SelfStudyModule902 - 390Duke2013
Ver:1.0.
SSM902 - 390Duke2013
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SSM902 - 390Duke2013 Index Introduction ...................................................................................................................... 4 General: ........................................................................................................................ 4 Specifications: ..............................................................................................................5 Intake & Exhaust system ................................................................................................. 6 Overview....................................................................................................................... 6 Throttlebody.................................................................................................................. 7 Fuel Supply...................................................................................................................... 8 Fuel pump..................................................................................................................... 8 Engine Management ..................................................................................................... 10 System overview ........................................................................................................ 10 Self-diagnosis ............................................................................................................. 11 Engine mechanicals ...................................................................................................... 13 Cranktrain ...................................................................................................................13 Valvetrain.................................................................................................................... 14 Drivetrain .................................................................................................................... 16 E-Starter ..................................................................................................................... 18 Lubrication circuit ........................................................................................................... 19 Coolant circuit ................................................................................................................ 21 Service .......................................................................................................................... 22 Maintenance Schedule ............................................................................................... 22 Service checklist ......................................................................................................... 22 Special tools .................................................................................................................. 23 NOTE: This self-study manual is not a replacement for a repair manual. Always refer to the repair manual for your specific model for all inspection, adjustment and repair instructions and procedures.
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SSM902 - 390Duke2013
Introduction General: Completely new, the KTM 390 Duke's state-of-the-art, single-cylinder engine once again underlines KTM's development strength. It's clear that the latest materials and production technologies not only deliver the bike's bountiful torque and overwhelming acceleration at all engine speeds, but also good manners in everyday use and outstanding fuel economy. With 375 cc, the single-cylinder engine only weighs 36 kg, thanks to the compact design. Moreover, it delivers a punchy 43 hp with such technical refinements as NiCaSil cylinder coating and forced oil lubrication with performanceboosting crankcase evacuation (the suction pump not only transfers oil, but also pressure from the crankcase, thereby reducing the running resistance of the crank train).
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SSM902 - 390Duke2013 Specifications: Engine code: 902 Type: Single cylinder, twin camshaft four stroke motor with balancer shaft Stroke/bore: 89mm / 60mm Compression ratio: 12,9 : 1 Mixture preparation: Dell Orto 46mm throttle body Engine Management: Bosch Motronic M17 Fuel type: 95 ROZ lead-free Exhaust emission level: Euro 3 Oil type: Motorex Formula 4T 10W40 or 15W50 Lubrication method: 1 Eaton type pressure pump and 1 suction pump Oil quantity: 1,6l Coolant method: Liquid cooled Coolant quantity: 1,1l of 50% water and 50% antifreeze Spark plug: BOSCH Super R6 VR5 NE Spark plug gap: 0.8 mm Idle speed: 1600 rpm +/-50
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SSM902 - 390Duke2013
Intake & Exhaust system Overview
Air is filtered through the paper filter located under the seat. This clean air then enters the 46mm throttle body where it is mixed with atomised fuel from the injector. The resulting exhaust gases are monitored by the ECU through a Lambda sensor . The exhaust gases are converted to harmless gases by a 3-way catalytic converter in the silencer. The exhaust emissions are compliant with EURO 3 specifications.
4 Catalytic Converter
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SSM902 - 390Duke2013 Throttlebody
1 TPS (Throttle Position Sensor) 2 TMAP (Temperature & Manifold Absolute Pressure) sensor 3 Injector 4 ICS (Idle Speed Control) stepper motor
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SSM902 - 390Duke2013
Fuel Supply Fuel pump
The fuel pump is a vane type pump and supplies fuel to the injector at ~ 2.7 bar.
The fuel enters the electrically powered vane pump through the fuel filter . The pump conveys the fuel via the conveyor line to the injector. If the fuel pressure is higher than 2.7 bar, the pressure control valve opens so that the regulated fuel can return to the tank via the return line . The fuel level sensor is a float type system. Page 8 of 26
SSM902 - 390Duke2013 The fuel supply system can be tested with the XC_1 function “actuator test” and the EFI pressure-measuring tool (part. Nr.: 610.29.094.000) and the adapter (part.Nr.: 61029093000) using the 0,45mm reduction jet.
Reference value at every operating condition: 2,5 – 2,9 bar
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SSM902 - 390Duke2013
Engine Management System overview
TMAP sensor
Injector
TPS sensor Coolant temp sensor Gear position sensor
Sparkplug
Lambda sensor
Crankshaft sensor
ISC stepper motor
The information gathered by the sensors is converted to electrical signals and is sent to the ECU where it is processed. The result is an electrical signal that is sent to the actuators. The actuators then richen/lean the fuel mixture, advance/retard the ignition curve as necessary for the current riding conditions, and control the idle speed. The XC_1 diagnostic tool is connected via CAN DataBus with the diagnostic plug under the seat.
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SSM902 - 390Duke2013 Self-diagnosis The BOSCH Motronic M17 engine management system has self-diagnostic capability. This means that the ECU (Engine Control Unit) is constantly monitoring the sensors and actuators. Any discrepancy or deviation from normal values triggers a P-code in the ECU. This P-Code is stored in the ECU and can only be removed with the XC_1 diagnostic tester. Once a failure or a P-code is detected, the vehicle alerts the rider with an illuminated engine management lamp. In the workshop, a corresponding blink code and also the Pcode can be read out. Note: The Blink code is removed by correcting the fault. The P-Code is removed with XC_1 diagnostic tool. To read the blink code: Hold the throttle open Turn on the ignition (DO NOT START THE ENGINE) Keep the throttle open for 5 seconds Close the throttle The blink code is displayed in the dashboard
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SSM902 - 390Duke2013 Example Blink Code 13 » Signal of MAP sensor too high or low:
1
long Interval
2
short Interval
3
Repetition
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SSM902 - 390Duke2013
Engine mechanicals Cranktrain
The drivetrain consists of a plain metal bearing crankshaft connected to a plain metal bearing connecting rod. This in turn is connected to the forged alloy piston of 89mm diameter by the piston pin. The piston is a forged alloy of aluminium and silicon, resulting in a high strength and low wear material that resists expansion. The piston rings comprise: 1 Compression ring, 1 taper-faced ring, 1 oil scraper ring. The balancer shaft is driven by the crankshaft, which also drives the waterpump. The crankshaft is marked with a classification code. This code is necessary when measuring the big-end journal (see repair manual for tolerances).
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SSM902 - 390Duke2013 Valvetrain
The inlet (36mm) and the exhaust (29mm) valves are actuated by a double overhead camshaft system. The camchain is kept under tension by a mechanical tensioner. DLC (Diamond-Like Carbon) coated finger followers keep the valve train inertia and wear at a minimum. Valve clearance adjustment (cold): Inlet: 0,10 +/- 0,02 mm Exhaust: 0,15 +/- 0,02 mm
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SSM902 - 390Duke2013 Camchain tensioner The camchain tensioner is a mechanical type tensioner. The procedure to prepare and release the tensioner during assembly is shown below:
Preparing the tensioner for assembly (transport position) – turn the tensioner screw clockwise until the tensioner is locked in the retracted position.
After assembly – rotate the tensioner screw anti-clockwise for a few degrees and remove the screwdriver. The tensioner will return to the loaded position under its own spring load.
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SSM902 - 390Duke2013 Drivetrain Gear selection
The six speed gearbox is selected by the shift drum through 3 shift forks mounted on two shift rails . The wear limits of the shift forks are indicated in the repair manual.
Gears
The 6 gears are forged alloyed steel of chromium and nickel, and then case hardened. This results in a high durability and toughness.
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SSM902 - 390Duke2013 Clutch
The multiplate oil-bath clutch consists of 7 steel plates and 8 friction plates . The first plate in the stack has a larger internal diameter to accommodate the anti-judder conical springs . Note: Always soak new friction plates in oil before assembly. The last plate in the stack must be offset from the rest of the plates. Take care of the direction of the anti-judder conical spring washer.
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SSM902 - 390Duke2013 E-Starter
The 12V 238W starter motor drives the starter gears through a torque limiter . During an engine backfire, hydraulic lock-up, severe engine pulse, or if the starter motor is re-engaged when an engine is in operation, the torque limiter prevents damage to the starter components.
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SSM902 - 390Duke2013
Lubrication circuit
The lubrication circuit is force-fed oil by an Eaton-type oil pressure pump . All moving components are fed oil from this pump. The oil is pumped through a fine oil filter , after which it lubricates the plain metal main bearings , and the plain metal big end bearing . Piston lubrication and cooling is achieved by an oil jet A. The oil passage then leads to the stator cooling and the gearbox lubrication . The clutch is lubricated by two jets in the clutch cover B, this leads to the camshaft journals and then to the four camshaft lobe lubrication jets C. The suction pump D evacuates oil from the crankcase.
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SSM902 - 390Duke2013
The camshaft lobes are lubricated by 4 oil jets located in the camshaft bridge. The lubricant used has to conform to the SAE 5W40 or 10W50 grade. JASO T903 MA (Japanese Automotive Standards Organisation) specification: The friction modifiers present in most automotive oils change the friction properties of the oil, reducing the friction of the multiplate wet type clutches. The MA specification oil has no friction modifiers present that cause clutch slippage and should be used for all multiplate wet type clutches.
Oil pressure is measured from the oil filter cover:
Oil pressure at idle: > 0.7 bar Oil pressure at 5000 rpm: > 2,4 bar Page 20 of 26
SSM902 - 390Duke2013
Coolant circuit
The coolant system contains 1.1 litres of a coolant mixture of 50% water and 50% antifreeze. The thermostat is closed if the temperature of the coolant is below 88° C. The waterpump pumps the coolant around the cylinder and cylinder head, but the coolant does not enter the radiator. The thermostat opens at 88° C and is fully open at 96° C. The waterpump pumps the coolant through the cylinder, cylinder head, the radiator and the thermostat. The pressure in the cooling system (max 1.4 bar) is regulated by a valve in the radiator cap. The coolant level in the compensating tank must be between the min and max mark when the engine is cold. The fan switches on at 96° C and off at 90° C.
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SSM902 - 390Duke2013
Service Maintenance Schedule
The maintenance schedule lays out the service intervals and what components need to be checked during this time. The schedule is found in the owners manual. The service schedule assumes normal use of the vehicle in normal conditions. The service shedule for the 390 Duke is every 7500km. The first service is performed at 1000 km.
Service checklist
The service checklist is found in dealer.net and gives the technician a list of the required tasks to be performed for the specific service being done.
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SSM902 - 390Duke2013
Special tools 51012011000
Circlip pliers (external) For removal of the oil filter
51129003000
Clutch holder For holding the clutch securely when loosening nuts
59029019000
Valve spring compressor For compressing the valve springs for removal of the valve collets
59029041100
Feeler Gauge For correct measurements of intake and exhaust valve clearances
6002901200
Plastiguage For measuring correct oil clearance on the crankshaft and connecting rod plain metal bearings
6002901500
Piston ring compressor For compressing the piston rings on the piston before assembly into the cylinder
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SSM902 - 390Duke2013 6122900100
Engine stand Holds the engine securely while working on the engine
6122901500
Engine lock To lock the engine at TDC for disassembly and assembly
77229172000
Sparkplug Spanner For removal of the sparkplug
77329030100
Piston circlip insertion tool For mounting the piston circlip securely
90129002050
Engine holder Necessary to mount the engine in the motor stand
90129002060
Engine holder Necessary to mount the engine in the motor stand
90129005000
Seal protector To protect the waterpump seal from damage during assembly of the crankcases
90129002000
Crankshaft protection To prevent damage to the crankshaft during use of the puller and crankcase separator
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SSM902 - 390Duke2013 90129021000
Castellated nut tool For rotation of the motor to TDC
90129022000
Castellated nut tool For removal of the castellated nut on the balancer shaft drive gear mounted on the crankshaft
90129026000
Valve guide limit tool For checking the wear limit of the valve guides
90129043000
Assembly sleeve For correct installation of the waterpump seal
90129048100
Engine casing separator For separating the engine cases (To be used together with crankshaft protection 90129002000)
90129056000
Press tools For press removal and assembly of the balancer shaft bearings.
77029041100
Valve spring compressor tool For compressing the valve springs for removal of the valve collets. (To be used with valve spring compressor 59029019000)
90229009000
Rotor puller For removal of the rotor. (To be used together with crankshaft protection 90129002000)
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SSM902 - 390Duke2013
2013 by KTM-Sportmotorcycle AG, Mattighofen Austria All rights reserved Reproduction, even in part, is permitted only with the express written permission of the copyright owner.
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