KTM 1290 Super Duke GT 2016-2019 Service Workshop Manual

Workshop Service and Repair Manual for the KTM Super Duke 1290 GT This full workshop manual set covers every component, service and repair procedure in full factory specification with clear concise step by step photographs and technical drawings for the Super Duke GT with torque setting values throughout where required for fasteners and reassembly, below is an exhaustive list of the items covered within this set.

This is the most comprehensive service manual set available for the Super Duke 1290GT as used by main and independent service centres the world over.

This Manual Covers the Following:

Means of Representation
Safety Advice
Important Notes
Serial Numbers

FORK, TRIPLE CLAMP
Cleaning the dust boots of the fork legs
Removing and installing the fork legs
Performing a fork service
Disassembling and assembling the fork legs
Removing and Installing the spring
Checking the fork legs
Checking the play of the steering head bearing
Adjusting the steering head bearing play
Lubricating the steering head bearing
Removing and Installing the lower triple clamp
Changing the steering head bearing
Changing the steering damper

HANDLEBAR, CONTROLS
Adjusting the basic position of the clutch lever
Adjusting the handlebar position
Programming the switch for the cruise control system
Changing the throttle grip
Replacing the heated grips

SHOCK ABSORBER, SWINGARM
Measuring the rear wheel dimension
unloaded
Checking the static sag of the shock absorber
Adjusting the spring preload of the shock absorber
Removing and Installing the shock absorber
Checking the heim joint for play
Changing the heim joint
Removing and Installing the spring
Removing and Installing the heim joint
Checking the swingarm and bearing
Removing and Installing the swingarm
Changing the swingarm bearing
Programming the swing angle sensor
Programming the shock absorber control motor

EXHAUST
Removing and Installing the main silencer
Removing and Installing the pre silencer
Removing and Installing the manifold Removing and Installing control motor of exhaust valve controller
Changing throttle cables of exhaust valve controller
Checking throttle cable tension of the exhaust valve controller
Adjusting throttle cable tension of the exhaust
valve controller

AIR FILTER
Removing and Installing the upper part of the air filter box
Changing the air filter, cleaning the air filter box
Removing and Installing the lower part of the air filter box

FUEL TANK, SEAT, TRIM
Removing and Mounting the front rider’s seat
Removing and Mounting the passenger seat
Removing and Installing the tank spoiler
Removing and Installing the fuel tank
Checking the fuel pressure
Changing the fuel pump
Changing the fuel filter
Removing and Fitting front spoiler

MASK, FENDER, DECAL
Removing and installing the front fender
Removing and Installing the windshield

WHEELS
Programming tire air pressure sensor
Removing and Installing the front wheel
Changing the front brake discs
Changing the front wheel bearing
Removing and Installing the rear wheel
Checking that the rear wheel nut (right side) is tightened to the specified torque
Changing the rear brake disc
Checking and adjusting the chain tension
Checking the chain, rear sprocket, engine sprocket, and chain guide
Removing and Installing the rear sprocket carrier
.
Opening the chain/riveting the chain
Changing the drivetrain kit
Cleaning the chain
Checking/changing the rear hub shock absorbers of the rear sprocket carrier
Removing and Installing the rear hub
Changing the rear wheel bearing

WIRING HARNESS, BATTERY
Removing and Installing the battery
Recharging the battery
Changing the main fuse
Changing the fuses in the fuse box
Checking the charging voltage
Checking the open-circuit current

BRAKE SYSTEM
Checking the brake linings
Changing the front and rear brake fluid
Adjusting the basic position of the hand
brake lever
Setting the step plate of the foot brake lever
Adjusting the basic position of the foot brake lever
Checking the wheel speed sensor spacing

LIGHTING SYSTEM, INSTRUMENTS
Activating/deactivating the ignition key
Checking the setting of the lighting system
Adjusting the headlight range
Changing the headlight bulb
Changing cornering lights
Adjusting the cornering light range
Resetting the service display using the KTM diagnostic tool
Setting the service interval display

ENGINE
Removing the engine
Installing the engine
Setting the engine to ignition top dead centre
of the front and rear cylinders
Engine bearer
Front and rear valve covers
Starter motor
Oil filler tube
Heat exchanger
Front and rear timing chain tensioner
Front and rear camshafts
Cylinder heads
Pistons
Alternator cover
Ignition pulse generator
Torque limiter and idler
Rotor
Idler and timing chain
Oil filter
Balancer shaft
Balancer shaft drive wheel
Gear position sensor
Suction pump
Water pump wheel
Shift shaft sensor
Clutch cover
Clutch discs
Clutch basket
Oil nozzle for the clutch
lubrication
Primary gear
Force pump
Shift shaft
Shift drum locating
Locking lever
Engine case
Crankshaft
Middle suction pump
Transmission shaft
Oil spray tube
Timing chain rails
Main bearing
Main bearing shells
Conrod bearing
Timing assembly
Timing chain tensioner
Oil pressure regulator valve
valve clearances
Changing the SAS membrane

IGNITION SYSTEM
Alternator – checking the stator winding
Changing the spark plugs
Changing spark plugs (air filter removed)

THROTTLE VALVE BODY
Removing and Installing the throttle valve body
Executing the initialization run
Checking the CO adjustment using the KTM
diagnostics tool

TECHNICAL DATA
Engine
Tolerance, engine wear limits
Engine tightening torques
Capacities
Engine oil
Coolant
Fuel
Chassis
Electrical system
Tyres
Forks
Shock absorber
Chassis tightening torques

WIRING DIAGRAM 16 Pages Super Duke GT

ADDITIONAL
Cleaning and Protective Treatment
Storage
Substances
Auxiliary Substances
Special Tools
Standards
Index of Special Terms
List of Abbreviations
Index