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Manual KTM 990 SUPER DUKE

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  • KTM 990 SUPER DUKE - page 1

    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 ...

  • KTM 990 SUPER DUKE - page 2

    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 . In your own interest, please pay particular attention to notices that are marked as follows: 1 – IGNORING THESE INSTRUCTIONS, CAN ENDANGE ...

  • KTM 990 SUPER DUKE - page 3

    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 . Before you go for your first ride, be sure to read this manual carefully and thorough ...

  • KTM 990 SUPER DUKE - page 4

    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 . The 990 Super Duke is designed and constructed for normal use on public roads but not for use on race courses or offroad t ...

  • KTM 990 SUPER DUKE - page 5

    INDEX » 4 IMPOR T ANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 IMPOR T ANT LIMITED W ARRANTY AND LIMITED GUARANTEE INFORMA TION . . . . . . . . . . . . . . . . . .3 SERIAL NUMBER LOCA TIONS . . . . . . . . . . . . . . . . . . . . . . ...

  • KTM 990 SUPER DUKE - page 6

    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 . . . . . . . . . . . . . . . . . . . . . . . .44 Checking the front brake pads . . . . . . . . . . . ...

  • KTM 990 SUPER DUKE - page 7

    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. Engine number, engine type The engine number and the engine type are stamped into the left side of the engine below the engine sprocket ...

  • KTM 990 SUPER DUKE - page 8

    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 . Hand brake lever The hand brake lever [2] is mounted on the ...

  • KTM 990 SUPER DUKE - page 9

    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. 5 display modes can be selected with the MODE button. The indicator lamps [3] provide addition ...

  • KTM 990 SUPER DUKE - page 10

    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 ...

  • KTM 990 SUPER DUKE - page 11

    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 ...

  • KTM 990 SUPER DUKE - page 12

    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. TRIP F When the fuel level ...

  • KTM 990 SUPER DUKE - page 13

    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. 40°C (104°F). When the upper bar lights up 120°C (248°F), all of the bars will start to blink and the red warning la ...

  • KTM 990 SUPER DUKE - page 14

    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 switched on. The red warning l ...

  • KTM 990 SUPER DUKE - page 15

    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 to the left, then turn the ignition key to the left. ...

  • KTM 990 SUPER DUKE - page 16

    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). The engine cannot be started in position (ignition circuit and starter cir ...

  • KTM 990 SUPER DUKE - page 17

    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. T o mount the seat, place it on the motorcycle and position the hooks [2] on the bott ...

  • KTM 990 SUPER DUKE - page 18

    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. THE HELMET LOCK IS PROVIDED TO SECURE THE HELMET TO THE MOTORCYCLE WHEN P AR ...

  • KTM 990 SUPER DUKE - page 19

    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). Side stand Fold the side stand [1] forw ...

  • KTM 990 SUPER DUKE - page 20

    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 axle passage. More information is pro ...

  • KTM 990 SUPER DUKE - page 21

    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“. Damping action during compression of shock absorber The shock absorber's damping action during compression travel (compression damping) can be adjuste ...

  • KTM 990 SUPER DUKE - page 22

    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 provided in the chapter "A ...

  • KTM 990 SUPER DUKE - page 23

    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 ...

  • KTM 990 SUPER DUKE - page 24

    – 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 . FOR THIS PUR- POSE, RIDE THE MOTORCYCLE CAREFULL Y A T MODERA TE SPEED DURING THE FIRST 200 KILOMETERS WITH NEW TIRES, TIL T- ING THE VEHICLE A ...

  • KTM 990 SUPER DUKE - page 25

    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 ...

  • KTM 990 SUPER DUKE - page 26

    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. 9 BAGGAGE ...

  • KTM 990 SUPER DUKE - page 27

    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. 3 Switch transmission to id ...

  • KTM 990 SUPER DUKE - page 28

    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). – If this is not the case, the battery is dis- charged – If the lights are on, proceed as described i ...

  • KTM 990 SUPER DUKE - page 29

    – 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. – THE P ASSENGER MUST HOLD ON TO THE DRIVER OR THE HOLDING STRAP ON ...

  • KTM 990 SUPER DUKE - page 30

    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 . THE HOTTER TH ...

  • KTM 990 SUPER DUKE - page 31

    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. NOTE: Press the SE ...

  • KTM 990 SUPER DUKE - page 32

    31 ...

  • KTM 990 SUPER DUKE - page 33

    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 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 ...

  • KTM 990 SUPER DUKE - page 34

    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-ON-PARTS Replace the graphite gasket in the rear exhaust manifold slide z Check actuating cables for damage, smooth operation, and kink-less arrange- ...

  • KTM 990 SUPER DUKE - page 35

    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. Maintenance work performed by an authorized KTM workshop is not a substitute for care and maintenance by the driver! 990 SUPER DUKE 2006 A clean motorcycle can be ...

  • KTM 990 SUPER DUKE - page 36

    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 brake fluid level z Check brake pads for wear z Check lighting system for proper operation z Check horn for proper operation z Lubricate actuating cables ...

  • KTM 990 SUPER DUKE - page 37

    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. – DO NOT CLEAN THE MOTORCYCLE WITH A POWER WASHER OTHER WISE W A TER WILL GET INTO THE BEARING ...

  • KTM 990 SUPER DUKE - page 38

    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. W e have provided a table with pragmatical values to help you tune up your motorcycle. These tune-up specifications are reference values only and should serve as a basis for your per- son ...

  • KTM 990 SUPER DUKE - page 39

    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. 1 turn will change the preload by 1 mm. Changing the preload will ...

  • KTM 990 SUPER DUKE - page 40

    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. – T urn 2 turns in a counterclockwise direction. THE DAMPING UNIT OF THE SHOCK ABSORBER I ...

  • KTM 990 SUPER DUKE - page 41

    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). Correct the chain tension if necessary . – IF CHAIN TENSION IS TOO GREA T , P AR TS WITHIN THE ...

  • KTM 990 SUPER DUKE - page 42

    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 LUBRICA TION IS ALLOWED TO REACH THE REAR TIRE OR T ...

  • KTM 990 SUPER DUKE - page 43

    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. The lateral balance ensures that the brake pads always have the best possibl ...

  • KTM 990 SUPER DUKE - page 44

    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 ...

  • KTM 990 SUPER DUKE - page 45

    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. A T THE HAND BRAKE LEVER ...

  • KTM 990 SUPER DUKE - page 46

    – 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. – BRAKE FLUID CAN CAUSE SKIN IRRIT A TION. A VOID CONT ACT WITH SKIN AND EYES. IF YOU GET BR ...

  • KTM 990 SUPER DUKE - page 47

    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). If the push rod is not screwed in fa ...

  • KTM 990 SUPER DUKE - page 48

    – 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. – BRAKE FLUID CAN CAUSE SKIN IRRIT A TION. A VOID CONT ACT WITH SKIN AND EYES. IF YOU GET BRA ...

  • KTM 990 SUPER DUKE - page 49

    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. First mount the rear stand (see Dismountin ...

  • KTM 990 SUPER DUKE - page 50

    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. position the front wheel according ...

  • KTM 990 SUPER DUKE - page 51

    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. The rear wheel should not touch the gr ...

  • KTM 990 SUPER DUKE - page 52

    – 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. – IT IS VER ...

  • KTM 990 SUPER DUKE - page 53

    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 . The charge condition and type of charge are very important for the battery&ap ...

  • KTM 990 SUPER DUKE - page 54

    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] and fold the battery cover [4] down. First disconnect the negative te ...

  • KTM 990 SUPER DUKE - page 55

    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. Do not exceed the amperage and charging time. Quick charg- ing at a high amperage has an a ...

  • KTM 990 SUPER DUKE - page 56

    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. Always replace blown fuses with an equivalen ...

  • KTM 990 SUPER DUKE - page 57

    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] . Spare fuses [2] of 10 and 15 amperes are located next to the fuse box. Replace a blown fuse o ...

  • KTM 990 SUPER DUKE - page 58

    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. BULB FOR HIGH BEA ...

  • KTM 990 SUPER DUKE - page 59

    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. CONTROL: Make a mark on a light colored wall ...

  • KTM 990 SUPER DUKE - page 60

    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. T u ...

  • KTM 990 SUPER DUKE - page 61

    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 ...

  • KTM 990 SUPER DUKE - page 62

    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 . – FOR THE COOLING SYSTEM, USE ONL Y HIGH-GRAD ...

  • KTM 990 SUPER DUKE - page 63

    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. Have the cooling system chec ...

  • KTM 990 SUPER DUKE - page 64

    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 . Completely fill the radiator with cooling liquid. Mount the radiator cap and move the motor- cyc ...

  • KTM 990 SUPER DUKE - page 65

    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. T urning the adjusting screw in a clockwise direction will move the clutch lever away ...

  • KTM 990 SUPER DUKE - page 66

    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. TIL TING THE HANDLEBAR TOO F AR BACK WILL REDUCE THE STEERING ANGLE SINCE THE HAN- DLEBAR INSTRUMENTS WILL TOUCH THE FUEL T ANK IF THE HA ...

  • KTM 990 SUPER DUKE - page 67

    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 ...

  • KTM 990 SUPER DUKE - page 68

    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 0.3 liter . Mount the plug and check the engine ...

  • KTM 990 SUPER DUKE - page 69

    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. Since many parts must be demounted for an oil change, we recommend ha ...

  • KTM 990 SUPER DUKE - page 70

    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. Clean all rubber seal rings and check for damage. Replace if necessary . ...

  • KTM 990 SUPER DUKE - page 71

    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. Insert a new oil filter [3] in the engine case, grease the O-ring and mount the oi ...

  • KTM 990 SUPER DUKE - page 72

    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. Switch off the engine and ch ...

  • KTM 990 SUPER DUKE - page 73

    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 . TROUBLESHOOTING » 72 TRO ...

  • KTM 990 SUPER DUKE - page 74

    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 wiring harness is oxidized Error in the injection system A gear is engaged and the side stand is folded down Pay attention to starting off information (s ...

  • KTM 990 SUPER DUKE - page 75

    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. Bleed the cooling system (see Maintenance work) FI lamp is blinking / lights up Error in the injection system Visit an authorized KTM workshop Engine stalls whi ...

  • KTM 990 SUPER DUKE - page 76

    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. No values are visible in the multi ...

  • KTM 990 SUPER DUKE - page 77

    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 /high Continues to run 14 Ambient air pressure sensor Output signal too low /high Continues to run 15 T ilt angle sensor Output signal too low /high C ...

  • KTM 990 SUPER DUKE - page 78

    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. WHICH CAN CAUSE MALFUNCTIONING OR CA ...

  • KTM 990 SUPER DUKE - page 79

    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). – Check the q ...

  • KTM 990 SUPER DUKE - page 80

    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 (6.3 in) Front brake Disk brake, 2 perforated brake disks Ø 320 mm (12.6 in), fixed ...

  • KTM 990 SUPER DUKE - page 81

    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 (6.5 in) Dry weight 184 kg (406.2 lbs) Max. axle load, front 200 kg (441.5 lbs) Max. axle load, rear ...

  • KTM 990 SUPER DUKE - page 82

    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 243 + 25 Nm Engine carrier bolts M10 45 N ...

  • KTM 990 SUPER DUKE - page 83

    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 M12x1.5 2 ...

  • KTM 990 SUPER DUKE - page 84

    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 RON 91) * V alve timing 4 valves controlled over bucket t ...

  • KTM 990 SUPER DUKE - page 85

    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 0.8 mm Cooling system liquid cooled, permanent circulation of cooli ...

  • KTM 990 SUPER DUKE - page 86

    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 . . . . . . . .44 Adjusting the fork and shock absorber . . . . . ...

  • KTM 990 SUPER DUKE - page 87

    Important . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Important limited warranty and limited guarantee information . .3 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Indicator lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Instructions for i ...

  • KTM 990 SUPER DUKE - page 88

    87 ...

  • KTM 990 SUPER DUKE - page 89

    88 ...

  • KTM 990 SUPER DUKE - page 90

    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 ...

Manufacturer KTM Category Motorcycle

Documents that we receive from a manufacturer of a KTM 990 SUPER DUKE can be divided into several groups. They are, among others:
- KTM technical drawings
- 990 SUPER DUKE manuals
- KTM product data sheets
- information booklets
- or energy labels KTM 990 SUPER DUKE
All of them are important, but the most important information from the point of view of use of the device are in the user manual KTM 990 SUPER DUKE.

A group of documents referred to as user manuals is also divided into more specific types, such as: Installation manuals KTM 990 SUPER DUKE, service manual, brief instructions and user manuals KTM 990 SUPER DUKE. Depending on your needs, you should look for the document you need. In our website you can view the most popular manual of the product KTM 990 SUPER DUKE.

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A complete manual for the device KTM 990 SUPER DUKE, how should it look like?
A manual, also referred to as a user manual, or simply "instructions" is a technical document designed to assist in the use KTM 990 SUPER DUKE by users. Manuals are usually written by a technical writer, but in a language understandable to all users of KTM 990 SUPER DUKE.

A complete KTM manual, should contain several basic components. Some of them are less important, such as: cover / title page or copyright page. However, the remaining part should provide us with information that is important from the point of view of the user.

1. Preface and tips on how to use the manual KTM 990 SUPER DUKE - At the beginning of each manual we should find clues about how to use the guidelines. It should include information about the location of the Contents of the KTM 990 SUPER DUKE, FAQ or common problems, i.e. places that are most often searched by users in each manual
2. Contents - index of all tips concerning the KTM 990 SUPER DUKE, that we can find in the current document
3. Tips how to use the basic functions of the device KTM 990 SUPER DUKE - which should help us in our first steps of using KTM 990 SUPER DUKE
4. Troubleshooting - systematic sequence of activities that will help us diagnose and subsequently solve the most important problems with KTM 990 SUPER DUKE
5. FAQ - Frequently Asked Questions
6. Contact detailsInformation about where to look for contact to the manufacturer/service of KTM 990 SUPER DUKE in a specific country, if it was not possible to solve the problem on our own.

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