KTM 990 manual

990 ADVENTURE 990 ADVENTURE S KTM Sportmotorcycle AG A–5230 Mattighofen www.ktm.at 12/2005 FOTO: MITTERBAUER KTM Group Partner ART. NR. 3.211.81 EN OWNER’S MANUAL 2006[...]

1 All information contained is without obligation. KTM-Sportmotorcycle AG particularly reserves the right to modify any equipment, technical specifications, prices, colors, shapes, materials, services, service work, constructions, equipment and the like so as to adapt them to local conditions or to cancel any of the above items, all without previou[...]

IMPORTANT INFORMATION » 2 INTENDED PURPOSE The KTM 990 Adventure is designed to resist the usual wear and tear of normal use on roads and easy terrain (unpaved roads). OWNER'S MANUAL Carefully read the entire Owner's Manual before you start riding your motorcycle, even if this will take a little time. It contains use- ful tips and inform[...]

IMPORTANT INFORMATION » W ARRANTY The service work specified in the „Lubrication and Maintenance Schedule“ must be performed by an authorized KTM workshop. This is the only place that has the qualified technicians and the special tools required for the 990 Adventure. Be sure to have the workshop verify all service work carried out in the servi[...]

INDEX » 4 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 IMPOR T ANT INFORMA TION . . . . . . . . . . . . . . . . . . . . . . . . . .2 SERIAL NUMBER LOCA TIONS . . . . . . . . . . . . . . . . . . . . . . . .6 Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Engine number , engine [...]

INDEX » 5 Compression damping of shock absorber . . . . . . . . . . . . . .44 Rebound damping of shock absorber . . . . . . . . . . . . . . . . .45 Adjusting the preload of the shock absorber . . . . . . . . . . . .46 Breathing the fork legs . . . . . . . . . . . . . . . . . . . . . . . . . .46 Cleaning the dust sleeves of the telescopic fork . . [...]

Chassis number The chassis number is located on the right side of the steering head tube and on the type label. Write this number into the relevant area on page 1. Engine number, engine type The engine number and engine type are embossed in the engine case near the shift lever . Write this number into the relevant area on page 1. SERIAL NUMBER LOCA[...]

Clutch lever The clutch lever [1] is located on the left side of the handlebar . The adjusting screw [A] is used to change the original position of the clutch lever (see maintenance work on chassis and engine). The clutch is hydraulically actuated and adjusts itself automatically . Hand brake lever The hand brake lever [2] is mounted on the handleb[...]

Multi-functional digital speedometer The universal instrument is divided into 3 parts. Use the MODE and SET [1] button to change the display and the basic settings in the display . Display [2] shows all of the information that may be of interest to you. 5 display modes can be selected with the MODE button. The indicator lamps [3] provide additional[...]

CLOCK Y ou will recognize the CLOCK display by the blinking dots between the hours and minutes. It displays the speed, temperature of the cooling liquid and the clock. T o switch to the next display mode, press the MODE button. ODO The speed, temperature of the cooling liquid and the total kilometers or miles traveled are shown in the ODO mode. T o[...]

Setting options in the display KILOMETERS OR MILES. Y ou can have the speed and distance shown in kilometers or miles in the display . The dis- play can be adapted to the respective country on long-distance trips. T o switch from kilometers to miles, switch on the ignition and press the MODE [1] button for approx. 10 seconds. The km/h display will [...]

RESETTING TRIP 2 The trip meter 2 runs continuously and counts up to 999.9. It can be used similarly to TRIP 1 or together with a switch available as an accessory (see below) for trips according to a roadbook. T o return the trip meter 2 to zero, switch on the ignition, change to the TRIP 2 mode and press the SET button. NOTE: A T ripmaster switch [...]

OPERATION INSTRUMENTS » 12 120°C (248°F) 110°C (230°F) 100°C (212°F) 70°C (158°F) 60°C (140°F) 50°C (122°F) 40°C (104°F) 1 Cooling liquid temperature display The temperature display [1] is shown in 7 bars. The more bars that light up, the hotter the cooling liquid. When the lowest bar lights up, the cooling liquid has reached a tempe[...]

OPERATION INSTRUMENTS » 13 Indicator lamps The green indicator lamp will blink in the blinker rhythm when the blinker is switched on. NOTE: The indicator lamp will blink slower when a blinker is broken. The green indicator lamp will light up when the gearbox is in an idling position. The blue indicator lamp will light up when the high beams are sw[...]

OPERATION INSTRUMENTS » 14 ABS warning lamp – models with ABS (antilock brake system) The ABS warning lamp [1] must light up when the ignition is switched on and go out at a speed of approx. 5 KPH after you drive off. If it stays on or lights up while driving, the ABS is defective. The ABS is no longer active and the wheels can lock when braking[...]

OPERATION INSTRUMENTS » 15 Tachometer The tachometer shows the engine speed in revolutions per minute. Do not run the engine beyond the black mark at 9500 rpm. The speed limiter will set in at 9600 rpm, drastically reducing the engine power above this rotational speed. When you switch on the ignition, the indicating needle will move to the black m[...]

OPERATION INSTRUMENTS » 16 5 6 2 1 1 3 4 Combination switch The rocker switch LIGHTS [1] actuates the high beam or low beam. = High-beam light = Low-beam light The light signal (high beam) is actuated with button [2] . The indicator switch [3] returns to central position after actuation. Press flasher switch towards switch housing to switch off th[...]

OPERATION INSTRUMENTS » 17 1 2 2 3 Storage compartment A storage compartment is located under the seat to hold small, frequently used items. T o open, turn the quick release [1] approx. 180° in a counterclockwise direction and lift the cover . T o lock, close the cover , insert the quick release in the dolly and turn 180° in a clock- wise direct[...]

OPERATION INSTRUMENTS » 18 1 2,3,4,5,6 N Fuel taps Both fuel taps [1] must be open when the motorcycle is running. The level in the fuel tanks is equalized by means of a connecting hose. Only close the fuel taps to remove the tanks. Shift lever The shift lever is mounted on the left side of the engine. The position of the gears is shown in the ill[...]

OPERATION INSTRUMENTS » 19 1 2 3 Center stand The bike is equipped with a side stand and a center stand [2] . Foot brake pedal The foot brake pedal [3] is located in front of the right footrest. Its basic position can be adjusted to your seat position (see maintenance work). Side stand Fold the side stand [1] forward to the stop with your foot and[...]

OPERATION INSTRUMENTS » 20 1 2 3 3 4 Compression damping of fork The fork's damping action during compression travel (compression damping) can be adjusted. This allows you adjust the damping behavior to match your driving style and the payload. The adjusting screws [2] are located under the cap [1] on the lower end of the fork legs. More info[...]

OPERATION INSTRUMENTS » 21 1 2 Damping action during compression of shock absorber The shock absorber's damping action during compression travel (compression damping) can be adjusted. This allows you adjust the shock absorber's damping behavior to match your driving style and the payload. The damping rate can be adjusted in the low and h[...]

OPERATION INSTRUMENTS » 22 1 2 Rebound damping of shock absorber The shock absorber's damping action during rebound travel (rebound damping) can also be adjusted. This allows you adjust the damping behavior to match your driving style and the payload. The adjusting screw [1] is located on the bottom of the shock absorber . More information is[...]

OPERATION INSTRUMENTS » 23 1 2 2 3 Baggage carrier plate The base plate for your choice of case system can be attached to the baggage carrier plate [1] . – Do not load more than 8 kg on the trunk carrier rack. – Observe the baggage manufacturer's instructions. Grips The passenger can hold on to both grab handles [2] . Footrests The passen[...]

Instructions for initial operation – Make sure the work for the „pre-delivery inspection“ was performed by your author- ized KTM workshop. The DELIVERY CER- TIFICA TE and SERVICE MANUAL will be handed over when you pick up your vehicle. – Read these operating instructions care- fully before your first ride. – Enter the chassis, engine and[...]

GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE » 25 – The tires must be designed for a maxi- mum speed of 240 kph (speed symbol V) and must be authorized by KTM. – Do not exceed the respective maximum speed for tires designed with a speed index of less than "V“ (240 kph). A sticker showing the maximum speed must be affixed to the[...]

Check the following before each start When you start, the motorcycle must be in perfect mechanical condition. For safety reasons, you should make a habit of performing an overall check of your motorcycle before each start. The following checks should be performed: 1 FUEL Check the fuel quantity in the tanks. 2 CHAIN Check the tension and condition [...]

DRIVING INSTRUCTIONS » 27 6 COOLING FLUID Check the level of cooling fluid when the engine is cold. 7 ELECTRICAL SYSTEM Start the engine and check the headlight, taillight, brake light, turn signal, indicator lamps and horn for proper functioning. 8 CHECK OIL LEVEL Insufficient oil results in premature wear and consequently to engine damage. 9 BAG[...]

DRIVING INSTRUCTIONS » 28 1 3 4 5 2 Starting the engine 1 Switch on emergency OFF switch [1] . 2 Switch on ignition (turn ignition key [2] into position ). NOTE: Y ou will hear the operation of the fuel pump for approx. 2 seconds after switch- ing on the ignition. The FI indicator lamp will also light up during this time and the engine should not [...]

IF THE ENGINE IS DOES NOT CRANK WHEN YOU ACTUA TE THE ST ARTER TIP SWITCH: – the transmission is switched to idle – Check if the emergency OFF switch is on – Check if the ignition is on – the headlight is on (the light is switched off when actuating the starter button) – If this is not the case, the battery is dis- charged – If the ligh[...]

– While riding your motorcycle, never switch the ignition lock to positions And . – Do not try to change the settings of the multi-functional Speedometer while driv- ing. Y our attention will be distracted from the traffic and may cause you to lose control of your motorcycle. – The passenger must hold on to the driver or the grab handle on th[...]

or slippery surfaces without running a risk of having the wheels lock. – The ABS cannot prevent one or both wheels from losing the road grip if the motorcycle is banked during the braking procedure. Although the wheel will not lock, the centrifugal force will cause the wheel to lose traction and cause the motorcycle to crash despite the ABS. – [...]

Stopping and parking Apply the brakes fully and put the engine into neutral. T o stop the engine, switch off the ignition. Park the motorcycle on a firm surface and lock. – Always park your motorbike on a solid and horizontal surface. – Never leave your motorcycle without supervision as long as the engine is running. – Motorcycle engines prod[...]

NOTE REGARDING THE CENTER ST AND: W e advise the following procedure to place the motorcycle on the center stand as effortlessly as possible: a) press main stand to ground using foot b) put your weight on the stand stabilizer and pull the motorcycle back by the footrest sup- port (see illustration). Make sure that the ground is solid and that your [...]

Fuel In the condition at delivery , the LC8 engine requires unleaded fuel with at least RON 95 (USA = Premium PON 91). If using lower octane fuel, it is easy to change over to the pre-programmed ignition curve for 80 - 94 octane (RON) (see activating the ignition curve for low-octane fuel). After refueling, it will take approx. 8 minutes for the fu[...]

35[...]

PERIODIC MAINTENANCE SCHEDULE » 990 ADVENTURE 2006 A clean motorcycle can be checked more quickly which saves money! 1st Service after 1000 km every 7500 km or once a year every 15000 km or every 2 years ENGINE Change engine oil and oil filter z z z Clean oil screens of engine and oil tank z z z Clean magnetic drain plugs of engine and oil tank z [...]

PERIODIC MAINTENANCE SCHEDULE » 990 ADVENTURE 2006 A clean motorcycle can be checked more quickly which saves money! 1st Service after 1000 km every 7500 km or once a year every 15000 km or every 2 years ADD-ON-PARTS Check actuating cables for damage, smooth operation, and kink-less arrangement, adjust and lubricate z z z Check fluid level of the [...]

PERIODIC MAINTENANCE SCHEDULE » 990 ADVENTURE 2006 ADDITIONAL SERVICE WORK TO BE PERFORMED UNDER A SEPARATE ORDER at least once a year every 15000 km or every 2 years Perform complete fork maintenance z Perform complete shock absorber maintenance z Clean and lubricate steering-head bearing and sealing elements z T reat the electrical contacts and [...]

PERIODIC MAINTENANCE SCHEDULE » 990 ADVENTURE 2006 VITAL CHECKS AND CARE PROCEDURES TO CONDUCTED BY THE OWNER OR THE MECHANIC before each start after every cleaning every 1000 km or after off road use Check oil level z Check brake fluid level z Check brake pads for wear z Check lighting system for proper operation z Check horn for proper operation[...]

– When cleaning the motorcycle, do not use a high pressure cleaning unit if possible, otherwise water will penetrate the bearings, carbu- retor , electric connectors etc. – Do not use toothed washers or spring washers with the engine fastening screws, as these work into the frame parts and keep wor king loose. Instead, use self-locking nuts. ?[...]

Removing and remounting the seat Insert the ignition key in the seat lock and turn in a counterclockwise direction to unlock the seat. Lift the back of the seat and pull off towards the rear . T o remount, fit the nose [1] of the seat in the front, lower the back while pushing towards the front. Both noses [2] should fit into the frame. Insert the [...]

Adjusting compression damping of fork Hydraulic compression damping determines the reaction when the fork is compressed. The degree of compression can be adjusted with adjusting screws at the bottom of the fork legs. Carefully pry out the protection cover [1] with a screwdriver and remove. T urn the adjusting screws [2] clockwise to increase dampin[...]

Adjusting the spring preload on the fork The fork spring preload can be adjusted by turning the adjusting screws [4] (wrench size 24 mm) ± 5 mm (0,2 in). T urning in a clockwise direction will increase the preload, turning in a counterclockwise direc- tion will decrease the preload. 1 turn will change the preload by 1 mm. Changing the preload will[...]

Compression damping of shock absorber The shock absorber can synchronize the compression damping in the low and high-speed range separately (Dual Compression Control). Low and high speed refers to the movement of the shock absorber during compression and not to the speed of the motorcycle. The low and high-speed technology overlaps. The low-speed s[...]

ST ANDARD ADJUSTMENT HIGH-SPEED: – T urn the adjusting screw in a clockwise direction up to the stop with a socket wrench (wrench size 17 mm). – T urn the adjusting screw in a counterclockwise direction the number of turns specified for the respective type of shock absorber . 990 Adventure . . . . . . . .1.5 turns 990 Adventure S . . . . . .1.5[...]

Adjusting the preload of the shock absorber The baggage and passenger put the main load on the shock absorber . T o guarantee maxi- mum handling performance, the preload of the shock absorber must be adapted to the load. The preload is hydraulically adjusted by turning the hand wheel [1] . T urning in a clockwise direction will increase the preload[...]

Cleaning the dust sleeves of the telescopic fork The dust-protection bellows [3] are to remove dust and coarse dirt particles from the fork tube. However , after some time, dirt may also get in behind the dust-protection bellows. If this dirt is not removed, the oil sealing rings located behind it may start to leak. Use a screwdriver to lever the d[...]

Correct chain tension Loosen collar nut [1] , loosen counter nuts [2] , and turn right and left adjusting screws [3] equally far . T ighten counter nuts [2] . Before tightening the wheel spindle, verify that the chain adjusters [4] are sitting close to the adjusting screws and that the rear wheel has been aligned with the front wheel. T ighten coll[...]

Chain maintenance The maintenance of the X-ring chain is reduced to a minimum. Clean with a soft water jet. Never use a brush or solvent to clean the chain. When the chain is dry use a chain spray specially made for X-ring chains (Motorex Chainlube 622). – No lubrication is allowed to reach the rear tire or the brake disk, eitherwise the road adh[...]

General informations about KTM disc brakes BRAKE CALIPERS: The brake calipers of this series “float“. This means that the brake calipers are not solidly attached to the caliper support. Thus, the brake pads are always in optimum contact with the brake disc. Secure the screws of the caliper support with Loctite 243 and tighten to 25 Nm. For safe[...]

BRAKE FLUID: KTM fills the brake systems with Motorex Brake Fluid DOT 5.1 brake fluid, one of the best brake fluids that is currently available. W e recommend that you continue to use it. DOT 5.1 brake fluid is based on glycol ether and of an amber color . If you do not have any DOT 5.1 for refilling, you may use DOT 4 brake fluid. However , you sh[...]

ABS (ANTILOCK BRAKE SYSTEM) 990 ADVENTURE: The ABS is a safety system that prevents the wheels from locking when driving straight ahead without the influence of lateral forces. The ABS unit [1] , consisting of a hydraulic unit, an electronic control unit and the electric pump motor , is located under the seat. Sensors [2] on the front and rear whee[...]

Adjusting of free travel at the hand brake lever Free travel at the hand brake lever may be readjusted by using adjusting screw [1] . In this way , the position of the point of pressure (i.e., the resistance you feel on the hand brake lever when the brake pads are pressed against the brake disc) can be adjusted for any hand size. At the hand brake [...]

Checking rear brake fluid level The brake fluid reservoir for the rear disk brake is combined with the foot brake cylinder and has an inspection window . The brake fluid level should not drop below the "MIN" mark when the motorcycle is in a vertical position. – If the brake fluid level drops below the minimum either the brake system has[...]

55[...]

Dismounting and mounting the front wheel Jack the motorcycle up at the underride protection until the front wheel no longer touches the ground. Loosen the collar screw [1] and the clamp screws [2] at both fork leg axle passages. Unscrew the collar screw approx. 8 turns, pressing your hand against the collar screw to push the axle passage out of the[...]

T o mount the front wheel, lift the wheel into the fork, slightly pull one brake caliper out and push the tire in between the brake calipers. Insert the brake disks in the brake calipers and mount the axle passage. Mount the collar screw [1] and tighten slightly . T ighten the clamp screws [2] on the right fork leg axle passage (in the direction of[...]

MAINTENANCE WORK ON CHASSIS AND ENGINE » 58 1 2 A 3 A 4 5 Dismounting and mounting the rear wheel NOTE FOR MODELS WITH ABS (ANTILOCK BRAKE SYSTEM): The ABS sensor [6] can be removed to make it easier to dismount and mount the rear wheel. Loosen the HH screw [7] and pull out the ABS sensor . When remounting, apply Loctite 243 (screw retainer) to th[...]

MAINTENANCE WORK ON CHASSIS AND ENGINE » 59 TIRES – AIR PRESSURE front rear Road, driver only 2.4 bar (34psi) 2.6 bar (37psi) Road, with passenger 2.4 bar (34psi) 2.8 bar (40psi) maximum payload 2.4 bar (34psi) 2.8 bar (40psi) Tires, air pressure T ire type, tire condition, and how much air pressure the tires have in them affect the way your mot[...]

MAINTENANCE WORK ON CHASSIS AND ENGINE » 60 Checking spoke tension The correct spoke tension is very important for the stability of the wheels and thus for rid- ing safety . A loose spoke causes the wheel to become unbalanced and before long other spokes will have come loose. Check spoke tension, especially on a new motorcycle, in reg- ular interv[...]

MAINTENANCE WORK ON CHASSIS AND ENGINE » 61 Battery The battery is located in the underride protection in front of the engine and is maintenance- free. It is not necessary to check the electrolyte level or to refill water . Simply keep the bat- tery poles clean and slightly grease them with an acid-free grease if necessary . The charge condition a[...]

Demounting and mounting the battery The battery does not need to be demounted unless the motorcycle is being immobilized. T o demount the battery , remove the screws [1] and fold the underride protection [2] down. Remove the screws [3] and tilt the battery cover [4] to the front. First disconnect the neg- ative pole and then the positive pole. Remo[...]

Charging the battery The battery does not need to be dismounted to charge. Remove the screws [1] and the engine cover [2] . Remove the red protection cover and connect the charging device with the positive terminal post at screw [3] and the negative terminal post at screw [4] . Charge the battery as specified in the following table. Do not exceed t[...]

Main fuse The main fuse protects all of the motorcycle's current consumers. The main fuse is located in the starter relay under the right engine cowl. Remove the screws [1] and take off the engine cowl [2] . Do not burn yourself on the hot exhaust pipe. Lift the starter relay [3] out of the bracket, remove the cap [4] and check the main fuse [[...]

Fuses for individual current consumers A fuse box with additional fuses is mounted in the storage compartment to separately pro- tect the current consumers against short circuits. The current consumers and the corresponding fuse capacities are listed on the cover of the fuse box [1] . Spare 10, 15, 25 and 40-ampere fuses [2] are also located next t[...]

Replacing the headlight lamps Remove the 5 screws on the left and right and take off both side covers [1] . Use a screw- driver to detach the retaining tabs [2] , tilt the windshield and headlight forward and pull the connector off the connector support. Place the headlight on a soft pad to keep it from being damaged. Never touch the glass of the b[...]

P ARKING LIGHT BULB [C] : Pull the bulb socket [7] out of the reflector and pull the bulb out of the bulb socket. USA design: The parking light [E] is located in the upper part of the headlight in the USA design. Bulb [F] (see T echnical specifications – Chassis / Lighting) with high and low beams is mounted in the lower part of the headlight. Co[...]

Adjusting the headlight range The payload can make it necessary to correct the headlight range. The headlight range can be adjusted with the adjusting screw [1] . T urning in a clockwise direction will increase the headlight range, turning in a counterclockwise direction will reduce the headlight range. TO CHECK: Make a mark on a light wall behind [...]

Replacing the flasher bulbs Remove the screw on the back of the turn signal, carefully fold the lens [5] towards the motorcycle and remove. Slightly depress the bulb, turn it approx. 30° counterclockwise and pull it out of the socket. T o mount the lamp reverse the worksteps indicated above. MAINTENANCE WORK ON CHASSIS AND ENGINE » 69 5[...]

Cooling system The water pump in the engine ensures a forced circulation of the cooling liquid. When the engine is cold, the cooling liquid only circulates in the cylinders and cylinder heads. The thermostat will open when the engine reaches approx. 75°C (167°F) and the cooling liquid will also be pumped through the aluminum radiator . Cooling is[...]

A mixture of 50% antifreeze and 50% distilled water is used as the cooling liquid. How ever , the anti-freeze protection must be at least -25° C (-13° F). Aside from antifreezing protec- tion, this mixture also provides great corrosion protection which is why it must not be replaced by pure water . – For the cooling system, use only high-grade [...]

Checking the cooling liquid level in the radiator Remove the 5 screws and the right cover [1] , disconnect the flasher cable and tank ventilation. If possible, always check level of cooling liquid when engine is cold. If you have to open the radiator cap when engine is hot, use a rag to cover the cap and open slowly to release pres- sure. Carefully[...]

Bleeding the cooling system Remove the 5 screws and the left cover [3] , disconnect the flasher cable and tank ventilation. Remove the bleeder screw [4] on the left side of the radiator . T o be able to completely bleed the cooling system, raise the motorcycle approx. 50 cm in the front. Add cooling liquid until it runs out of the discharge opening[...]

Changing the original position of the clutch lever The adjusting screw [1] can be used for individual adjustment of the original position of the clutch lever , thus allowing adjustment to an optimal position for every hand size. T urning the adjusting screw counterclockwise reduces the distance between the clutch lever and the handlebar . T urning [...]

Engine oil Automobile engine oil used to be used for four -stroke motorcycles before there were sepa- rate motorcycle specifications. Different technical developments made it necessary to have a separate specification for four -stroke motorcycles - the JASO T903 MA standard. Whereas car engines require long changing intervals, motorcycle engines re[...]

76 Changing the engine oil and the oil filter, cleaning the oil screen Y ou may only change the engine oil yourself after the warranty period has expired. The war- ranty will become void if you change the oil yourself during the warranty period. NOTE: The LC8 engine has a dry-sump lubrication system. The engine oil is pumped from the oil sump in th[...]

MAINTENANCE WORK ON CHASSIS AND ENGINE » Remove the 6 screws and the cover [4] . Remove the 5 screws, take off the left panel [5] and disconnect the turn signal cable. Close both fuel taps [6] on the connecting line. 4 6 6 5 77[...]

78 Remove the 3 screws [1] , lift the tank approx. 15 mm and carefully tilt to the side. Disconnect the fuel lines, disconnect the connector for the fuel pump and the pickup cable (fuel level) and set down the tank. Remove the lower screw [2] on the right tank. Remove the HH screws and take off the bat- tery cover [3] . Remove the drain plug [4] on[...]

MAINTENANCE WORK ON CHASSIS AND ENGINE » 79 Carefully pull the oil screen [7] out of the oil tank. Thoroughly clean the drain plugs, the cover and both oil screens. Clean all rubber seal rings and check for damage. Replace if necessary . Mount the oil drain plug on the engine with a new seal ring and tighten to 20 Nm. Slide the oil screen [8] into[...]

MAINTENANCE WORK ON CHASSIS AND ENGINE » 80 Insert a new oil filter [1] in the engine case, grease the O-ring and mount the oil filter cover together with the O-ring. T ighten the screws to 6 Nm. Only use original KTM oil filters. The engine can be damaged if other filters are used. Mount the oil drain plug on the oil tank with a new seal ring and[...]

MAINTENANCE WORK ON CHASSIS AND ENGINE » 81 Add 2.5 liters (0.7 USgal) of fully synthetic engine oil meeting the JASO MA standard (e.g. Motorex Power Synt 4T) and mount the oil dipstick. Start the engine, allow to run warm for 4 minutes and switch off the engine. Remove the oil dipstick and add engine oil up to the MAX mark (approx. 0.5 liters, 0.[...]

Activating the ignition curve for low-octane fuel If you are traveling to a country where fuel having at least 95 octane (RON) is not available, you can easily activate the corresponding ignition curve. A plug and socket connection [1] on a brown/black cable is located near the upper shock absorber holder . If the two connectors are connected to ea[...]

If you have your motorcycle serviced as set forth in this manual, no malfunctioning is to be expected. Nevertheless, if an error does arise, we recommend that you look for the error according to the following chart. Please note that you cannot perform all of the work yourself. If you are not sure, contact your KTM dealer . TROUBLE SHOOTING » 83 TR[...]

TROUBLE SHOOTING » TROUBLE CAUSE REMEDY Engine cranks but doesn’t start. Blown fuse for the fuel pump Clutch not attached to the fuel line The plug and socket connector on the wiring harness is oxidized Error in the injection system A gear is engaged and the side stand is folded down Replace the FUEL PUMP fuse Connect the clutch to the fuel line[...]

TROUBLE SHOOTING » TROUBLE CAUSE REMEDY Engine overheats Defect fan or thermoswitch for fan Air in the cooling system Thermostat defective Contact an authorized KTM workshop. Bleed the cooling system (see Maintenance work) Have the thermostat checked (opening temperature 75°C, 167°F) or replaced; contact an authorized KTM workshop FI lamp is bli[...]

TROUBLE SHOOTING » TROUBLE CAUSE REMEDY Flasher lights, brake light, horn and multi-functional digital speedometer fail Bulb burned out Blown fuse Replace bulb Replace fuse HORN BRAKELIGHT SPEEDO. T ime is not displayed or not cor- rectly displayed Blown fuse, thus no continuous power supply Replace fuse ACC 1 / CLOCK and set the clock. The batter[...]

TROUBLE SHOOTING » 87 The blink code indicates which component is affected by an error . This allows the error to be identified if no diagnosis tool is available. BLINK CODE SIGNAL / COMPONENT ERROR DESCRIPTION ENGINE 12 Coolant temperature sensor Output signal too low /high Continues to run 13 Air temperature sensor Output signal too low /high Co[...]

CLEANING » CONSERVATION FOR WINTER OPERATION » 88 Regular cleaning and paintwork care is part of the maintenance work and helps to maintain the value of your motorcycle. Never clean your motorcycle with a high-pressured cleaner or a high-pressured water jet. The water could otherwise run into the electrical components, connectors, sheathed cables[...]

STORAGE » 89 Should you desire to make a pause over a longer space of time, please observe the following instructions: – Drive the tanks empty to be able to fill up with fresh fuel when starting the motorcycle up again. – Clean motorcycle thoroughly (see chapter: CLEANING) – Change engine oil and oil filter (old engine oil contains aggressiv[...]

TECHNICAL SPECIFICATIONS – CHASSIS » CHASSIS 990 ADVENTURE / 990 ADVENTURE S Frame T ubular chrome-molybdenum-steel space frame Fork WP – Up Side Down 4860 MXMA (Multiadjuster) Wheel travel front ADVENTURE = 210 mm (8.3 in), ADVENTURE S = 245 mm (9.6 in) Rear suspension WP Suspension Progressive Damping System shock absorber with hydraulic pre[...]

TECHNICAL SPECIFICATIONS – CHASSIS » CHASSIS 990 ADVENTURE / 990 ADVENTURE S Lighting flasher 12V 10W (socket BA15s) licens plate illumination 12V 5W (socket W2.1x9,5d) Battery maintenance-free battery 12V 11.2 Ah Steering head angle 63.4° Wheel base 1570 mm (61.8 in) Seat height, unloaded ADVENTURE: 860 mm (33.8 in), ADVENTURE S: 895 mm (35.2 [...]

TECHNICAL SPECIFICATIONS – CHASSIS » TIGHTENING TORQUES – CHASSIS HH clamp bolts on top triple clamp M8 20 Nm HH clamp bolts for steering stem M8 20 Nm HH clamp bolts on bottom triple clamp M8 15 Nm AH bolt for handlebar mount M10 20 Nm Collar bolts for handlebar clamps M8 20 Nm HH clamp bolts on fork leg axle passages M8 15 Nm Collar screw on[...]

TECHNICAL SPECIFICATIONS – CHASSIS » TIGHTENING TORQUES – CHASSIS Exhaust nuts on manifold M8 evenly , do not bend sheet metal HH bolts on exhaust suspension M6 Loctite 243 + 12 Nm Spoke nipple M5 5 Nm ± 1 Nm HH nuts on rear sprocket bolts M10x1,25 Loctite 243 + 50 Nm Hexagon nut on engine sprocket M20x1,5 sheet retainer + 100 Nm Engine carri[...]

TECHNICAL SPECIFICATIONS – ENGINE » ENGINE 990 LC8 Design Liquid-cooled, 2-cylinder 4-stroke engine with 75° V arrangement with balancer shaft and electric starter Displacement 999 cc Bore / Stroke 101/62.4 mm Compression ratio 11.5:1 Fuel unleaded fuel with at least RON 95 (USA: Premium PON 91*) / RON 80 - 94 for other ignition curve) V alve t[...]

TECHNICAL SPECIFICATIONS – ENGINE » ENGINE 990 LC8 Mixture preparation EFI (electronic fuel injection) Ignition system breakerless transistorized electronic ignition system with digital ignition advance Ignition timing Map-controlled via TPS Generator 12V 450W at 6000 rpm Spark plug NGK DCPR 8 E Electrode distance 0.8 mm Cooling system liquid co[...]

HEAD WORD INDEX » 96 ABS button – models with ABS (antilock brake system) . . . . .14 ABS fuses – models with ABS (antilock brake system) . . . . . . .64 ABS warning lamp – models with ABS (antilock brake system) . .14 Accessories and payload . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 Activating the ignition curve for low-octa[...]

HEAD WORD INDEX » 97 Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 Fuel taps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 Fuses for individual current consumers . . . . . . . . . . . . . . . . .65 General informations about KTM disc brakes . . . . . . . . . . . . .50 Gen[...]

98[...]

990 ADVENTURE 990 ADVENTURE S KTM Sportmotorcycle AG A–5230 Mattighofen www.ktm.at 12/2005 FOTO: MITTERBAUER KTM Group Partner ART. NR. 3.211.81 DE BEDIENUNGSANLEITUNG 2006[...]