Tips on throttle cable adjustments on a KTM 990

Discussion in 'Crazy-Awesome almost Dakar racers (950/990cc)' started by Toddwmac, Apr 8, 2010.

  1. Toddwmac

    Toddwmac ADV addict

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    I just installed a G2 on my 990 and have about 1/2 inch play in the cable. Before I start cranking on the adjustment nobs on the cable I was wondering if there are any words of wisdom from the garage.

    I'm familiar with cable adjustments on mtn bikes but not on a motorcycle.

    BTW, the KTM is FI and is a dual cable control...if that makes a difference.

    Thanks
    Todd
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  2. 99spike

    99spike n99b

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    Keep me posted
    my mechanic adjusted mine yesterday following a loss of power & stalling issue. He is sayng that EFI needs to be plugged to computer during adjustment or stepper motors for primary butterfly will cause stalling issue.... Apparently it's important for to keep some slack also or said motoe can strip it's gears
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  3. PowerCell

    PowerCell Manufacture

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    What he said... :thumb



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  4. Jody H

    Jody H Been here awhile

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    I adjusted mine in the air-box to get the majority of the slack out, then fine tuned at the throttle adjusters.
    Just leave a little slack and get them adjusted evenly.
    No need to hook it up to a computer as long as you don't take all the slack out or do something stupid with the adjustment.
    It's not rocket surgery.
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  5. PowerCell

    PowerCell Manufacture

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    This is the advice of a fool...



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  6. rider911

    rider911 Shortcut Navigator

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    Hey Powercell could you explain why you cant, or what goes wrong if you do what Jody H said.
    Ive got mine apart and was going to put it back together tomorrow with the same technique as what Jody said.
    If I havent played with the idle settings of the butterflys stops I dont understand how setting the throttle cables up the same as you would on any other 4 stroke with a return cable would need to be tuned with a diagnostic tool.
    If you have fiddled with the throttle bodies and disturbed other ajustments I can understand the need for the computer set up but not simply cable ajustment.
    Any advice would be appriciated
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  7. Blue&Yellow

    Blue&Yellow but orange inside...

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    So let me see if i get this right....

    If I decide to install a G2 throttle kit I need it to be done by a certified KTM workshop so that they can plug their computer into my EFI? Is that what you're saying? In other words: it's not something I can do myself?
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  8. rider911

    rider911 Shortcut Navigator

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    Yes B & Y that seems a bit hard to believe as I would think the vast majority of G2 throttle cams are fitted at home by owners with average mechanical skills

    Maybe im wrong .... it has been known to happen!
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  9. PowerCell

    PowerCell Manufacture

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    There are no adjustable throttle stops on the Keihin FI. The idle is controlled by a stepper motor. The motor will be set in whatever position it had been when the engine was last shut down. The diagnostic software lets you force the motor to zero for the purpose of adjusting the cables.
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  10. rider911

    rider911 Shortcut Navigator

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    So if I put it all back together with slackish cables and start it up and let it idle for a while, shut it off and go back and adjust the cables with normal amount of slack? I would imagine the idle position of the throttle butterfly would be close to fully closed and you would only need enough slack for safety if the stepper motor cycles to the fully closed (zero) position at some stage.

    I just pulled the throttle bodies off to do the valve clearence and threw a rag over them so havent really studied the whole assembly procedure yet.

    Do you think this will suffice? There is no diagnostic tools for about 700km

    Thanks
    #10
  11. Toddwmac

    Toddwmac ADV addict

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    Thanks guys..I'm not sure exactly where this leaves me but I do know I'm not going to start playing with the barrel adjustments. While I got my G2 installed and working well (I like the feel) it seems I should get it to a mechanic for the slack.
    Thanks
    T
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  12. Jody H

    Jody H Been here awhile

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    A fool with 9000 trouble free, stall free miles since G2 installation and cable adjustment.
    A fool with 3000 trouble free, stall free miles since a valve job and another slack adjustment
    If you're not smart enough to adjust cable slack without a certified Orange level mechanic and a computer, maybe you should stick to Huffy pedal powered bikes.
    What are you going to do when you break a cable deep into Copper Canyon Mexico or the middle of Africa, fly in a mechanic and his computer to replace and adjust them for you?
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  13. PowerCell

    PowerCell Manufacture

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    You're right. I don't know what I'm doing... I'll keep my mouth shut next time... :thumb
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  14. beardothebeardo

    beardothebeardo Been here awhile

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    Would this still hold true for the slower ramped throttle tube for the RC8?
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  15. Toddwmac

    Toddwmac ADV addict

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    For those of us that appreciate the guidance...please don't.
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  16. CHRIS_D

    CHRIS_D Been here awhile

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    Folks Powercell can be short :D but he knows his crap. Research his past post, he's a major KTM guy and I would personally take his advice seriously.

    Yes I too have adjusted my cables, installed a G2 and even mechanically set my throttle (using set screw on the throttle bodies) to 1.5K RPM. I also have removed my secondary, so this may be why I haven't been experiencing any problems.
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  17. killurtv

    killurtv free range moron

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  18. DSM8

    DSM8 Where fun goes to die....

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    I installed mine with the 400 cam but like others have removed the secondary butterflys so I have had no problem what so ever with my cable adjustments.
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  19. Toddwmac

    Toddwmac ADV addict

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    As a follow up, I ended up taking a "hybrid" approach (Hate that term these days). Anyway, I called 2 dealers and both agreed that the barrel adjustments for this amount of play were fine. They made sure to state to be sure to leave 2-3mm play and adjust with the motor off. I also consulted the 690 manual since it does talk about adjusting the throttle. It calls out the barrel adjustments but it also talks about the KTM diag computer.

    I did the adjustments at the adjusters and after a day on the trail and time in the city, all is well. The bike ran great but I will bring it up to the tech during my 1st service (300 miles from now) to make sure all is good.

    Thanks
    Todd
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  20. Fluffycat

    Fluffycat Been here awhile

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    I think Jody H meant the adjusters up by the twist grip, as the fine tuners. There is another adjuster down by the throttle bodies for cable slack.
    Cable slack on the 990 amplifies the poor fuelling/jerkiness that many complain about. Just adjust it to factory spec.(Off my head 3-4mm). You don't need a diagnostic tool for cable slack!.:lol3
    #20