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.
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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:

long Interval

short Interval

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
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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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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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