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Duke 390 SSM - 902 - EN
Duke 390 SSM - 902 - EN
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 performance-
boosting 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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Specifications:
Type: Single cylinder, twin camshaft four stroke motor with balancer shaft
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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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Throttlebody
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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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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.
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Engine Management
System overview
TMAP
sensor Injector
TPS
sensor
Coolant
temp
sensor
Gear Sparkplug
position
sensor
Lambda
sensor
ISC
stepper
Crankshaft motor
sensor
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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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 P-
code can be read out.
Note:
The Blink code is removed by correcting the fault.
The P-Code is removed with XC_1 diagnostic tool.
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Example Blink Code 13 » Signal of MAP sensor too high or low:
1 long Interval
2 short Interval
3 Repetition
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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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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.
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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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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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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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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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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.
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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.
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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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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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Special tools
51012011000 Circlip pliers (external)
For removal of the oil filter
6002901200 Plastiguage
For measuring correct oil clearance on the
crankshaft and connecting rod plain metal
bearings
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6122900100 Engine stand
Holds the engine securely while working on
the engine
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90129021000 Castellated nut tool
For rotation of the motor to TDC
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