KTM 990s manual

KTM-Sportmotorcycle AG A–5230 Mattighofen www.ktm.at KTM Group Partner OWNER’S MANUAL MANUALE D’USO MANUEL D’UTILISATION MANUAL DE INSTRUCCIONES ART. NR. 3.211.57 990 SUPER DUKE BEDIENUNGSANLEITUNG 2005[...]

ENGLISH 1 IMPORTANT » Please insert the serial numbers of your motorcycle in the boxes below Frame number Engine number Key number Stamp of dealer All information contained is without obligation. KTM-Sportmotorcycle AG particularly reserves the right to modify any equipment, technical specifications, prices, colors, shapes, materials, services, se[...]

ENGLISH 2 INTRODUCTION » W e would like to congratulate you on your purchase of a KTM motorcycle. Y ou are now the owner of a state-of-the-art sport motorcycle that guarantees to bring you lots of fun and enjoyment, provided that you clean and maintain it appropriately . Before you go for your first ride, be sure to read this manual carefully and [...]

ENGLISH 3 IMPORTANT LIMITED WARRANTY AND LIMITED GUARANTEE INFORMATION » The 990 Super Duke is designed and constructed for normal use on public roads but not for use on race courses or offroad terrain. The service, care and operating instructions for the engine and chassis specified in the owner's manual must be observed to ensure that the b[...]

ENGLISH 4 INDEX » Page SERIAL NUMBER LOCA TIONS . . . . . . . . . . . . . . . . . . . .5 Chassis number , T ype label . . . . . . . . . . . . . . . . . . . .5 Engine number , engine type . . . . . . . . . . . . . . . . . . . .5 OPERA TION INSTRUMENTS . . . . . . . . . . . . . . . . . . . . .5 Clutch lever . . . . . . . . . . . . . . . . . . . . . [...]

ENGLISH 5 SERIAL NUMBER LOCATIONS » Chassis number, Type label The chassis number is stamped on the right side of the steering head tube. Enter this number in the field on page no 1. The type label is located on the right frame tube under the seat. Engine number, engine type The engine number and the engine type are stamped into the left side of t[...]

ENGLISH 6 OPERATION INSTRUMENTS » 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 set- tings in the display . Display [2] shows all of the information that may be of interest to you. 5 dis- play modes can be selected with the MODE button. The[...]

ENGLISH 7 OPERATION INSTRUMENTS » Setting options in the display KILOMETERS OR MILES. Y ou can have the speed and distance shown in kilometers or miles in the dis- play . The display 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.[...]

ENGLISH 8 OPERATION INSTRUMENTS » 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 liq- uid has reached a temperature of approx. 40°C (104°F). When the upper bar lights up 120°C (248°F), all of the bars will [...]

ENGLISH 9 OPERATION INSTRUMENTS » Ignition lock The ignition lock has 3 switching positions. Ignition off, (engine can't be started) Ignition on, (engine can be started) Ignition off, handlebar blocked T o switch the ignition to position turn the ignition key to position and firmly press it into the lock. T urn the handlebar all the way to th[...]

ENGLISH 10 OPERATION INSTRUMENTS » Filler cap The filler cap [1] can be locked. It is equipped with a tank ventilation system. T o open, insert the ignition key , turn 45° in a clockwise direction and tilt the filler cap back. After refueling, pull out the ignition key and press down on the filler cap until the lock engages. Seat lock, removing t[...]

ENGLISH 11 OPERATION INSTRUMENTS » Helmet lock The steel rope [1] in the tool bag can be used to secure a helmet. T o secure, remove the seat, run the rope through the helmet, attach both ends to the hook [2] and mount the seat. THE HELMET LOCK IS PROVIDED TO SECURE THE HELMET TO THE MOTORCYCLE WHEN P ARKED. DO NOT A TT ACH THE HELMET OR OTHER OBJ[...]

ENGLISH 12 OPERATION INSTRUMENTS » Footrests The passenger footrests [1] fold up. 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 on the fork leg a[...]

ENGLISH 13 OPERATION INSTRUMENTS » 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 damp- ing behavior to match your driving style and the payload. The damping rate can be adjusted in the low[...]

– NEW WHEELS HA VE A SMOOTH SURF ACE, WHICH MEANS THA T THEY MUST BE RUN IN TO ACHIEVE FULL GRIP . FOR THIS PUR- POSE, RIDE THE MOTORCYCLE CAREFULL Y A T MODERA TE SPEED DURING THE FIRST 200 KILOMETERS WITH NEW TIRES, TIL TING THE VEHICLE A T DIFFERENT ANGLES SO THA T ALL SECTIONS ARE PROPERL Y ROUGHENED. TIRES WILL NOT DISPLA Y THEIR FULL GRIP C[...]

ENGLISH 15 DRIVING INSTRUCTIONS » 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 CHA[...]

ENGLISH 16 DRIVING INSTRUCTIONS » 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 switching on the ignition. The FI indicator lamp will also light up during this time and the engine should not be s[...]

ENGLISH 17 DRIVING INSTRUCTIONS » Starting off T urn on the light, pull the clutch lever and engage 1st gear . Slowly release the clutch lever while you gently accelerate. – BEFORE YOU ST AR T OFF , CHECK THA T THE MAIN ST AND HAS BEEN SWUNG UP FULL Y . IF THE ST AND DRAGS ON THE GROUND, THE MOTORCYCLE CAN GO OUT OF CONTROL. – AL WA YS TURN ON[...]

ENGLISH 18 DRIVING INSTRUCTIONS » Stopping and parking Apply the brakes fully and put the engine into neutral. T o stop the engine, switch off the ignition. Fold the side stand forward to the stop with your foot, put the weight of the motorcycle on the stand and park the bike on a firm sur- face. Lock the motorcycle. – AL W AYS P ARK YOUR MOTORB[...]

ENGLISH 19[...]

ENGLISH 20 PERIODIC MAINTENANCE » 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 zzz Clean oil screens of engine and oil tank zzz Clean magnetic drain plugs of engine and oil tank zzz Check oil lines for[...]

ENGLISH 21 PERIODIC MAINTENANCE » IMPORTANT RECOMENDED MAINTENANCE PROCEDURES TO BE PERFORMED BASED ON A SEPARATE SUPPLEMENT ORDER at least once a year every 2 years or 15000 km Perform complete fork maintenance z Perform complete suspension strut maintenance z Clean and lubricate steering-head bearing and sealing elements z T reat the electrical [...]

ALL MAINTENANCE AND ADJUSTMENT WORK MARKED WITH AN ASTERISK * REQUIRES SPECIAL TECHNICAL SKILLS. IN YOUR OWN INTE- REST , HAVE THIS WORK PERFORMED BY AN AUTHORIZED KTM WORKSHOP , WHERE YOUR MOTORCYCLE WILL BE SERVICED BY SPECIALL Y TRAINED TECHNICIANS. – DO NOT CLEAN THE MOTORCYCLE WITH A POWER W ASHER OTHERWISE W A TER WILL GET INTO THE BEARINGS[...]

ENGLISH 23 MAINTENANCE WORK ON CHASSIS AND ENGINE » 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 com- pression and not to the speed of the motorcycle. The [...]

ENGLISH 24 MAINTENANCE WORK ON CHASSIS AND ENGINE » Checking the chain tension Place the motorcycle on the side stand. Switch the transmission to neutral and push the chain up. The distance between the chain and the swing arm should be 7 mm when the upper part of the chain [A] is tensioned (see draw- ing). Correct the chain tension if necessary . [...]

ENGLISH 25 MAINTENANCE WORK ON CHASSIS AND ENGINE » Chain maintenance For long chain life, good maintenance is very important. X-ring chains require only modest maintenance. The best way is to use lots of water , but never use brushes or solvents. After letting the chain dry , you can use a special X-ring chain spray (Motorex Chainlube 622). NO LU[...]

ENGLISH 26 MAINTENANCE WORK ON CHASSIS AND ENGINE » General information on KTM disk brakes BRAKE CALIPERS: The front brake calipers [1] have 4 brake pistons each and are firmly con- nected to the fork legs. The front brake disks are designed as "floating" brake disks, i.e. they are not firmly connected to the front wheel. The lateral bal[...]

ENGLISH 27 MAINTENANCE WORK ON CHASSIS AND ENGINE » Adjusting the basic position of the hand brake lever The basic position of the hand brake lever can be modified by turning the adjusting screw [1] . This lets you adapt the position of the pressure point (the resistance you feel on the hand brake lever when the brake pads are pressed against the [...]

ENGLISH 28 MAINTENANCE WORK ON CHASSIS AND ENGINE » min. 1 mm 3 4 1 2 6 mm Changing the basic position of the foot brake lever * Loosen the counternut [1] and turn the push rod [2] until the foot brake lever is in the right position. T ighten the counternut again. For the best possible connection, the push rod should be screwed at least 6 turns (6[...]

ENGLISH 29 MAINTENANCE WORK ON CHASSIS AND ENGINE » A B 1 1 2 3 3 4 5 Dismounting and remounting the front wheel * Place the front of the motorcycle on a motorcycle stand (available as an acces- sory), lifting the front wheel entirely off the ground. T o remove the left and right brake caliper , remove the two screws [1] on each caliper and pull t[...]

ENGLISH 30 MAINTENANCE WORK ON CHASSIS AND ENGINE » 1 3 5 2 A 4 6 Dismounting and remounting the rear wheel * Place the back of the motorcycle on a motorcycle stand (available as an acces- sory), lifting the rear wheel entirely off the ground. Unscrew the collar nut [1] , remove the chain tensioner [2] , hold the rear wheel while you pull out the [...]

ENGLISH 31 MAINTENANCE WORK ON CHASSIS AND ENGINE » TIRES – AIR PRESSURE 990 Super Duke front rear Road, driver only 2,4 bar 2,4 bar Road, with passenger 2,4 bar 2,6 bar maximum payload 2,4 bar 2,6 bar 1 Tires, air pressure T ire type, tire condition, and how much air pressure the tires have in them affect the way your motorcycle rides, and they[...]

ENGLISH 32 MAINTENANCE WORK ON CHASSIS AND ENGINE » VOL T 3 3 4 1 2 2 Removing and remounting the battery * The battery only needs to be removed if the motorcycle is being immobilized. Remove the screws [1] on both sides, loosen the screws [2] 2 turns and remove the front spoiler towards the front. Push the cables to the side. Remove the screws [3[...]

ENGLISH 33 MAINTENANCE WORK ON CHASSIS AND ENGINE » 6 5 3 4 1 2 7 8 Main fuse The main fuse protects all of the motorcycle's electric power consumers. The main fuse is located on the left under the front spoiler . Pull the connector [1] out of the bracket, remove the cap [2] and check the main fuse [3] . A spare fuse [4] (30 amperes)is also p[...]

ENGLISH 34 MAINTENANCE WORK ON CHASSIS AND ENGINE » 1 1 2 3 4 A B 5 6 Replacing the headlight lamp * Remove the screws [1] on the left and right and tilt the headlight mask down towards the front. NEVER TOUCH THE GLASS OF THE BULB WITH YOUR FINGERS. THE GLASS OF THE BULB MUST REMAIN ABSOLUTEL Y FREE FROM GREASE. HEA T WILL OTHER- WISE CAUSE THE GR[...]

ENGLISH 35 MAINTENANCE WORK ON CHASSIS AND ENGINE » 2 3 4 1 Replacing the brake light and taillight bulbs Remove the seat. BULB FOR BRAKE LIGHT : T urn the bulb socket [1] approx. 30° in a counterclockwise direction and pull it out of the taillight housing. Slightly press in the bulb, turn approx. 30° in a counterclockwise direction and remove i[...]

ENGLISH 36 MAINTENANCE WORK ON CHASSIS AND ENGINE » 6 5 4 2 3 1 Cooling system The water pump in the engine ensures a forced circulation of the cooling liq- uid. When the engine is cold, the cooling liquid only circulates in the cylin- ders and cylinder heads. After the engine reaches the operating temperature (approx. 75°C, 167°F), the thermost[...]

ENGLISH 37 MAINTENANCE WORK ON CHASSIS AND ENGINE » 4 1 2 2 3 3 5 Checking the cooling liquid level in the radiator * Hold the radiator cap [1] with a cloth, carefully turn in a counterclockwise direction and remove. The radiator should be completely filled with cooling liquid; no air should be in the radiator . If any cooling liquid is missing, t[...]

ENGLISH 38 MAINTENANCE WORK ON CHASSIS AND ENGINE » 1 3 4 2 2 Changing the basic position of the clutch lever The basic position of the clutch lever can be modified by turning the adjust- ing screw [1] . This lets you adjust the best clutch lever position for any hand size. T o adjust, pull the clutch lever towards the front. T urning the adjustin[...]

ENGLISH 39 MAINTENANCE WORK ON CHASSIS AND ENGINE » 10W/50 5W/40 JASO T903 MA TEMPERATURE 0°C 32°F 3 3 2 1 2 4 Engine oil Automobile engine oil used to be used for four -stroke motorcycles before there were separate motorcycle specifications. Different technical developments made it necessary to have a separate specification for four -stroke mot[...]

ENGLISH 40 MAINTENANCE WORK ON CHASSIS AND ENGINE » 6 7 7 8 9 5 4 3 1 2 4 Changing the engine oil and the oil filter, cleaning the oil screen * NOTE: The LC8 engine has a dry-sump lubrication system. The engine oil is pumped from the oil sump in the engine case to the oil tank. The engine oil must also be drained from the oil tank during an oil ch[...]

ENGLISH 41 MAINTENANCE WORK ON CHASSIS AND ENGINE » Mount the oil drain plug on the engine with a new seal ring and tighten to 20 Nm. Slide the oil screen [1] into the guides in the oil pump housing with the TOP mark facing up. Make sure the form ring is in place and mount the cap [2] . T ighten the screws to 10 Nm. Insert a new oil filter [3] in [...]

ENGLISH 42 TROUBLESHOOTING » 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 deal[...]

ENGLISH 43 TROUBLESHOOTING » TROUBLE CAUSE REMEDY FI lamp is blinking / lights up Error in the injection system Visit an authorized KTM workshop Engine stalls while driving No fuel Fuse for fuel pump has blown Refuel Replace fuse FUEL PUMP High oil consumption Engine oil level too high Engine oil too thin (viscosity) Check engine oil level when th[...]

ENGLISH 44 TROUBLESHOOTING » BLINK CODE SIGNAL / COMPONENT ERROR DESCRIPTION ENGINE 02 Pulse generator Malfunction Stalls 06 Throttle sensor Output signal too low /high Continues to run 07 Sensor for 2nd throttle valve Output signal too low /high Continues to run 09 Intake manifold air pressure for sensor rear cylinder Output signal too low /high [...]

ENGLISH 45 CLEANING » CONSERVATION FOR WINTER OPERATION » STORAGE » Regular cleansing and paintwork care are part of the maintenance work and help to maintain the value of your motorcycle. NEVER CLEAN THE MOTORCYCLE WITH A POWER W ASHER OR A STRONG WA TER JET , OTHERWISE THE PRESSURE WILL ALLOW W A TER TO ENTER THE ELECTRIC COMPONENTS, PLUGS, CA[...]

ENGLISH 46 TECHNICAL SPECIFICATIONS – CHASSIS » CHASSIS 990 SUPER DUKE Frame T ubular chrome-molybdenum-steel space frame Fork WP Suspension – U p S ide D own 4860 ROMA Spring travel front 135 mm Rear suspension WP Suspension 4618 BA VP Spring travel rear 160 mm Front brake Disk brake, 2 perforated brake disks Ø 320 mm, fixed brake calipers R[...]

ENGLISH 47 TECHNICAL DATA - CHASSIS » TIGHTENING TORQUES – CHASSIS Collar bolt on front wheel spindle M24x1,5 60 Nm Collar nut wheel spindle rear M25x1,5 90 Nm AH bolt shock absorber top/bottom M14x1,5 80 Nm Collar nut for swing arm bolt M19x1,5 130 Nm AH bolts on subframe M8 Loctite 243 + 25 Nm AH bolts on back of footrest support M8 Loctite 24[...]

ENGLISH 48 TECHNICAL SPECIFICATIONS – ENGINE » 10W/50 5W/40 JASO T903 MA TEMPERATURE 0°C 32°F ENGINE 990 LC8 Design Liquid-cooled, 2-cylinder 4-stroke engine with 75° V arrangement with balancer shaft and electric starter Displacement 999 cm 3 Bore / Stroke 101/62,4 mm Compression ratio 11,5:1 Fuel unleaded fuel with at least RON 95 (USA: Pre[...]

ENGLISH 49 HEAD WORD INDEX » Page Accessories and payload . . . . . . . . . . . . . . . . . . . . .14 Adjusting compression damping of fork . . . . . . . . . . .22 Adjusting rebound damping of fork . . . . . . . . . . . . . .22 Adjusting the basic position of the hand brake lever .27 Adjusting the fork and shock absorber . . . . . . . . . . .22 Ad[...]

ENGLISH 50[...]

KTM-Sportmotorcycle AG A–5230 Mattighofen www.ktm.at KTM Group Partner OWNER’S MANUAL MANUALE D’USO MANUEL D’UTILISATION MANUAL DE INSTRUCCIONES ART. NR. 3.211.57 990 SUPER DUKE BEDIENUNGSANLEITUNG 2005[...]