KTM TECHNICAL BULLETIN TB 0904 - Peachtree Car Wash · KTM TECHNICAL BULLETIN TB 0904 ... The user acknowledges that all components of this technical information are KTM’s and/or

KTM TECHNICAL BULLETIN TB 0904 SEPTEMBER 24 » 2008

COPYRIGHT NOTICE The user acknowledges that all components of this technical information are KTM’s and/or third parties’ copyright protected property. Alteration, assignment, distribution and reproduction are forbidden. LIMITATION OF LIABILITY The information included in or available through this technical information may include inaccuracies or errors. In no event shall KTM and/or its suppliers be liable for any damages whatsoever, arising out of or in connection with the use of this technical information. Please always refer to the KTM owners and repair manuals for proper instructions or contact the KTM Dealer Technical Service Department.

KTM NORTH AMERICA, INC. EAST » 1119 Milan Avenue » Amherst » Ohio 44001 » Phone 440-985-3553 » Fax 440-985-3060

Technical Department WEST » 38429 Innovation Court » Murrieta » CA 92563 » Phone 951-600-8007

CANADA » 1375-1 Marie-Victorin » Saint-Bruno » QC J3V 6B7 » Phone 450-441-4451» Fax 450-441-3885

© 2008 KTM North America, Inc. – All rights reserved

Page 1

Subject: Checking the Oil Tank Return Pipe Bore

Affected Models: 2006 - 2007 990 Adventure, Adventure S and Super Duke

Initial Information:

» Market research has shown that pressure peaks in the oil circuit can occur when the oil tank return pipe bore is partially covered by residues from the casting process.

On the affected models linked to this technical bulletin, the oil tank opening needs to be checked through the connector on the preformed hose with the tool displayed in picture 1. The tool has been sent out automatically and free of charge to dealers that we indicate to have sold affected units. If you need this tool and have not received one, please contact the KTM North America Technical Service Department. In the event that the drop shaped head of the checking tool does not fit through the tank opening inside the connector (the procedure is described on page 3), the original oil tubes have to be replaced with the new oil tube kit with bypass which will eliminate the pressure peaks. Order p.n. 600.38.064.000 T-CONNECTOR W. REDUCTION RING (= bypass-kit) which is displayed in picture 2 using KTM Dealer.net.

NOTE: This Technical Bulletin only affects certain VIN numbers! Please check the VIN by performing a Motorcycle History search in KTM Dealer.net to determine if it’s affected. If the motorcycle is affected you will see a link to the bulletin and its repair status in the history results. KTM North America will not warranty units whose VIN numbers are not linked to this bulletin as it does not apply to them. It is the responsibility of the dealer to determine if the unit requires this update by checking the vehicle history.

Picture 1







Page 2

Procedure - Checking the oil tank return pipe bore:

990 Super Duke:

• Lift up the gas tank so you can reach the connector for the preformed hose on the oil tank.

• Loosen the Clamp STD DN16 and remove the preformed hose from the connector.

990 Adventure:

• Dismount the right gas tank so you can reach the connector for the preformed hose on the oil tank.

• Loosen the Clamp STD DN16 and remove the preformed hose from the connector.

Picture 2







Page 3

The procedure to check the opening inside the connector is identical on both models.

• Insert the drop shaped head of the checking tool into the connector of the preformed hose.

The tip of the tool should point towards the air box. (as seen in Picture 3).

• The tool must be inserted fully up to the holder (see Picture 4). Turn the tool a little, so that the head finds its way easily into the laterally located bore.

• If the tool cannot be inserted up to the holder (see picture 5), the new oil tube kit with bypass has to be mounted.

Picture 4

Picture 3

Picture 5







Page 4

Procedure - Mounting the new oil tube kit with bypass (if required):

Following is the procedure for the 990 Adventure (the 990 Super Duke is similar) 1. Disassemble the screws of the under ride protection and place it downwards.

2. Dismount the battery cover.

3. Disconnect the line to the airbox and the throttle body.

4. Loosen the clamp of the exhaust manifold/muffler. To do this, remove the front

screw of the right back side cover and lift it up carefully.

5. To get access to the engine connector bolt (picture 6), disassemble the nuts off the exhaust manifold and turn it upwards.

6. Dismount the connecting screws of the right engine holder to the oil tank, frame,

battery holder and the engine connector bolt (picture 6).

a.

Picture 6

engine connector bolt







Page 5

Picture 8:

standard oil tubes

7. Pull the engine holder forward as shown in picture 7 between the manifold and the engine - out to the front

8. Disconnect the oil ventilation hose (pos. 1, picture 8) and oil return hose (pos. 2,

picture 8) (In picture 8 the oil tube connectors at the tank are shown with the standard hoses)

Picture 7

1

2







Page 6

9. Mount the oil tube kit with the bypass (600.38.064.000 T-connector) as shown in pictures 9 and 10:

• Connect the preformed oil hose (long end) between the engine oil tube and the oil tank (picture 7 red arrow)

• Mount the T-connector to the front valve cover and the oil tank as shown in picture 8 (red arrows)

10. Reassemble the motorcycle in the reverse order 11. Run the engine first until operating temperature is reached, and check for oil

leakage before finally mounting the plastics. Fill up the oil tank to the normal level.

Picture 10:

Connection bypass-hose to the valve cover

Picture 9:

Connection bypass-hose at top of oil tank







Page 7

Warranty Input Information:

Please note that when entering a warranty claim on an affected model, you will choose TI Warranty Inc. Campaign Code from the drop down list and then enter the vehicles VIN in the field to the right and click NEXT

• To submit a claim for checking the Super Duke oil tank use TI number

G.08.104.38 and click NEXT.

• To submit a claim for checking the Super Duke oil tank and mounting the new oil

tube kit with bypass use TI number G.08.105.38 and click NEXT.

• To submit a claim for checking the Adventure oil tank use TI number G.08.106.38

and click NEXT.

• To submit a claim for checking the Adventure oil tank and mounting the new oil

tube kit with bypass use TI number G.08.107.38 and click NEXT.

The parts and labor will be added to the claim automatically for you. On the claim,

complete all fields that are marked with an orange asterisk.







Page 8

Warranty claim input information

Warranty type: TI – Warranty

Subassembly group: 38 Lubrication System

Failure code: 430 Constriction/Clogging

Campaign-code:

Choose

The applicable

campaign-code!

Super Duke:

1. G.08.104.38 Check oil tank

2. G.08.105.38 Check oil tank and mounting oil tube kit with bypass

Adventure:

3. G.08.106.38 Check oil tank

4. G.08.107.38 Check oil tank and mounting oil tube kit with bypass

Failure causing part: Super Duke:

610.38.081.000 Oil tank complete 05

Adventure:

600.38.081.033 Oil tank complete 04

Spare Parts 600.38.064.000 T-CONNECTOR W. REDUCTION RING (= bypass-kit) if necessary!

Labor time: Superduke:

1. Campaign-code G.08.104.38 20 min. Check only

2. Campaign-code G.08.105.38 55 min. Check and replace

990 Adventure:

3. Campaign-code G.08.106.38 20 min. Check only

4. Campaign-code G.08.107.38 80 min. Check and replace

Stock parts affected: No. Standard hoses may still be used on motorcycles that are not affected!

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KTM TECHNICAL BULLETIN TB 0904 - Peachtree Car Wash · KTM TECHNICAL BULLETIN TB 0904 ... The user acknowledges that all components of this technical information are KTM’s and/or