KTM TECHNICAL BULLETIN TB 0904 SEPTEMBER 24» 2008

Transcription

1 Subject: Checking the Oil Tank Return Pipe Bore KTM TECHNICAL BULLETIN TB 0904 Affected Models: 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. Picture 1 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 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. Page 1

2 Picture 2 Procedure - Checking the oil tank return pipe bore: 990 Super Duke: 990 Adventure: 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. 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. Page 2

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). 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 5 Page 3

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). engine connector bolt a. Picture 6 Page 4

5 7. Pull the engine holder forward as shown in picture 7 between the manifold and the engine - out to the front Picture 7 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) 2 1 Picture 8: standard oil tubes Page 5

6 9. Mount the oil tube kit with the bypass ( 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) Picture 9: Connection bypass-hose at top of oil tank Picture 10: Connection bypass-hose to the valve cover 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. Page 6

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 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 and click NEXT. To submit a claim for checking the Adventure oil tank use TI number G 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 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 7

8 Warranty claim input information Warranty type: Subassembly group: Failure code: Campaign-code: Choose The applicable campaign-code! Failure causing part: TI Warranty 38 Lubrication System 430 Constriction/Clogging Super Duke: 1. G Check oil tank 2. G Check oil tank and mounting oil tube kit with bypass Adventure: 3. G Check oil tank 4. G Check oil tank and mounting oil tube kit with bypass Super Duke: Oil tank complete 05 Adventure: Oil tank complete 04 Spare Parts T-CONNECTOR W. REDUCTION RING (= bypass-kit) if necessary! Labor time: Stock parts affected: Superduke: 1. Campaign-code G min. Check only 2. Campaign-code G min. Check and replace 990 Adventure: 3. Campaign-code G min. Check only 4. Campaign-code G min. Check and replace No. Standard hoses may still be used on motorcycles that are not affected! Page 8