4-pole 3
Auxiliary starter relay
Connector AF3
4-pole 4
Lighting relay
On
the
connector
support
under
the
multifunctional digital
speedometer
4
3
Connector AG
3-pole 5
Tachometer
1
On
the
connector
support
under
the
multifunctional digital
speedometer
3
5
Connector AH
2-pole 6
6
Rear brake light switch
Under the right rear side
cover
1 2
Connector AH1
2-pole 7
Turn signal relay
On
the
connector
support
under
the
multifunctional digital
speedometer
7
Connector AI, AI1, AI2
2-pole 8
Diodes
2
1
Behind
mask
the
headlight
8
13-121
Connector AJ
3-pole 1
1
2
3
1
Rear lighting system
Under the right rear side
cover
Connector AK
2-pole 2
2
Rear brake light switch
1
2
Under the right rear side
cover
Connector AL
2-pole 3
3
Pick up
1
Art.-No. 3.206.056-E
2
Between the water pipe
and the front cylinder
head
Connector AL1
2-pole 4
4
Clutch switch
Behind the headlight
under the connector
support
Connector AL2
2-pole 5
Repair manual KTM LC8
Fuel sender
Between the left tank and
the frame
Connector AL3
2-pole 6
ABS connection
Under the seat next to
the ABS unit
5
6
13-122
Connector AM
3-pole 1
1
3
Throttle sensor for the
2nd throttle
1
Connector AM1
3-pole 2
2
Throttle sensor
On the throttle body
Connector AM2
3-pole 3
Gear sensor
3
4
Connector AM3
3-pole 4
Side stand switch
On the left side of the engine
in front of the generator cover
Connector AM4
3-pole 5
Fuel pump
5
Between the left tank and
the engine
Connector AM5
3-pole 6
Speed sensor
6
Behind the headlight
under the connector
support
Connector AN
4-pole 7
7
Tripmaster switch
1 2
4
On
the
connector
support
under
the
multifunctional digital
speedometer
Connector AO
26-pole 8
20
14
8
1
ECU (Control unit)
Under the headlight
26
19
13
7
8
13-123
Connector AP
6-pole 1
Ignition switch
1
3
6
Under the fuse box
1
Connector AP1
6-pole 2
2
Diagnosis connector
Under the seat next to
the ABS unit
Connector AP2
6-pole 3
3
Rollover sensor
Art.-No. 3.206.056-E
Behind
mask
the
headlight
Connector AR
3-pole 4
3
1
Throttle sensor
2nd throttle
Connector AR1
3-pole 5
4
5
Throttle sensor
On the throttle body
Connector AR2
3-pole 6
Repair manual KTM LC8
Gear sensor
6
Connector AR3
3-pole 7
7
Side stand switch
On the left side of the
engine in front of the
generator cover
Connector AR4
3-pole 8
Fuel pump
Between the left tank and
the engine
8
13-124
Connector AR5
3-pole 1
Speed sensor
3
1
Behind the headlight
under the connector
support
1
Connector AS
2-pole 2
1
2
2
Rear ignition coil
Behind the air filter box
Connector AS1
2-pole 3
3
Front ignition coil
Behind the radiator
Connector AT
2-pole 4
Pick up
1
2
Between the water pipe
and the front cylinder
head
4
Connector AT1
2-pole 5
Clutch switch
Behind the headlight
under the connector
support
5
Connector AT2
2-pole 6
Fuel sender
Between the left tank and
the frame
6
13-125
Connector AT3
2-pole 1
1
ABS connection
1
2
Under the seat next to
the ABS unit
Connector AU
2-pole 2
Controller
21
On the right side of the
battery case under the
starter relay
2
Connector AU1
2-pole 3
Fan motor
3
Art.-No. 3.206.056-E
Behind the radiator on
the right side of the fan
Connector AV
2-pole 4
1
2
Temperature switch for
radiator fan
Behind the radiator on
the right side of the
compensating tank
4
Repair manual KTM LC8
Connector AX
2-pole 5
1
2
Coolant temperature
sensor
5
On the left between the
cylinders
Connector AY
1-pole 6
Oil pressure switch
On the outer left side of
the frame
6
13-126
Connector AZ
4-pole 1
1
2
3
4
Rear turn signal
1
Under the right rear side
cover
Connector BA
1-pole 2
Octane selector
Behind the air filter box
Connector BB
9-pole 3
1
3
7
9
2
3
Start/stop/light switch
On
the
connector
support
under
the
multifunctional digital
speedometer
5
Connector BC
6-pole 4
Front light
3
6
1
On
the
connector
support
under
the
multifunctional digital
speedometer
Connector BD
12-pole 5
3
1
10
12
Light/turn signal/horn
switch
On
the
connector
support
under
the
multifunctional digital
speedometer
Connector BE
3-pole 6
1
3
Tachometer
On
the
connector
support
under
the
multifunctional digital
speedometer
4
6
13-127
Connector BF
1-pole 1
Octane selector
1
Behind the air filter box
Connector BH
6-pole 2
Ignition switch
1
3
6
Under the fuse box
2
Connector BH1
6-pole 3
Diagnosis connector
Under the seat next to
the ABS unit
Art.-No. 3.206.056-E
3
Connector BI
2-pole 4
Controller
21
On the right side of the
battery case under the
starter relay
4
Connector BI1
2-pole 5
Fan motor
5
Repair manual KTM LC8
Behind the radiator on
the right side of the fan
Connector BJ
1-pole 6
Oil pressure switch
1
On the left side of the
frame under the air
filter box
6
13-128
Connector CA
4-pole 1
Rear lambda probe
1
2
3
4
On the left side of the
air filter box
4
1
Connector CA1
4-pole 2
5
Front lambda probe
On the right side of the
frame
2
Connector CA2
4-pole 3
Control motor for the
2nd throttle
On the throttle body
6
3
Connector CE
4-pole 4
Rear lambda probe
1
2
3
4
On the left side of the
air filter box
Connector CE1
4-pole 5
Front lambda probe
On the right side of the
frame
Connector CE2
4-pole 6
Control motor for the
2nd throttle
On the throttle body
Connector CK
2-pole 7
SLS Valve
2 1
Behind the air filter box
7
13-129
Connector CL
2-pole 1
Rear injection valve
1
2
On the throttle body
1
Connector CL1
2-pole 2
Front injection valve
On the throttle body
2
Connector CM
2-pole 3
3
Air temperature sensor
2
On the top of the air
filter box
Art.-No. 3.206.056-E
1
Connector CO
34-pole 4
26
18
10
1
ECU (Control unit)
Under the headlight
34
25
17
4
9
Connector CP
16-pole 5
Repair manual KTM LC8
4
1
EFI wiring harness
On the right side of the
frame
6
16
5
Connector CQ
16-pole 6
1
4
EFI wiring harness
On the right side of the
frame
16
13-130
Connector CR
1-pole 1
Connector for
attachments:
Kl 15 (positive ignition)
Kl 30 (continuous
positive polarity)
Kl 31 (ground)
Behind the headlight under
the connector support
1
Connector CW
2-pole 2
Left front turn signal
1 2
3
Connector CX
2-pole 3
Right front turn signal
2
Under the front left side
cover
Connector CW1
2-pole 4
5
Right front turn signal
2 1
Connector CX1
2-pole 5
Right front turn signal
Under the front right
side cover
4
Connector DL
26-pole 6
ABS-ECU (Control unit)
6
Under the seat
Connector DM
2-pole 7
7
Rear ABS sensor
In front of the ABS unit
Connector DM1
2-pole 8
Front ABS sensor
Behind the headlight
8
13-131
Connector DN
8-pole 1
ABS control lamp
Behind the headlight
1
2
Connector DO
8-pole 2
ABS control lamp
Behind the headlight
Connector DP
3-pole 3
Manifold air pressure
sensor for the rear
cylinder
Art.-No. 3.206.056-E
On the left side of the
frame
3
Connector DP1
3-pole 4
Manifold air pressure
sensor for the front
cylinder
On the right side of the
frame
4
Connector DP2
3-pole 5
Repair manual KTM LC8
Ambiant air pressure
sensor
Behind
mask
the
headlight
5
multi-func.-digital-speedometer
front
brake switch
v
C_AK1/2
1
2
C_AA/20
speed sensor
clutch switch
2
7
15
1
19
6
10
9
3
4
5
left fron t flas her
right fron t flasher
C_AH1/2
16
bu- br
or
bl
pu
bu
gn- gr
re-br
br-bl
ye-bl
1
2
gn- w h
br
ye
1
2
1
3
2
br
bl
C_AT3/2
wh
br
gn
bu
br
C_BL1/2
M
cool ing fan
M
cool ing fan
C_CD1/2
1
2
6
5
C_ AY/1
C_BJ/1
ye-bl
oil pr ess ur e s ens or
p
2
3
1
4
wh
temp er atur e switch
C_BL/2
C_CD/2
1
2
1
C_AV/2
2
C_BC1/6
bu
C_AC1/6
ye
gn
950 Super Enduro 2006/07
pu
br
br
bl-or
or
2
1
br-bl
bl-or
C_AM3/3
gn-bl
ye- bu
C_AR3/2
C_AL3/2
3
br
bl-wh
br
C_CR1/1
bl-wh
C_ BA /1
C_BF/1
2 1
3
C_BT/3
C_AJ1/3
bl
C_CR/1
br-bl
br-bl
or
ye-re
br-bl
br
gr
gn-gr
pu
1
3
2
N
ye- bu
gr
t°
C_AX/2
1
G
flas her relay
2
front
C_AS1/2
1
rear
1
2
EPC 1 EPC 2
3
C_AR2/3
C_ AM 2/ 3
2
ye-br
5
4
13
ignition switch
7 19 11 4 25 26 18
8
A
A
10
A
10
A
10
A
10
A
15 10
A
10
16
9
1
A
10
ye- bu
ye- wh
ye-bl
bl-or
2
Pick up
C_AT/2
C_AL/2
1
2 1
C_AT2/2
C_AL2/2
M
1
4
2
3
M
engi ne stop relay
starter m otor
C_AF4/4
fuel pump
fuse box
2
TPS
C_AR/3
C_A M /3
3
1
main harness - 630.11.075.000
8
1
C_AC/6
C_BC/6
3 16 10
br-wh
C_AO/26
20
2
sid es tand switch
1
2
3
4
C_BR/4
C_BK1/4
C_AW1/2
2 1
C_AW/2
1
C_AS/2
2
horn
1
tem peratu re sens or
1
2
2
1
2
ye- bu
bl-or
bl-or
or
C_AH3/2
wiring diagramm
neu tral s witch 2nd gear
3rd gear
2nd
C_AR1/3
C_ AM 1/ 3
1
3th
fuel level sen sor
Q
C_AL1/2
C_AT1/2
2
gr
C_CR2/1
or
adition al
curr ent
conn ec ti on
ACC1
diode
re-gn
br
bl-or
black
or-wh
bu
or
re-wh
or-bl
br
re
re-gn
or
ye
bu
ye
or
pi
or
ye-bu
ye-wh
or
re-bl
or
bl-wh
br-bl
C_CR3/1
br
or
re-gn
re-br
ye-br
headlight
positionlight
bl
pu-wh
br
bl-gn
C_BW/3
C_DI/2
bu-bl
ye-bu
s t a r t b o t t om
4
3 2
C_AF3/4
1
30
A
star t relay
br
flash er switch
re-bu
re-bl
re-wh
adition al
curr ent
conn ec ti on
ACC2
re-wh
hi gh /l ow b eam switch
horn swi tch stop button
pu-wh
ye-wh
br-bl
or
2
1
br
re
C_AT4/2
4
1
2
4
3
3
bu- gr
ye-bl
re- bu
ye- bu
1
2
re- wh
re- wh
rear
brake switch
start auxillary r elay
fuel pum p relay
lig ht sys tem relay
gn
heater el em en t heater el em en t
4
1
or -w h
ye
2
or
br
3
or
bu- bl
2
re- bu
re
1
re- wh
20.10.2005
temp er atur e switch
for car buretor heating
C_AK2/2
C_ AH 2/ 2
1
2
battery
re-bl
Art.-No. 3.206.056-E
bu-gr
bl
C_AI3/2
or
ignition coil
pi
ye
ye-bl
br-wh
re
gr
E
or
C
bu
re-wh
ye-bl
U
C_AH/2
C_AF2/4
C_AF1/4
C_AF/4
2
1
wh
gn- w h
br
wh
3
1
2
4
2
3
1
br
bl
C_BI/2
pu
G
1/8
left r ear fl ash er
lic en ce p late lamp
right rear flasher
2
C_AI2/2
1
2
C_AI1/2
1
2
C_AI/2
1
diode
diode
gen erator
diode
3
U
regu lator-rectifier
ye
C_AJ/3
C_BG/3
re-wh
bu-br
bl
gn-wh
C_AL4/2
ye
or
re-wh
re-ye
ye-bu
C_AK/2
gn-bl
C_AZ/4
C_BK/4
ye
pi
Repair manual KTM LC8
13-132
rear light/brakelight
C_AU/2
handle bar switch
for multi-func.-digitalspeedometer
speed sensor
v
C_DB/4
C_AK1/2
2
4
3
C_AH1/2
1
2
C_AA/20
2
7
15
1
19
6
10
9
3
4
5
16
14
13
11
ye-br
ye
gn-re
br
left front flasher
right front flasher
clutch switch
1
br
gn-gr
re-br
br-bl
ye-bl
gn-bl
1
2
gn-wh
1
2
pu
bu
1
3
br
ye-re
1
6
5
C_BJ/1
C_AY/1
C_BF/1
2 1
C_BT/3
3
2
M
cooling fan
M
3th
3
N
gr
ye-bu
t°
C_AX/2
1
G
flasher relay
2
front
C_AS1/2
1
rear
2 1
3
4
C_BR/4
C_BK1/4
1
2
EPC 1 EPC 2
2
3
C_AR2/3
C_AM2/3
sidestand switch
C_AW1/2
2 1
C_AW/2
1
C_AS/2
2
horn
1
temperature sensor
1
2
2
1
2
ye-bu
bl-or
bl-or
or
wiring diagramm
neutral switch 2nd gear
3rd gear
2nd
C_AM1/3
1
C_AR1/3
C_BL1/2
1
fuel level sensor
Q
C_AL1/2
C_AT1/2
2
1
C_BA/1
C_CD1/2
oil pressure sensor
p
2
3
C_AJ1/3
2
cooling fan
C_BL/2
C_CD/2
2
temperature switch
C_AV/2
1
2
4 1
C_AC1/6
C_BC1/6
950 Super Enduro
2007-2008
br
wh
gn
br
2
br
br
bl
bl-or
or
br
br-bl
2
1
3
ye
C_CR/1
bu-br
or
bl
pu
C_CR2/1
wh
C_CR1/1
bl-or
C_AM3/3
bu
ye-bu
C_AR3/2
C_AL3/2
multi-func.-digital-speedometer
headlight
C_AT3/2
ye
gn
bl-wh
front
brake switch
positionlight
ye-bl
br-bl
C_BW/3
C_DI/2
bu
aditional
current
connection
ACC1
bl-wh
br-bl
br
br
br-bl
br
gr
gn-gr
pu
or
bl
re-br
ye-br
gr
black
or
re
C_CR3/1
2
ye-br
3 16 10
C_AO/26
20
5
8
1
C_AC/6
C_BC/6
4
13
bl-or
aditional
current
connection
ACC2
or
br
bl-gn
C_AH3/2
C_AI3/2
or
re
gr
or
or
9
1
A
10
fuse box
main harness -
7 19 11 4 25 26 18
8
A
A
A
10
A
10 10
A
10
A
15 10
A
10
16
or
br
ye-bu
fuel pump
1
4
2
3
630.11.075.200
Pick up
C_AT/2
C_AL/2
2
1
ye-wh
ye-bl
bl-or
2 1
C_AT2/2
C_AL2/2
M
M
engine stop relay
starter motor
C_AF4/4
TPS
C_AR/3
C_AM/3
2 1
3
4
3 2
C_AF3/4
1
30
A
start relay
br
start bottom
re-wh
flasher switch
re-wh
high/low beam switch
horn switch stop button
re-bu
re-bl
pu-wh
diode
re-gn
or
ye
or-wh
bu
re-gn
pi
pu-wh
bl
re-gn
br-bl
or
2
1
br
re
C_AT4/2
24.05.2007
temperature switch
for carburetorheating
C_AK2/2
C_AH2/2
1
2
battery
re-bl
Art.-No. 3.206.056-E
pi
bu-gr
ye-bl
br-wh
ignition coil
br-wh
E
or
ye-bu
or-bl
ye-bu
or
re-bl
re-wh
bl-wh
ye
bu
bl
br
ye-wh
bu-bl
ye-bu
ignition switch
or
C
bl
2
4
3
3
bu-gr
ye-bl
re-bu
ye-bu
or-wh
ye
or
4
1
2
1
bu-bl
br
3
2
4
1
or
re
br
re-wh
C_AF2/4
C_AF1/4
C_AF/4
2
1
2
re-wh
re-wh
rear
brake switch
start auxillary relay
fuel pump relay
light system relay
gn
heaterelement heaterelement
1
re-wh
ye-bl
U
bu
ye
gn-wh
C_AL4/2
re-wh
bu-br
ye-wh
C_AH/2
re-wh
re-ye
br-bl
C_AK/2
C_BI/2
2
wh
gn-wh
br
3
2
1
4
1
wh
br
3
pu
bl
G
1/8
left rear flasher
licence plate lamp
right rear flasher
2
C_AI2/2
1
2
C_AI1/2
1
2
C_AI/2
1
diode
diode
generator
diode
3
U
regulator-rectifier
ye
C_AZ/4
or
C_BK/4
C_AJ/3
gn-bl
ye
C_BG/3
ye
pi
Repair manual KTM LC8
13-133
rear light/brakelight
C_AU/2
13-134
Aditional current connection
Battery
Carb heater (Carburator heater element)
Clutch switch
Cooling fan
Diode
ECU
Engine stop relay
Flasher relay
Flasher switch
Front brake switch
Fuel level sensor
Fuel pump
Fuel pump relay
Fuse box
Gear sensor
Generator
Headlight
High / low beam switch
Horn
Horn switch
Ignition coil
Ignition switch
Left front flasher
Left rear flasher
Licence plate lamp
Light system relay
Multi-func.-digital-speedometer
Neutral switch
Oil pressure sensor
Pick up
Position light
Rear brake switch
Rear light / brakelight
Regulator-rectifier
Right front flasher
Right rear flasher
Sidestand switch
Speed sensor
Start auxillary relay
Starter motor
Stop button
Temperature switch
Throttle position sensor (TPS)
Stromversorgung für Zusatzgeräte
Batterie
Vergaserheizelement
Kupplungsschalter
Lüftermotor
Diode
Steuergerät
Motor-Stoprelais
Blinkerrelais
Blinkerschalter
vorderer Bremslichtschalter
Benzinstandgeber
Kraftstoffpumpe
Kraftstoffpumpenrelais
Sicherungskasten
Gangerkennung
Generator
Scheinwerfer
Auf-Abblendschalter
Hupe
Hornschalter
Zündspule
Zündschloss
linker vorderer Blinker
linker hinterer Blinker
Kennzeichenbeleuchtung
Beleuchtungsrelais
Multifunktionsdigitaltachol
Leerlaufschalter
Öldruckschalter
Impulsgeber
Begrenzungslicht
hinterer Bremslichtschalter
hinteres Begrenzungslicht / Bremslicht
Regelgleichrichter
rechter vorderer Blinker
Rechter hinterer Blinker
Seitenständerschalter
Geschwindigkeitssensor
Starterhilfsrelais
Startermotor
Stoptaster
Temperaturschalter
Vergaserpotentiometer
NOTE to the connector designations:
The connector designations are comprised of letters and numbers - e.g.: C_AA1/20
– The 1st position C stands for connector (connector).
– The 2nd and 3rd positions AA stand for the connector type.
– The 4th position numbers the same type of connector if the connector is used for different
applications.
– The 5th and 6th positions 20 specify the number of pins in the connector, in this case 20
poles. The 5th position is not required for connectors with less than 10 pins.
Cable colours
bl: black
ye: yellow
bu: blue
gn: green
re: red
wh: white
br: brown
or: orange
pi: pink
gr: grey
pu: purple
30
A
M
battery
start relay
red-white 1
br
brown 0.5
4
red-white 1
1
A
H-page6/8
fus e box
F-page6/8
s t a r t a ux i l la r y r e l ay
3
2
4
1
1
4
2
3
light system relay
950 Super Enduro 2006/07
E-page3/8
D-page 4/8
C-page 5/8
B-page 5/8
A-page3/8
9
G
generator
G-page 6/8
A
A
8
3
U
red-white 1
red-white 1
red-white 1
red-blue 0.5
starter motor
regulator-rectifier
10 10
A
10
A
10
A
10
A
15 10
A
10
16
or
or-bl
re-wh
re-wh
ye
re-bu
or
ye-bu
3
or
bl-wh
re-wh
re-wh
ye-bl
2
re-wh
bu-br
1
re-wh
re-ye
4
2 1
clutch switch
3th
1
2
C_AI1/2
diode
5
N
3
green-black 0.5
pi nk 0.5
neutral switch (N) / 2nd gear / 3rd gear
2nd
C_ AR1/3
1
C_AM1/3
2
2
C_AI2/2
C_AT3/2
1
2
diode
4
C_ AC/6
C_ BC/6
ignition switch
C_ AL 3/2
y e l l ow 0 . 5
1
C_AI/2
diode
re-wh
start system
3
C_ BR/4
C_BK1 /4
start bottom
orange-white 0.5
orange-white 0.5
black
red 0.5
30
C_AF/4
C_AF2/4
or
re-bl
Art.-No. 3.206.056-E
brown 0.5
Repair manual KTM LC8
2/8
31
I-page6/8
J-page3/8
30
13-135
red-white 1
C_AF3/4
starter motor
30
A
M
battery
start relay
red-white 1
br
brown 0.5
4
red-white 1
3
9
1
A
10
F -pa ge 6 /8
G -pa ge 6 /8
H -pa ge 6 /8
fus e box
ge ne ra tor
G
U
red-white 1
red-white 1
s ta rt a ux illa ry re la y
3
2
4
1
1
4
2
3
light s ys te m re la y
950 Super Enduro 2007
E -pa ge 3 /8
D -pa ge 4 /8
C -pa ge 5 /8
B -pa ge 5 /8
A -pa ge 3 /8
8
A
A
10
A
10
A
10
A
10
A
15 10
A
10
16
or
or-bl
re -bu
re-wh
ye
re -wh
or
ye-bu
3
or
bl-wh
re -wh
re-wh
ye-bl
2
re-wh
bu-br
1
re-wh
re-ye
or
re-bl
red-white 1
red-blue 0.5
4
2
1
c lutc h s witc h
3 th
2
C _ A I 1 /2
1
diode
5
N
3
gre e n-bla c k 0 . 5
pink 0 . 5
ne utra l s witc h ( N ) / 2 nd ge a r / 3 rd ge a r
2 nd
C _ A R 1 /3
1
C _ A M1 /3
2
2
C _ A I 2 /2
C _ A T 3 /2
1
2
diode
4
C _ A C /6
C _ B C /6
ignition s witc h
C _ A L 3 /2
ye llow 0 . 5
C _ A I /2
1
diode
re -wh
s ta rt s y s te m
3
C _ B R /4
C _ B K 1 /4
orange-white 0.5
orange-white 0.5
black
red 0.5
re gula tor- re c tifie r
C_AF/4
C_AF2/4
s ta rt bottom
brown 0.5
30
2 /8
31
I -pa ge 6 /8
J -pa ge 3 /8
30
13-136
red-white 1
C_AF3/4
31
3
C_ BR/4
C_BK1 /4
2 1
black
red 0.5
ignition switch
C_AO/26
violet-white 0.5
brown-white 0.5
red-green 0.5
brown 0.5
2
3
20
7
yellow-brown 0.5
grey 0.5
18
10
black-brown 0.5
8
16
blue-grey 0.5
pi nk 0.5
1
1
2
2
EPC 1 EPC 2
C _ AW1 / 2
2 1
C _ AW/ 2
1
3
C_ AF4/4
1
1
front
C_ AS1/2
2
4
engi n e s t op r el ay
950 Super Enduro
orange 1
U
C
E
y e l l ow 0.5
b l ac k 0 .5
11
4
bl ue 0.5
yellow-white 0.5
yellow-blue 0.5
yellow-orange 0.5
19
26
13
25
2
C_ AL /2
C_AT/2
pick up
orange-black 0.5
ignition coil
start bottom
brown 0.5
A-page2/8
1
rear
C_ AS/2
2
1 2
C_AM/3
C_ AR/3
2
3th
1
3
C_ AR2/3
C_AM2/3
N
2
sidestand switch
J-page2/8
ECU
neutral switch (N) / 2nd gear / 3rd gear
2nd
C_AM1/3
C_ AR1/3
1
3
throttle position sensor
o-page5/8
fuel pump relay
brown 0.5
30
C_AF1/4
fuel pump
Art.-No. 3.206.056-E
1
black-blue 0.5
M
C_ AL 2/2
C_AT2/2
2
1
4
2
3
30
3/8
31
E-page2/8
yellow-black 1
brown 0.5
Repair manual KTM LC8
13-137
31
M-page6/8
L-page6/8
2
1
C_AH3/2
3 2
C_ BT/3
C_ AJ1/3
1
flasher switch
G
v i o l et 0. 5
bl ac k 0 . 5
violet 0.5
2
black 0.5
3
right front flasher
brown 0.5
left front flasher
950 Super Enduro
rear flasher light`s
C_BK/4
C_ AZ/4
1
1
6
horn switch
C_ B C1 / 6
C_ A C1 / 6
5
horn
brown 1
C_ AV/2
1
D-page2/8
black-white 1
2
1
2
1
2
temperature switch
turn indicator system
diode
C_AI3/2
2
yellow-blue 0.5
C-page2/8
grey 0.5
fl as he r re la y
brown 0.5
brown-black 1
black-orange 0.5
brown 0.5
C_CD/2
C_CD1/2
M
31
30
4/8
cooling fan
M
cooling fan
C_BL/2
C_BL2/1
30
13-138
orange 0.5
13-129
ignition switch
bl-or r-w
re
clutch switch
r-w
switch
position
ON
ye
pulled
unpulled
OFF
Repair manual KTM LC8
Art.-No. 3.206.056-E
LOCKED
flasher switch
cable
harness
TURN L
TURN R
or
pu
horn switch
bl
cable
color
HORN
OFF
OFF
gr
br
br
31
C_BF/1
C_BC1/6
C_BA/1
yellow 1
yellow 1
N-page6/8
bl ue 1
green 1
rear brake switch
front brake switch
950 Super Enduro
4
1
3
2
5
white 0.5
C-page2/8
brown 0.5
C_AK1/2
C_AK/2
2
1
4
green-white 0.5
2
1
C_BG/3
C_ AJ/3
3
white 0.5
2
rear light/brakelight
1
C_DI/2
positionlight
light-brake system
headlight
C_BK/4
C_ AZ/4
1
1
2
blue-yellow
C_AH1/2
C_AH/2
B-page2/8
1 3
C_BW /3
2
headlight
brown 0.5
30
brown 0.5
5/8
31
30
13-140
C_AC1/6
O-page3/8
high/low beam switch
horn switch stop button
13-141
light switch
high/low beam switch
brake switch
cable
harness
cable
switch
pushed
unpushed
gn- yewh bu
bl
bl
cable
color
LIGHT OFF
P.LIGHT
LO
HI
Repair manual KTM LC8
Art.-No. 3.206.056-E
P.LIGHT
bu
ye gn
wh
31
3
orange 0.5
1
speed sensor
v
2
black-brown 0.5
C_AM3/3
C_ AR3/3
black-orange 0.5
1
yellow-black 0.5
19
3 5
7
M-page4/8
L-page4/8
9 4
2
N-page5/8
1 6
brown 0.5
temperature sensor
brown-black 0.5
950 Super Enduro
t°
C_ AX/2
2
10 15 16
violett 0.5
C_AA/20
multi-func.-digital-speedometer
blue 0.5
p
1
C_BJ/1
C_AY/1
1
fuel l ev el s ens or
Q
C_ AL 2/2
C_AT2/2
2
brown 0.5
instruments-tachometer
oil pressure sensor
green-grey 0.5
red-brown 0.5
green-black 0.5
orange 0.5
K-page3/8
C_CR3/1
red-black 0.5
blue-brown 0.5
H-page2/8
C_CR2/1
aditional
current
connection
ACC2
F-page2/8
black 0.5
G-page2/8
C_CR1/1
yellow-red 0.5
I-page2/8
aditional
current
connection
ACC1
30
brown 0.5
6/8
31
30
13-142
C_CR/1
left front flasher
positionlight
headlight
right front flasher
ACC1
ACC2
M
ECU
C_ AF3/4
battery
regulator
temperature sensor
temperature switch
30
A
950 Super Enduro
clutch switch
carburetorheating
fuellevelsensor
right-left front flasher
multi-func.-digital-speedometer
horn switch
starter motor
start relay
Art.-No. 3.206.056-E
ground connection
brown
Repair manual KTM LC8
7/8
rear light/brakelight
m ai n r el ay
rear flasher
fuel pump module
engine stop relay
13-143
front brake switch
fl as he r re la y
diode
Fa n
8
A
A
9
1
A
10
fuse box
fuel pump relay
A
A
10
A
10 10
A
10
A
10 15 10
16
30
A
battery
positive connection
ignition switch
rear brake switch
950 Super Enduro
multi-func.-digital-speedometer
yellow-blue
engine stop relay
yellow
yellow-blue
horn
red-white
C_ AF3/4
yellow-black
black-white
light switch
M
blue-brown
high/low beam switch
yellow
black-orange
Orange
red-yellow
regulator
green
green
ACC1
ACC2
carburetorheating
8/8
s ta r t a ux i l l a r y r e l ay
C_AF/4
start relay
red-black
starter motor
13-144
13-145
Connector AA
20-pole 1
1
11 1
Multifunctional digital
speedometer
Behind
the
multi
functional digital speedo
meter
20 10
Connector AC
6-pole 2
Ignition switch
1
4
3
6
Behind
mask
the
3
headlight
2
Connector AC1
6-pole 3
Light/horn/stop switch
Art.-No. 3.206.056-E
Behind
mask
the
headlight
Connector AF
4-pole 4
1
42
Auxiliary starter relay
Under the seat
Connector AF1
4-pole 5
Fuel pump relay
Under the seat
Connector AF2
4-pole 6
Lighting relay
Repair manual KTM LC8
Under the seat
Connector AF3
2-pole 7
Starter relay
Under the seat
Connector AF4
2-pole 8
Engine stop relay
Under the seat
6 458
7
13-146
Connector AH
2-pole 1
Rear brake light switch
On the right side of the
frame
1 2
Connector AH1
2-pole 2
Front brake light switch
Behind
mask
the
1
6
headlight
Connector AH2
2-pole 3
4
2
3
Temperature switch for
the carburetor heater
Behind
mask
the
headlight
Connector AH3
2-pole 4
Flasher relay
Behind
mask
the
headlight
Connector AI
2-pole 5
2
1
Diode for neutral switch
Under the seat
Connector AI1
2-pole
Diode for side stand
switch
Under the seat
Connector AI2
2-pole
Diode for side stand
switch
Under the seat
Connector AI3
2-pole 6
Diode for flasher control
Behind the headlight
mask next to the flasher
relay
5
13-147
Connector AJ
3-pole 1
1
2
3
Rear lighting
Under the seat in the
back of the storage
compartment
1
Connector AJ1
3-pole 2
Flasher switch
Behind
mask
the
headlight
2
Connector AK
2-pole 3
Rear brake light switch
Art.-No. 3.206.056-E
1
2
On the right side of the
frame
Connector AK1
2-pole 4
Front brake light switch
Behind
mask
the
headlight
Connector AK2
2-pole 5
Temperature switch for
carburetor heater
Behind
mask
Repair manual KTM LC8
3
the
headlight
5
4
13-148
Connector AL
2-pole 1
Pulse generator
1
2
1
On the left between the
oil
tank
and
the
generator cover
Connector AL1
2-pole 2
Fuel sender
On the front left next to
the radiator
2
3
Connector AL2
2-pole 3
Fuel pump
On the front left next to
the radiator
Connector AL3
2-pole 4
4
Clutch switch
Behind the headlight
Connector AL4
2-pole 5
Carburetor heater
Between the steering
head and the ECU
5
13-149
Connector AM
3-pole 1
Throttle sensor
1
3
Between the steering
head and the ECU
1
Connector AM1
3-pole 2
2
Gear sensor
On the left between the
oil
tank
and
the
generator cover
3
Connector AM2
3-pole 3
Side stand switch
Art.-No. 3.206.056-E
On the left between the
oil
tank
and
the
generator cover
Connector AM3
3-pole 4
Speed sensor
Behind the headlight
4
Connector AO
26-pole 5
Repair manual KTM LC8
20
14
8
1
Control unit
Behind
head
26
19
13
7
the
steering
5
13-150
Connector AR
3-pole 1
3
1
Throttle sensor
Between the steering
head and the ECU
1
Connector AR1
3-pole 2
Gear sensor
3
2
On the left between the
oil
tank
and
the
generator cover
Connector AR2
3-pole 3
Side stand switch
On the left between the
oil
tank
and
the
generator cover
Connector AR3
3-pole 4
Speed sensor
Behind the headlight
4
Connector AS
2-pole 5
1
2
Rear ignition coil
5
Behind the air filter box
Connector AS1
2-pole 6
Front ignition coil
Behind the radiator
6
13-151
Connector AT
2-pole 1
Pulse generator
1
2
On the left between the
oil
tank
and
the
generator cover
1
Connector AT1
2-pole 2
Fuel sender
On the front left next to
the radiator
3
2
Connector AT2
2-pole 3
Fuel pump
Art.-No. 3.206.056-E
On the front left next to
the radiator
Connector AT3
2-pole 4
Clutch switch
Behind the headlight
4
Connector AT4
2-pole 5
Carburetor heater
Repair manual KTM LC8
Between the steering
head and the ECU
5
Connector AU
2-pole 6
Controller output
21
Under the seat next to
the battery case
6
13-152
Connector AV
2-pole 1
Temperature switch
1
2
On the left side of the
radiator
1
Connector AW
2-pole 2
Front EPC cylinder
2
1
On the right side of the
frame
2
Connector AW1
2-pole 3
Rear EPC cylinder
Behind the air filter box
3
Connector AX
2-pole 4
Coolant temperature
sensor
1
2
On the left between the
cylinders
4
Connector AY
1-pole 5
Oil pressure switch
On the left side of the
frame under the air
filter box
5
Connector AZ
4-pole 6
1
2
3
4
Rear flasher
Under the seat in the
back of the storage
compartment
6
13-153
Connector BA
1-pole 1
Emergency off switch
Behind
mask
the
3
headlight
4
1
Connector BC
6-pole 2
Ignition switch
3
6
1
Behind
mask
the
headlight
Connector BC1
6-pole 3
Light/horn/stop switch
Art.-No. 3.206.056-E
Behind
mask
the
headlight
Connector BF
1-pole 4
Emergency off switch
Behind
mask
the
headlight
Repair manual KTM LC8
Connector BG
3-pole 5
1
2
3
Rear lighting
Under the seat in the
back of the storage
compartment
5
Connector BI
2-pole 6
Controller outlet
2 1
Under the seat next to
the battery case
6
2
13-154
Connector BJ
1-pole 1
Oil pressure switch
1
On the left side of the
frame under the air
filter box
1
Connector BK
4-pole 2
1
1
2
3
2
Rear flasher
Under the seat in the
back of the storage
compartment
Connector BK1
4-pole 3
Tip switch
Behind
mask
the
headlight
3
Connector BL/BL1
2-pole 4
Radiator fan
On the left under the
radiator hose
1
2
4
Connector BR
4-pole 3
Tip switch
1
Behind
mask
the
headlight
4
Connector BT
3-pole 5
Flasher switch
1
3
Behind
mask
the
headlight
5
13-155
Connector BW
3-pole 1
1
Headlight
Behind
mask
1
the
headlight
3
3
Connector CD/CD1
2-pole 2
Radiator fan
1
2
On the left under the
radiator hose
2
Art.-No. 3.206.056-E
Connector
CR/CR1/CR2/CR3
1-pole 3
Connector for
attachments:
Ground, continuous
positive polarity, positive
ignition
Behind
mask
the
headlight
Connector DI
2-pole 4
Parking light
Repair manual KTM LC8
On the headlight
4
51,52
-A1
5
2
C_EF/14
1
6
4
2
5
Antenna
6
31
7
9
8
1
2
C_BR/4
C_BK/4
42
66
9 10 11 12 13 14
7
3
4
/3.E6
/3.E6
/3.B2
-X12 splice
Connector for
optional
alarm system
66 ALA-A1
7 flaR-X200
9 flaL-X200
136
1
C_AI/2
990 Supermoto 2008
alarm system dummy plug
3
153
1
60,61
C_EL/2
45,46
C_DV/2
65
4
29,137
C_EG/14
2
52
3
61,135,136,175,143
1
2
1
C_BV/2
C_BS/2
-S3
seat
surveillance
2
175,143 -X12-P1
153
154
7
6
159
1
3
C_EB/4
fuel pump relay
2
137
44
28
4
5
8
-K2
3
47
1
77
fuel
pump
M
C_AR/3
C_AM/3
2
-M2
fue-P1
fuel-A2
10A
10A
2
1
2
1
4
/3.B2
/2.E5
10A
2
1
-F1 -F5 -F6
21
1
3
49
-K1
/3.B2
/3.A5
M
ACC
-K3
lig-X19
-M1
starter
motor
C_EB/4
50
light relay
2
battery, generator, starter
/3.B2
4
3
155
2
1
157
ALA-A2
C_AC/6
64
23
28,29
-X1 splice
56,57
C_DN/8
48
48
C_DO/8
58,59
51
Immobilizer
156
46
22
30
158
CAN-H
/3.B2
/2.A2
47
CAN-L
/2.B2
76
-A2
4
3
1
3
2
1
-G1
-K4
/2.C1
battery
-A1-X5
-X2 splice
C_EB/4
power relay
2
4
C_AF/4
30
A
start relay
55
diode
40
54
C_BC/6
-V1
45
57
start/stop switch
63
for optional alarm system
56
53
-S2
5,13,20,38,50,54,55,63,65,197
-S1
30
4
1
2
1
3
C_AU/2
C_EB/4
43
start auxillary
relay
2
59
58
gn
re-wh
re-wh
3
-K5
STR-A3
-N1
626.11.076.000
main harness -
/2.B5
/2.C1
generator
G
U
regulator-rectifier
gn
gn
5,13,20,38,76,197,159
GND-X14
C_BI/2
antenna
immobilizer
40
154
64
41
135
60
42,43
ignition switch
3 P.
Page:1
13-156
114
air temp.
sensor
t°
C_CM/2
1
2
115
113
-B3
1
6
4
rollover
sensor -B4
C_AP/6
5
-B5
t°
3
2
1
t°
-B6
2
1
p
C_DP/3
-B7
1
3
2
1
p
C_DP/3
-X101
-B8
manifold
pressure
sensor front
3
1
2
125
2
1
p
C_DP/3
GND-P1
2
/3.B2
198,5,13 GND-X14
-X53
-B9
75
manifold
pressure
sensor rear
3
2.1
C_BJ/1
C_AY/1
1
89,179,186,126
pick up
C_AT/2
C_AL/2
1
2
3
152
4
C_AO/26
1
118
ECU
-L3
-A4
/3.D6
-X6 splice 86,189,190
73,76,198,197,159
3
-X7 splice
74
5
-X8 splice
184
6
87
7
8
19
125
122
7
6
5
4
3
2
1
C_DN/8
1
2
3
4
C_CO/34
5
6
Neu-P1
192
7
8
/3.B2
97
98
110
104
106
108
102
100
-X301 splice
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34
215
211
207
219
206
218
205
199
203
208
204
212
209
202
210
1
C_CL/2
176
ignition
coil
front
1
MIL-P1
-L1
TAC-P1
2
1
C_CL/2
injection
rear
2
ignition
coil
rear
-L2
1
/3.B2
/3.B2
C_AS/2
2
-Y3
215,216,217
1
C_AR/3
C_AM/3
1
M
-M4
1
or 1
2
2
C_CK/2
1
main harness 626.11.076.000
210
1
M
-M5
C_CE/4
C_CA/4
2
211
3 P.
Page:2
2nd throttle
stepper motor
3
4
3
-Y1
-Y2
purge valve
exhaust air
valve
2
2
C_AE/4
3
1
C_AM/3
C_AR/3
2nd throttle
position sensor
ISC
stepper motor
4
-B13
C_DU/2
-Y4
3
main throttle
position sensor
212,213,214
-B12
injection
front
2
180
C_AS/2
2
199,200,201
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
2.11
2.12
2.13
2.14
2.15
2.16
/3.F1
-X302 splice
-X303 splice
111
109
107
105
103
101
99
142 CLU-A2
-X11 splice
-X10 splice 191
17,157
-X9 splice
179
158,16
8
E C U
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
96
C_AR/2
114
C_AM/2
126
1,3,14,53,68,70,93,104,127,185,155
-X5 splice
2
124
C_AR/3
119
atmospheric
pressure
sensor
3
140
990 Supermoto 2008
hego sensor
rear
L
4
C_CE/4
1
C_CA/4
2
C_CE/4
-X4 splice
-X305 splice
18,228
C_CA/4
hego sensor
front
L
3
4
-X54
C_CZ/3
C_CY/3
2
2.3 2.2 2.1
3
-X3 splice
16
-X304 splice
15,227
17
158
CAN-L
/1.B5
/3.B2
18
129
228
GND-X14 76,5,13,20,38,197,159
94
53,155
tem-P1
80,91,95,97,113,116,120,129,138,150,184
-A1-X5
152
20
93
157
128
15
130
CAN-H
123
C_DO/8
185
/1.B4
127
3
83,90,109,117,119,139,151,183
139
/1.E8
80
121
90
2
116
1
138
73
74,75
117
/1.B7
81
120
91
N
39
C_EC/3
92
124
38
39
118
14
150
193
151
194
83
186
3th
140
2nd
187
C_AM/3
101
84
92
227
96
195
84,121,188
130
85
81
STR-A3 41
/1.E8
86
188
2
189
C_AT/2
107
-A3 Starter Interlock Unit
102
1
105
-S4
190
-B2
176
-X51
183
6
103
5
180
19
95
4
67
3
94
2
191
1
192
C_AP/6
110
-X50
106
t°
82
85,142,187
111
-B1 t°
88
gear position
switch
69
sidestand
sensor
123
218
CAN-BUS
connector
122
203
diagnostic
connector
2
-X300
C_CQ/16
87
fuel-A2
44
987 65 43 2 1
16 15 14 13 12 11 10
128
C_CP/16
70
88
98
202
89
100
108
/1.E5
99
200
82
219
water temp.
sensor
67
Art.-No. 3.206.056-E
68
205
213
201
69
204
3
216
2
206
214
207
1
208
217
209
Repair manual KTM LC8
13-157
-S5
-H9
-B10 t°
-P1
C_AK/2
75
33
175
144
176
115
148
77
170
177
178
179
180
112
181
156
66
229
182
C_AH/2
C_CX/2
/2.B6
143
144
CLU-A2
142
141
163
162
166
168
167
164
165
75
GND-P1
8
HI
2
4
P.light
7
5
L
R
6
3
164,171,172
79,146,147,198
1
C_AY/1
2
1
flasher
relay
G -K6
C_AH/2
12,34
C_AI/2
1
133,134
diode
2
24
2
-V2
34
2
1
-M3
1
C_AU/2
C_BI/2
M
2
79
2
/1.E3
9
flaR-X200
7
6,160,173,177
flaL-X200
-X18 splice
/1.E3
-X17 splice 8,163,174,178
/2.C4
62,72
1
C_AV/2
t
GND-X14 198,5,13
-X16 splice
35,133
10A
10A
10A
2
1
35
15A
2
1
36
instruments-tachometer
9
2.1
C_BJ/1
-X15 splice
-X52
-X14 splice
141,161,162,165,168,169,181,229
beam horn flasher switch
LO
C_BD/12
C_AD/12
1
172
166,170
990 Supermoto 2008
-S7
-X13 splice
145,149,182
66
ALA-A1
156
180
MIL-P1
ALA-A2
77
179
fue-P1
115
tem-P1
Neu-P1
176
TAC-P1
1
C_EH/1
25
1
26
-F2 -F3 -F4 -F7
27
37
P
/1.E6
36
2
1
2
145
148
149
160
175,143
-S8
-X21
32,33
1
C_CR/1
5
6,7
8,9
4
-X22
1
C_CR/1
-X23
226
224
220
225
1
C_CR/1
-X24
220,221,222,223
1
C_CR/1
aditional current
connection ACC2
-X201 splice
2.4 2.3 2.2 2.1
aditional current
connection ACC1
37
temperature
switch
-S9
146
cooling
fan
78
-X19 splice
49
78
front brake
switch
flasher
right front
ambient temp.
sensor
multi-func.-digital-speedometer
speed
sensor
position
light
G
-B11
-H1
C_AR/3
C_DI/2
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
9
8
7
6
5
4
3
2
1
-X12-P1
71
2
C_CW/2
C_AL/2
C_CW/2
C_ED/32
C_AM/3
2
1
3
C_CW/2
/1.D6
/1.B4
/2.D7
/2.B2
/1.E5
/2.B6
/2.D7
/1.B4
/1.E3
/2.D4
169
161
167
32
171
ACC
173
62
10
72
71
1
C_AH/2
221
226
222
225
4,12
13
10,11
223
224
2
11
174
C_AK/2
1
1
2
134
132
2
1
C_BW/3
C_CX/2
C_AJ/3
626.11.076.000
main harness -
C_CX/2
196
112
131
P
C_DI/2
1
C_CX/2
3
2
1
2
headlight
flasher
left front
clutch
switch
-H2
-H3
-S6
132
147
C_CV/4
-X200
C_BY/4
1
2
1
1
C_AT/2
131
1
2
3
4
C_CW/2
C_BG/3
C_CW/2
2
1
2
C_CX/2
3
1
2
lig-X19
-H8
1
2
-H4
-S10
-H5
-H6
horn
rear brake
switch
flasher
right rear
rear light/
brake light
-H7
licence plate
lamp
3 P.
Page:3
flasher
left rear
oil pressure
switch
13-158