This article describes the installation of our CUMPAN on a KTM Super Duke 990 R as an example.
The installation steps are exemplary for all KTM models with LC8 engine from 2003-2013 and partly for the KTM models with LC4 engine from 2007-2013.
The following models are involved in detail:
KTM LC4 models from 2007-2013: 690 Duke | 690 Enduro (R) | 690 Rally | 690 SMC (R)
KTM LC8 models from 2003-2013: 950 Adventure (S) | 950 Super Enduro (R) | 990 Adventure (R) | 990 Super Duke (R) | 990 Supermoto (R/T) | 1190 RC8 (R)
The installation steps:
LC4 shopping list
LC8 shopping list
Installing the temperature sensor
For the LC8 engine, we select the M14x1.5 temperature sensor and install it at the front in the direction of travel, at the bottom of the engine housing (position no. 7 ), directly on the seat of the oil filter. For better accessibility, the front spoiler and battery compartment are removed from the Super Duke 990. The original screw cap can then be removed and the M14 temperature sensor installed (observe tightening torque of 20NM). The spilled oil must be collected and the corresponding amount replaced later.
Three installation locations can be selected on the LC4 engine (position no. 3 ) can be selected, the M10x1 temperature sensor is used for all of them. The first position, which is in the direction of travel, is located on the water pump housing and records the cooling water temperature. The other two positions record the oil temperature.
When selecting the temperature sensor and the installation position, make sure that the thread length of the temperature sensor is suitable and that the sensor is not installed outdoors in an exposed position where it can be easily damaged.
Connection of the speed signal
On the LC8 engine, the signal cable from the crankshaft sensor exits the engine housing on the right-hand side (position no. 1 ) . This cable is followed by a white, two-pin connector to which you can install either the RPM signal tap or a PRESSLOK™ Branch connector.
On the LC4 engine, the signal cable from the crankshaft sensor exits the engine housing on the rear, right-hand side of the engine (position no. 17 ). This cable is followed by a white, two-pin connector to which you can install either the RPM signal tap or a PRESSLOK™ Branch connector.
Important: The speed signal is applied to the white/yellow cable. The pin assignment within the LC4 and LC8 models may vary, i.e. when using the RPM signal tap, the pins may have to be swapped so that the tap is on the line of the white/yellow cable.
Installing and connecting the aisle sensor
The gear sensor is located on the LC8 engine on the left-hand side of the engine, at the height of the side stand (position no. 25 ) . The two screws of the gear sensor and the three-pin connector must be loosened for disassembly. The side stand can be removed for better accessibility, although this is not absolutely necessary. The new gear sensor is installed in reverse order (observe the tightening torque of 6NM), as is the connection of the plug.
The three-pin connector supplies the original signals for the engine control unit. The two-pole power cable supplies the 12V voltage for the electronics of the gear sensor and must be connected to a switched 12V line accordingly. The ACC2 connection, for example, is suitable for this.
The black and white cable transports a voltage signal 0 – 5V, which provides the CUMPAN with information about the gear engaged. This cable must be connected to analog input 1 or 2 of the CUMPAN using the PRESSLOK™ Butt connector.
The installation on the LC4 engine is almost identical, the gear sensor is also located on the left-hand side of the engine, at the height of the side stand (position no. 32 ) .
Note: The original gear sensor detects the neutral position as well as the 2. and 3rd gear. The information as to whether the 2. or 3rd gear is engaged is used by the engine control unit to reduce the power in these gears at full load. This throttling is necessary to comply with the emissions standard.
Deactivating this throttling may be relevant for racing, for which purpose only the line for the 2. and 3rd gear must be shut down. To do this, either remove the pins from the three-pin plug or cut the cables (insulate open contact points!). The cable colors are assigned as follows:
Neutral – green / green-black (sensor side / vehicle side)
2nd gear – blue-red / gray (sensor side / vehicle side)
3rd gear – yellow-green / yellow-brown (sensor side / vehicle side)
Installing the oil pressure sensor (LC8)
The oil pressure sensor is installed on the oil filter cover (position no. 6 ) . To do this, first remove the oil filter cover and collect the leaking oil. The leaked amount should be refilled later. Make sure that no impurities enter the oil circuit.
The oil filter cover already has a recess on the inside in the middle, which is used to center the core hole. Once the core hole has been drilled, the hole should be chamfered and the thread (M10x1) then cut. The oil pressure sensor must then be fitted with Teflon tape or another sealant and installed. It is mounted on the outside of the cover. Finally, the oil filter cover can be refitted (observe tightening torque of 6NM).
As with the gear sensor, the 12V cable and the black and white signal cable must also be connected here. We recommend connecting the oil pressure signal to analog 2 (black-blue cable) of the CUMPAN.
In principle, it is also possible to install the oil pressure sensor on the LC4 engine, but we have not yet been able to test it in practice. All that is required is a suitable position or thread.
From the 2012 models onwards, the oil pressure sensor can be installed in the same position (position no. 31 ) as on the current models.
The following set can be used for this purpose: Add-on oil pressure sensor
Power connection
The last step is to establish the power supply. This means that the CUMPAN, the gear sensor and, if necessary, the oil pressure sensor are connected to a switched 12V line. ACC2 connections for auxiliary consumers are already fitted to almost all KTM models at the factory. The ACC splitters can be used to expand these slots to ensure the required number of slots.
The Red One positive terminal must be plugged into the black-red cable on the ACC2 connection. The black ground wire is connected to the brown cable.
Settings on the CUMPAN
Once the 12V power supply has been established and the correct installation of all components has been checked, the CUMPAN can be switched on with the ignition.
Two settings are mandatory in the menu:
[MENU] / [SENS] / Damping “250” / Sensor “BIKE”
[MENU] / [INPUT] / IN1 “GEAR” / IN2 “PRESSURE”
All other settings are described in detail in the user manual described.
