Instruction/ maintenance manual of the product 990 SUPER DUKE KTM
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990 SUPER DUKE KTM Sportmotorcycle AG A–5230 Mattighofen www.ktm.at 10/2005 FOTO: MITTERBAUER KTM Group Partner ART. NR. 3.211.83 EN OWNER’S MANUAL 2006.
We strongly suggest that you read this manual carefully and completely before going on your first ride. It contains a great deal of information and advice which will help you use and handle your bike properly .
INTRODUCTION » 2 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 .
IMPORTANT LIMITED WARRANTY AND LIMITED GUARANTEE INFORMATION » In accordance with the international quality management ISO 9001 standard, KTM uses quality assurance processes that lead to the highest possible product quality .
INDEX » 4 IMPOR T ANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 IMPOR T ANT LIMITED W ARRANTY AND LIMITED GUARANTEE INFORMA TION . . . .
INDEX » 5 General information on KTM disk brakes . . . . . . . . . . . . . .42 Adjusting the basic position of the hand brake lever . . . . . .44 Checking the front brake fluid level . . . . . . . . . . . . . . . . .44 Refilling front brake fluid . .
Chassis number, Type label The chassis number is stamped on the right side of the steering head tube. Enter this num- ber in the field on page no 1. The type label is located on the right frame tube under the seat.
Clutch lever The clutch lever [1] is fitted on the left hand side of the handle bar . The adjusting screw [A] is used to change the original position of the clutch lever (see maintenance work on chas- sis and engine). The clutch is hydraulically actuated and adjusts itself automatically .
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 dis- play . Display [2] shows all of the information that may be of interest to you.
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.
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.
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.
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 temperature of approx.
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.
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.
Emergency OFF tip switch, light switch, starter tip switch The emergency off switch [1] is provided for emergency situations and should not be used to switch off the engine. The engine is ready for operation in position (ignition circuit and starter circuit are switched on).
Seat lock, removing the seat The seat lock [1] can be locked with the ignition key . T o remove the seat, insert the ignition key and turn 90° in a clockwise direction. Lift the seat in the back while pressing near the holding strap and pull off towards the back.
Tool set The tool set [1] is located in the storage compartment under the seat. Helmet lock The steel rope [2] 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 [3] and mount the seat.
Shift lever The shift lever is mounted on the left side of the engine. The position of the gears is shown in the illustration. Neutral, or the idle speed, is located between first and second gear . The basic position of the shift lever can be adjusted according to your seating position (see Maintenance work).
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.
Spring preload of the fork The fork's preload can be adjusted by means of the adjusting screws [1] . More information is provided in the chapter „Adjusting the fork and shock absorber“.
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 .
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.
– THE TIRES MUST BE DESIGNED FOR A SPEED OF OVER 240 KPH (SPEED SYMBOL ZR) AND MUST BE RELEASED BY KTM. – NEW TIRES HA VE A SMOOTH SURF ACE, WHICH MEANS THA T THEY MUST BE RUN IN TO ACHIEVE FULL GRIP .
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.
6 COOLING FLUID Check the level of cooling fluid when the engine is cold. 7 ELECTRICAL SYSTEM Start the engine and check the headlight, tail lamp, brake light, turn signals, indicator lamps, horn and emergency-off switch for proper functioning. 8 CHECK OIL LEVEL Insufficient oil results in premature wear and consequently to engine damage.
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 started.
IF THE ENGINE IS DOES NOT CRANK WHEN YOU ACTUA TE THE ST AR TER 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 (Light switch in position).
– WHILE RIDING YOUR MOTORCYCLE, NEVER SWITCH THE IGNITION LOCK TO POSITIONS AND . – DO NOT TRY TO CHANGE THE SETTINGS OF THE MUL TI-FUNCTIONAL SPEEDOMETER WHILE DRIVING. YOUR A TTENTION WILL BE DISTRACTED FROM THE TRAFFIC AND MA Y CAUSE YOU TO LOSE CONTROL OF YOUR MOTORCYCLE.
DRIVING INSTRUCTIONS » 29 – ON SAL T -SPRAYED OR DIR TY ROADS BRAKE ACTION MA Y BE DELA YED AS WELL. FIRST , THE BRAKES MUST BE BRAKED CLEAN. – REMEMBER THA T THE STOPPING DISTANCE WILL BE LONGER IF YOU ARE CARRYING A P ASSENGER OR BAGGAGE. – WHEN YOU BRAKE, THE BRAKE DISCS, BRAKE P ADS, BRAKE CALIPER AND BRAKE FLUID HEA T UP .
Fuel In the condition at delivery , the LC8 engine requires unleaded fuel with at least RON 95 (USA = Premium RON 91, see technical specifications – engine). After refueling, it will take approx. 8 minutes for the fuel warning lamp to switch off and for TRIP F to automatically reset to 0 and return to the previous display mode.
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PERIODIC MAINTENANCE » 990 SUPER DUKE 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 ENG.
PERIODIC MAINTENANCE » 990 SUPER DUKE 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.
PERIODIC MAINTENANCE » 34 IF MOTORCYCLE IS USED FOR COMPETITION 7500 KM SERVICE SHOULD BE CARRIED OUT AFTER EVER Y RACE! Service intervalls should never be exceeded by more than 500 km.
PERIODIC MAINTENANCE » 990 SUPER DUKE 2006 VITAL CHECKS AND CARE PROCEDURES TO CONDUCTED BY THE OWNER OR THE MECHANIC before each start after every cleaning every 1000 km Check oil level z Check brak.
ALL MAINTENANCE AND ADJUSTMENT WORK MARKED WITH AN ASTERISK * REQUIRES SPECIAL TECHNICAL SKILLS. IN YOUR OWN INTEREST , HA VE THIS WORK PERFORMED BY AN AUTHORIZED KTM WORKSHOP , WHERE YOUR MOTORCYCLE WILL BE SERV- ICED BY SPECIALL Y TRAINED TECHNICIANS.
Adjusting the fork and shock absorber There are a number of ways to adjust the fork and shock absorber to match the chassis to your driving style and the payload.
Adjusting the spring preload on the fork The fork spring preload can be adjusted by turning the adjusting screws [2] (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.
ST ANDARD ADJUSTMENT LOW -SPEED: – T urn adjusting screw [1] clockwise as far as it will go. – T urn 20 clicks in a counterclockwise direction. ST ANDARD ADJUSTMENT HIGH-SPEED: – T urn adjusting screw (wrench size 17 mm) clockwise as far as it will go.
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 [1] is tensioned (see drawing).
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).
General information on KTM disk brakes BRAKE CALIPERS: The front brake calipers [1] have 4 brake pistons each and are firmly connected 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.
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 .
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 brake disk) to fit any hand.
– ACTUA TE THE FRONT BRAKE UNTIL YOU FEEL THE POINT OF PRESSURE. – NEVER USE DOT5 BRAKE FLUID! IT IS BASED ON SILICONE OIL AND OF A PURPLE COLOR. SEALS AND BRAKE HOSES MUST BE ESPECIALL Y ADAPTED TO IT . – STORE BRAKE FLUID OUT OF REACH OF CHILDREN.
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 mm) into the heim joint (see drawing).
– ACTUA TE THE REAR BRAKE UNTIL YOU FEEL THE POINT OF PRESSURE. – NEVER USE DOT5 BRAKE FLUID! IT IS BASED ON SILICONE OIL AND OF A PURPLE COLOR. SEALS AND BRAKE HOSES MUST BE ESPECIALL Y ADAPTED TO IT . – STORE BRAKE FLUID OUT OF REACH OF CHILDREN.
Dismounting and remounting the front wheel * Special stands are required to dismount the wheels to make sure the motorcycle is securely fixed. The front stand only adequately fixes the motorcycle together with the rear stand. The stands shown in the illustration can be found in the KTM Power Parts catalog.
Before you remount the front wheel, clean and grease the shaft seal rings [5] and the bear- ing surface [A] of the distance bushings and mount the distance bushings (wide distance bushing in the left shaft seal ring). When mounting the distance bushing, be careful not to press the sealing lips towards the inside.
Dismounting and mounting the rear wheel * Special stands are required to dismount the wheels to make sure the motorcycle is securely fixed. The stands shown in the illustration can be found in the KTM Power Parts catalog. Mount the rear stand. Make sure the stand rests on solid ground and is correctly mounted.
– IF YOU DON’T HAPPEN TO HA VE A TORQUE WRENCH A T HAND, MAKE SURE YOU HA VE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POSSIBLE. A LOOSE WHEEL SPINDLE MA Y LEAD TO AN UNST ABLE DRIVING BEHA VIOR OF YOUR MOTORCYCLE. – AFTER MOUNTING THE REAR WHEEL, KEEP OPERA TING THE FOOTBRAKE UNTIL THE PRES- SURE POINT RETURNS.
Battery The battery is located in the front spoiler 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 battery poles clean and slightly grease them with an acid-free grease if necessary .
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.
MAINTENANCE WORK ON CHASSIS AND ENGINE » 54 VOL T 1 Charging the battery The battery discharges every day , even if it is not used. Always disconnect the battery when charging. Charge the battery as described in the instruc- tions [1] on the battery housing.
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 plugged into the bracket.
Fuses for individual power consumers A fuse box is mounted under the seat containing additional fuses that protect the individ- ual electric power consumers. The power consumers and the corresponding capacities are listed on the cover of the fuse box [1] .
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 OTHERWISE CAUSE THE GREASE TO EV AP- ORA TE AND SETTLE DOWN ON THE REFLECTOR.
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.
BULB FOR THE T AILLIGHT : Remove the bulb socket [1] from the housing and pull the bulb out of the socket. Insert a new bulb and press the bulb socket all the way into the taillight housing. Mount the seat. Replacing the flasher bulbs Remove the screw on the back of the turn signal, carefully fold the lens [2] towards the motorcycle and remove.
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 .
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 pro- tection, this mixture also provides great corrosion protection which is why it must not be replaced by pure water .
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, the cooling system is probably leaking.
T o completely bleed the cooling system, the motorcycle must be raised approx. 50 cm (20 in) in the front. Add cooling liquid until it runs out of the vent holes without bubbles and immediately mount the screw to prevent air from entering the radiator .
Changing the basic position of the clutch lever The basic position of the clutch lever can be modified by turning the adjusting 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.
Adjusting the handlebar tilt Loosen the screws [1] . Adjust the handlebar and tighten the screws to 20 Nm. Make sure the handlebar instruments do not touch the fuel tank when the handlebar is com- pletely turned.
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.
Refilling engine oil T o refill engine oil, take off the right spoiler [1] by removing the screws [2] . Also remove the screws [3] and take off the spoiler . Unscrew the plug [4] and refill engine oil. W ait 20 seconds and check the oil level again. The quantity of oil between the MIN and MAX marks is 0.
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 change.
Remove the drain plug [6] on the oil tank and allow the oil to drain into a receptacle. Remove the screws [7] and tilt the oil return valve [8] to the side. Carefully pull the oil screen [9] out of the oil tank. Thoroughly clean the drain plugs, the cover and both oil screens.
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 fac- ing up. Make sure the form ring is in place and mount the cap [2] . T ighten the screws to 10 Nm.
Remove the right spoiler (see Refilling the engine oil) and unscrew the plug [6] . Add 2.5 liters (0.7 USgal) of fully synthetic engine oil meeting the JASO MA standard (e.g. Motorex Power Synt 4T) and remount the plug. Start the engine and allow to run warm in neutral until 4 bars on the temperature indicator light up.
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.
TROUBLESHOOTING » 73 TROUBLE CAUSE REMEDY Engine cranks but doesn’t start. Operating error Blown fuse for the fuel pump Clutch not attached to the fuel line The plug and socket connector on the wir.
TROUBLESHOOTING » 74 TROUBLE CAUSE REMEDY Engine overheats Blown fan fuse Defect fan or thermoswitch for fan Air in the cooling system Replace fuse F AN Contact an authorized KTM workshop.
TROUBLESHOOTING » 75 TROUBLE CAUSE REMEDY The battery is discharged The ignition (power consumer) has- n’t been switched off The battery isn’t charged by the generator Recharge the battery according to the relevant instructions. V oltage regulator and generator should be checked by an authorized KTM workshop.
TROUBLESHOOTING » 76 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 .
CLEANING » 77 Regular cleaning 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 W A TER JET , OTHERWISE THE PRESSURE WILL ALLOW WA TER TO ENTER THE ELECTRIC COMPONENTS, PLUGS, CABLES, BEARINGS, ETC.
STORAGE » 78 If you plan to immobilize your motorcycle for a longer period of time, proceed as follows: – Run the tank empty to be able to add fresh fuel when starting up again. – Clean the motorcycle thoroughly (see CLEANING chapter). – Change the engine oil and the oil filter (old engine oil contains aggressive impurities).
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 (5.3 in) Rear suspension WP Suspension 4618 BA VP Spring travel rear 160 mm (6.
TECHNICAL SPECIFICATIONS – CHASSIS » CHASSIS 990 SUPER DUKE Battery maintenance-free battery 12V 11.2 Ah Steering head angle 66.5° Wheel base 1438 ± 10 mm (56.6 ± 0.4 in) Seat height, unloaded 855 mm (33.6 in) Ground clearance, unloaded 165 mm (6.
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.
TECHNICAL SPECIFICATIONS – CHASSIS » TIGHTENING TORQUES – CHASSIS HH bolts for side stand fixture - side stand bracket M10 Loctite 243 + 25 Nm HH bolts for side stand mounting M10 Loctite 243 + 35 Nm HH bolt for spring rest on side stand M8 Loctite 243 + 25 Nm HH bolt for side stand switch M4 Loctite 243 + 2 Nm Drain plug on oil tank M12x1.
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.
TECHNICAL SPECIFICATIONS – ENGINE » 84 ENGINE 990 LC8 Ignition system breakerless transistorized electronic ignition system with digital ignition advance Ignition timing Map-controlled via TPS Map-controlled via TPS 12V 450W at 6000 rpm Spark plug NGK DCPR 8 E Electrode distance 0.
Accessories and payload . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 Adjusting compression damping of fork . . . . . . . . . . . . . . . . .37 Adjusting rebound damping of fork . . . . . . . . . . . . . . . . . . . .37 Adjusting the basic position of the hand brake lever .
Important . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Important limited warranty and limited guarantee information . .3 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Indicator lamps .
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990 SUPER DUKE KTM Sportmotorcycle AG A–5230 Mattighofen www.ktm.at 10/2005 FOTO: MITTERBAUER KTM Group Partner ART. NR. 3.211.83 DE BEDIENUNGSANLEITUNG 2006.
An important point after buying a device KTM 990 SUPER DUKE (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought KTM 990 SUPER DUKE yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data KTM 990 SUPER DUKE - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, KTM 990 SUPER DUKE you will learn all the available features of the product, as well as information on its operation. The information that you get KTM 990 SUPER DUKE will certainly help you make a decision on the purchase.
If you already are a holder of KTM 990 SUPER DUKE, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime KTM 990 SUPER DUKE.
However, one of the most important roles played by the user manual is to help in solving problems with KTM 990 SUPER DUKE. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device KTM 990 SUPER DUKE along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
