Instruction/ maintenance manual of the product Super Duke 990s KTM
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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.
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.
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 .
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.
ENGLISH 4 INDEX » Page SERIAL NUMBER LOCA TIONS . . . . . . . . . . . . . . . . . . . .5 Chassis number , T ype label . . . . . . . . . . . . . . . . . . . .5 Engine number , engine type . . . . . . . . . . . . . . . . . . . .5 OPERA TION INSTRUMENTS .
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.
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.
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.
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.
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.
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.
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.
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.
– 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.
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.
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.
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 .
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.
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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 Chang.
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.
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.
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.
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).
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).
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.
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] .
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.
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.
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.
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.
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.
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] .
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.
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.
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.
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 .
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.
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.
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.
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] .
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.
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.
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.
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.
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.
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 M14.
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.
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 .
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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.
An important point after buying a device KTM Super Duke 990s (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 Super Duke 990s 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 Super Duke 990s - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, KTM Super Duke 990s you will learn all the available features of the product, as well as information on its operation. The information that you get KTM Super Duke 990s will certainly help you make a decision on the purchase.
If you already are a holder of KTM Super Duke 990s, 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 Super Duke 990s.
However, one of the most important roles played by the user manual is to help in solving problems with KTM Super Duke 990s. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device KTM Super Duke 990s 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
