KTM may stop manufacturing certain models without previous notice. KTM shall not be held liable for any deviations of availability and/or ability to deliver, illustrations, descriptions, printing and/or other errors.
Take special care to follow the recommended run in, inspection, and maintenance intervals. Heeding these guidelines will signifi- cantly increase the life of your motorcycle. To ensure that all work to your KTM is performed properly and to avoid warranty con- flicts, KTM recommends that you always have your KTM serviced by a recognized and qualified KTM dealer.
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 bike runs smoothly and to avoid premature wear.
» SERIAL NUMBER LOCATIONS 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.
» OPERATION INSTRUMENTS Clutch lever The clutch lever  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).
Use the MODE and SET  button to change the display and the basic settings in the dis- play. Display  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  provide additional information on the motorcycle's running condition. Display TEST...
OPERATION INSTRUMENTS CLOCK TRIP 1 TRIP 2 TRIP F » CLOCK You 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. To switch to the next display mode, press the MODE button. The speed, temperature of the cooling liquid and the total kilometers or miles traveled are shown in the ODO mode.
OPERATION INSTRUMENTS 10 sec » Setting options in the display KILOMETERS OR MILES. You 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. To switch from kilometers to miles, switch on the ignition and press the MODE  button for approx.
» OPERATION INSTRUMENTS 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.
OPERATION INSTRUMENTS 120°C (248°F) 110°C (230°F) 100°C (212°F) 70°C (158°F) 60°C (140°F) 50°C (122°F) 40°C (104°F) » Cooling liquid temperature display The temperature display  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.
OPERATION INSTRUMENTS » 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.
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 To switch the ignition to position turn the ignition key to position into the lock.
OPERATION INSTRUMENTS » Emergency OFF tip switch, light switch, starter tip switch The emergency off switch  is provided for emergency situations and should not be used to switch off the engine. The engine is ready for operation in position on).
To mount the seat, place it on the motorcycle and position the hooks  on the bottom of the seat behind the dollies  on the subframe. Press down on the seat near the holding strap while sliding it forwards.
To secure, remove the seat, run the rope through the helmet, attach both ends to the hook  and mount the seat. THE HELMET LOCK IS PROVIDED TO SECURE THE HELMET TO THE MOTORCYCLE WHEN PARKED. DO NOT ATTACH THE HELMET OR OTHER OBJECTS TO THE STEEL ROPE WHILE DRIVING. YOU CAN EASILY LOSE CONTROL OF THE MOTORCYCLE.
» OPERATION INSTRUMENTS 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 2,3,4,5,6 Maintenance work).
» OPERATION INSTRUMENTS Footrests The passenger footrests  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  are located on the fork leg axle passage.
The damping rate can be adjusted in the low and high-speed range (Dual Compression Control). The designation low and high-speed refers to the movement of the shock absorber and not to the motorcycle's driving speed. The adjusting screw  for the low-speed range can be adjusted with a screwdriver.
» OPERATION INSTRUMENTS 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  is located on the bottom of the shock absorber. More information is provided in the chapter "Adjusting the fork and shock absorber.“...
GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE Instructions for initial operation – Make sure the work for the „pre-delivery inspection“ was performed by your author- ized KTM workshop. The DELIVERY CER- TIFICATE and SERVICE MANUAL will be handed over when you pick up your vehicle.
GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE – THE TIRES MUST BE DESIGNED FOR A SPEED OF OVER 240 KPH (SPEED SYMBOL ZR) AND MUST BE RELEASED BY KTM. – NEW TIRES HAVE A SMOOTH SURFACE, WHICH MEANS THAT THEY MUST BE RUN IN TO ACHIEVE FULL GRIP.
Insufficient oil results in premature wear and consequently to engine damage. 9 BAGGAGE, PAYLOAD Never exceed the maximum total weight (380 kg, 838 lbs) and the motorcycle's wheel loads. The maximum total weight is comprised of: – the motorcycle in a running condition and refueled (195 kg, 430 lbs) –...
– MAXIMUM PERIOD FOR CONTINUOUS STARTING: 5 SECONDS. WAIT AT LEAST 5 SECONDS BEFORE TRYING AGAIN. – DON’T RIDE YOUR MOTORCYCLE WITH FULL LOAD AND DON’T REV ENGINE WHEN COLD. BECAUSE THE PISTON IS WARMING UP FASTER THAN THE WATER COOLED CYLINDER, IT CAN CAUSE ENGINE DAMAGE.
– If this is not the case, refill the tank – if sufficient fuel is in the tank, pro- ceed as described in the „Trouble- shooting“ section or contact a KTM dealer. NOTE: This motorcycle is equipped with a safety start- ing system.
– IN THE EVENT THAT, WHILE RIDING ON YOUR MOTORCYCLE, YOU NOTICE ANY UNUSUAL OPERATION-RELATED NOISE, STOP IMMEDIATELY, TURN THE ENGINE OFF, AND CONTACT AN AUTHORIZED KTM DEALER. Braking Close throttle and apply the hand and foot brakes at the same time. Carefully apply the brakes on sandy, wet or slippery surfaces.
Fold the side stand forward to the stop with your foot, put the weight of the motor- cycle on the stand and park the bike on a firm surface. Lock the motorcycle. – ALWAYS PARK YOUR MOTORBIKE ON A SOLID AND HORIZONTAL SURFACE.
NOTE: Press the SET key for 2 seconds to immediately turn off the fuel warning lamp. THIS MOTORCYCLE IS EQUIPPED WITH A CATALYTIC CONVERTER THAT WILL BE DESTROYED IF YOU USE LEADED FUEL. ALWAYS USE UNLEADED FUEL. Fuel expands when its temperature rises. Therefore do not fill the tank to the top (see fig.).
Check clutch linings Check clutch pressure booster system Check rubber boots for cracks or leaks Check fault memory with the KTM diagnosis tool Perform a status check of neutral, clutch, 2nd/3rd gear and side stand switch using the KTM diagnosis tool...
PERIODIC MAINTENANCE 990 SUPER DUKE 2006 A clean motorcycle can be checked more quickly which saves money! Replace the graphite gasket in the rear exhaust manifold slide Check actuating cables for damage, smooth operation, and kink-less arrange- ment,adjust and lubricate...
IF MOTORCYCLE IS USED FOR COMPETITION 7500 KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY 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...
PERIODIC MAINTENANCE 990 SUPER DUKE 2006 VITAL CHECKS AND CARE PROCEDURES TO CONDUCTED BY THE OWNER OR THE MECHANIC Check oil level Check brake fluid level Check brake pads for wear Check lighting system for proper operation Check horn for proper operation...
– DO NOT CLEAN THE MOTORCYCLE WITH A POWER WASHER OTHERWISE WATER WILL GET INTO THE BEARINGS, ELECTRIC SOCKET CONNECTORS, ETC. – USE SPECIAL KTM SCREWS WITH THE CORRECT THREAD LENGTH TO FASTEN THE SPOILER TO THE TANK. MOUNTING OTHER SCREWS OR LONGER SCREWS COULD PUNCTURE THE TANK AND CAUSE FUEL TO LEAK OUT.
There are a number of ways to adjust the fork and shock absorber to match the chassis to your driving style and the payload. We 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- sonal chassis and suspension tuning.
MAINTENANCE WORK ON CHASSIS AND ENGINE STANDARD ADJUSTMENT LOW-SPEED: – Turn adjusting screw  clockwise as far as it will go. – Turn 20 clicks in a counterclockwise direction. STANDARD ADJUSTMENT HIGH-SPEED: – Turn adjusting screw (wrench size 17 mm) clockwise as far as it will go. –...
IF YOU DON’T HAPPEN TO HAVE A TORQUE WRENCH AT HAND, MAKE SURE YOU HAVE THE TIGHT- ENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POSSIBLE. A LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAVIOR OF YOUR MOTORCYCLE.
REDUCED AND THE MOTORCYCLE COULD EASILY GET OUT OF CONTROL. – THE CHAIN DOES NOT HAVE A CHAIN JOINT FOR SAFETY REASONS. ALWAYS HAVE THE CHAIN REPLACED IN AN AUTHORIZED KTM WORKSHOP WHERE THE SERVICE TECHNICANS HAVE THE REQUIRED RIVETING TOOL.
FACTOR AND THEREFORE THE BRAKING POWER CAN DEVIATE SIGNIFICANTLY FROM ORIGINAL KTM BRAKE PADS. IF YOU USE DIFFERENT BRAKE PADS THAN THOSE PROVIDED WITH THE ORIG- INAL EQUIPMENT, IT CANNOT BE WARRANTED THAT THEY ARE AUTHORIZED FOR USE IN ROAD TRAFFIC.
MAINTENANCE WORK ON CHASSIS AND ENGINE 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. We recommend that you continue to use it. DOT 5.1 brake fluid is based on glycol ether and of an amber color.
A LEAK OR THE BRAKE PADS ARE COMPLETELY WORN DOWN. IN THIS CASE, CONSULT AN AUTHORIZED KTM DEALER IMMEDIATELY. – HAVE THE BRAKE FLUID CHANGED AT AN AUTHORIZED KTM WORKSHOP EVERY 2 YEARS. Refilling front brake fluid * It is not necessary to refill brake fluid under normal conditions (see General information on KTM disk brakes).
MAINTENANCE WORK ON CHASSIS AND ENGINE min. 1 mm – ACTUATE 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 ESPECIALLY ADAPTED TO IT. –...
A LEAK OR THE BRAKE PADS ARE COMPLETELY WORN DOWN. IN THIS CASE, CONSULT AN AUTHORIZED KTM DEALER IMMEDIATELY. – HAVE THE BRAKE FLUID CHANGED AT AN AUTHORIZED KTM WORKSHOP EVERY 2 YEARS. Refilling rear brake fluid * It is not necessary to refill brake fluid under normal conditions (see General information on KTM disk brakes).
MAINTENANCE WORK ON CHASSIS AND ENGINE min. 1 mm – ACTUATE 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 ESPECIALLY ADAPTED TO IT. –...
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 Dismounting and remounting the rear wheel), then the front stand.
– IF YOU DO NOT HAVE A TORQUE WRENCH TO MOUNT THE WHEEL, HAVE THE TORQUES COR- RECTED BY AN AUTHORIZED KTM WORKSHOP AS SOON AS POSSIBLE. A LOOSE AXLE PAS- SAGE CAN CAUSE THE MOTORCYCLE'S HANDLING PERFORMANCE TO BECOME INSTABLE.
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 HAVE A TORQUE WRENCH AT HAND, MAKE SURE YOU HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POSSIBLE. A LOOSE WHEEL SPINDLE MAY LEAD TO AN UNSTABLE DRIVING BEHAVIOR OF YOUR MOTORCYCLE.
– Tire type and size can be found in the technical specifications and in the homologation certificate. – For the type of tires authorized by KTM, contact your authorized KTM dealer or special- ized tire dealer. – Tire condition has to be checked every time you want to ride your motorcycle. Before leaving check for punctures and nails or other sharp objects that might have become embedded in the tire.
NEVER DISCONNECT THE BATTERY WHILE THE ENGINE IS RUNNING. THIS WILL DESTROY THE RECTIFIER-REGULATOR. STORAGE: If the motorcycle is being immobilized for longer periods of time, remove and charge the battery. Storage temperature 0 - 35°C (32 - 95°F), avoid direct sunlight. Charge the battery every 3 months.
Always use special charging devices to charge maintenance-free batteries, e.g. the KTM charg- ing device (item no. 58429074000). You can also use this charging device to test the off- load voltage and startability of the battery and generator.
Pull the connector  out of the bracket, remove the cap  and check the main fuse . A spare fuse  (30 amperes)is also plugged into the bracket. Always replace blown fuses with an equivalent fuse. Visit an authorized KTM workshop if a new fuse blows again after it is inserted.
Replace a blown fuse only with an equivalent one. If a new fuse that has just been set in gets blown again, you are strongly advised to have it inspected by a KTM dealer. UNDER NO CIRCUMSTANCES IS A STRONGER FUSE ALLOWED TO BE SET IN OR A FUSE ALLOWED TO BE “REPAIRED”.
Attach the retaining clip, connect the connector to the bulb and mount the rubber cap. BULB FOR THE PARKING LIGHT: Since a number of parts need to be removed to replace the parking light bulb, we recom- mend that you have the lamp replaced at an authorized KTM workshop.
Make a mark on a light colored wall behind a horizontal surface, at the height correspon- ding to the center of the headlight. Position your motorcycle 5 meters (16.4 ft) from the wall in a fully loaded condition (baggage, driver, passenger) and switch on the low beam.
Replacing the flasher bulbs Remove the screw on the back of the turn signal, carefully fold the lens  towards the motorcycle and remove. Turn the cap [3 approx. 15° in a counterclockwise direction and remove. Slightly depress the bulb, turn it approx. 30° counterclockwise and pull it out of the socket.
TO DRIVE IF THERE IS ENOUGH COOLING LIQUID IN THE SYSTEM. CONTACT AN AUTHORIZED KTM WORKSHOP TO HAVE THE ERROR ELIMINATED. YOU WILL DAMAGE THE ENGINE IF YOU CONTINUE TO DRIVE WHEN THE COOLING LIQUID TEMPERATURE WARNING LAMP IS ON.
If you need to add cooling liquid quite often, the cooling system may leak. If the compen- sating tank is empty, also check the cooling liquid level in the radiator. Have the cooling system checked by an authorized KTM workshop. »...
If any cooling liquid is missing, the cooling system is probably leaking. Have the cooling system checked at an authorized KTM workshop. IF POSSIBLE, CHECK THE COOLING LIQUID LEVEL WHEN THE ENGINE IS COLD. IF YOU NEED TO REMOVE THE RADIATOR CAP WHEN THE ENGINE IS HOT, HOLD THE CAP WITH A CLOTH AND OPEN SLOWLY, ALLOWING ANY EXCESS PRESSURE TO ESCAPE (DANGER OF SCALDING).
MAINTENANCE WORK ON CHASSIS AND ENGINE Remove the bleeder screw  on the left side of the radiator. To 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.
KTM workshop. KTM USES BIODEGRADABLE, HYDRAULIC MINERAL OIL TO ACTUATE THE HYDRAULIC CLUTCH. DO NOT MIX THIS OIL WITH ANY OTHER HYDRAULIC OIL. ALWAYS USEORIGINAL KTM HYDRAULIC OIL (AVAILABLE FROM YOUR AUTHORIZED KTM WORKSHOP) TO MAKE SURE YOUR CLUTCH OPERATES SMOOTHLY.
DLEBAR INSTRUMENTS WILL TOUCH THE FUEL TANK IF THE HANDLEBAR IS TILTED TOO FAR BACK, THE HANDLEBAR INSTRUMENTS MAY DAMAGE THE FUEL TANK Checking and adjusting the throttle cable play * This work will require a diagnostics tool. Visit your authorized KTM dealer. »...
5W/40 10W/50 KTM recommends Motorex Power Synt 4T in the 10W/50 viscosity (for temperatures over 0°C, 32°F) or 5W/40 (for temperatures under 0°C, 32°F). Checking the engine oil level Check the engine oil level when the engine is warm (at least 4 bars on the temperature indi- cator light up).
MAINTENANCE WORK ON CHASSIS AND ENGINE Refilling engine oil To refill engine oil, take off the right spoiler  by removing the screws . Also remove the screws  and take off the spoiler. Unscrew the plug  and refill engine oil. Wait 20 seconds and check the oil level again. The quantity of oil between the MIN and MAX marks is 0.3 liter.
Since many parts must be demounted for an oil change, we recommend having the engine oil changed by an authorized KTM workshop. During the guaranty period, the oil change must be performed by an authorized KTM mechanic. Otherwise, the guarantee will become void.
» MAINTENANCE WORK ON CHASSIS AND ENGINE Remove the drain plug  on the oil tank and allow the oil to drain into a receptacle. Remove the screws  and tilt the oil return valve  to the side. Carefully pull the oil screen  out of the oil tank. Thoroughly clean the drain plugs, the cover and both oil screens.
Insert a new oil filter  in the engine case, grease the O-ring and mount the oil filter cover together with the O-ring. Tighten the screws to 6 Nm. ONLY USE ORIGINAL KTM OIL FILTERS. THE ENGINE CAN BE DAMAGED IF OTHER FILTERS ARE USED.
» MAINTENANCE WORK ON CHASSIS AND ENGINE Remove the right spoiler (see Refilling the engine oil) and unscrew the plug . 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. If you are not sure, contact your KTM dealer. TROUBLE...
Visit an authorized KTM workshop Switch to neutral gear Have the air filter/fuel filter replaced at an authorized KTM workshop Visit an authorized KTM workshop Refill cooling liquid (see maintenace work), check cooling sys-...
Blown fuse, thus no continuous rectly displayed power supply REMEDY Replace fuse FAN Contact an authorized KTM workshop. Bleed the cooling system (see Maintenance work) Visit an authorized KTM workshop Refuel Replace fuse FUEL PUMP Check engine oil level when the engine is warm; correct if necessary Use thicker engine oil;...
Recharge the battery according to the relevant instructions. Voltage regulator and generator should be checked by an authorized KTM workshop. Replace fuse HORN BRAKELIGHT SPEEDO. Check the pickup cable for damage, visit an authorized KTM workshop ERROR DESCRIPTION Malfunction Output signal too low /high...
» TROUBLESHOOTING The blink code indicates which component is affected by an error. This allows the error to be identified if no diagnosis tool is available. BLINK CODE SIGNAL / COMPONENT Coolant temperature sensor Air temperature sensor Ambient air pressure sensor Tilt angle sensor Lambda probe for rear cylinder Lambda probe for front cylinder...
(e.g. Motorex 900) and cleaned with a brush. – After the motorcycle has been rinsed with a soft water jet, it should be dried by air pressure and a cloth. Then take a short drive until the engine has reached the working temperature and also use the brakes.
– Go on a short, cautious test ride NOTE: before you store your motorcycle at the end of the season, check all parts for proper functioning and wear. If service, repairs or con- versions are necessary, have them carried out while the motorcycle is immobilized (workshops are not fully utilized). This will help to avoid...
TECHNICAL SPECIFICATIONS – CHASSIS CHASSIS 990 SUPER DUKE Frame Tubular chrome-molybdenum-steel space frame Fork WP Suspension – Up Side Down 4860 ROMA Spring travel front 135 mm (5.3 in) Rear suspension WP Suspension 4618 BAVP Spring travel rear 160 mm (6.3 in) Front brake Disk brake, 2 perforated brake disks Ø...
TECHNICAL SPECIFICATIONS – CHASSIS TIGHTENING TORQUES – CHASSIS Collar bolt on front wheel spindle Collar nut wheel spindle rear AH bolt shock absorber top/bottom Collar nut for swing arm bolt AH bolts on subframe AH bolts on back of footrest support Engine carrier bolts HH clamp bolts on top triple clamp HH clamp bolts on bottom triple clamp...
TECHNICAL SPECIFICATIONS – CHASSIS TIGHTENING TORQUES – CHASSIS HH bolts for side stand fixture - side stand bracket HH bolts for side stand mounting HH bolt for spring rest on side stand HH bolt for side stand switch Drain plug on oil tank Exhaust nuts on manifold Exhaust clamps Exhaust clamps for ball joint...
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) * Valve timing 4 valves controlled over bucket tappet and 2 camshafts, camshaft drive with gears/chain Valve diameter...
Only use fully synthetic engine oils that meet the JASO MA quality requirements (see information on the can). KTM recommends Motorex Power Synt 4T in the 10W/50 viscosity (for temperatures over 0°C, 32°F) or 5W/40 (for temperatures under 0°C, 32°F).