KTM 990 Adventure AUS/UK Owner's Manual
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KTM 990 Adventure AUS/UK Owner's Manual

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OWNER'S MANUAL
2010
990 Adventure EU
990 Adventure AUS/UK
990 Adventure R EU
990 Adventure R AUS/UK
990 Adventure R FR
Art. no. 3211514en

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Summary of Contents for KTM 990 Adventure AUS/UK

  • Page 1 OWNER'S MANUAL 2010 990 Adventure EU 990 Adventure AUS/UK 990 Adventure R EU 990 Adventure R AUS/UK 990 Adventure R FR Art. no. 3211514en...
  • Page 3 DEAR KTM CUSTOMER We would like to congratulate you on deciding to purchase a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcy- DEAR KTM CUSTOMER cle that will give you enormous pleasure if you service and maintain it accordingly.
  • Page 4 Reproduction, even in part, is permitted only with the express written permission of the copyright owner. ISO 9001(12 100 6061) According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead to the maximum possible quality of the products.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Combination instrument - display........26 TABLE OF CONTENTS MEANS OF REPRESENTATION ..........7 Combination instrument - speedometer....... 27 IMPORTANT INFORMATION ........... 8 Setting kilometers or miles ..........27 VIEW OF VEHICLE..............12 Combination instrument - time .......... 28 View of vehicle, front left side (vehicle differs slightly from photo) ................
  • Page 6 TABLE OF CONTENTS Passenger footrests............42 Adjusting the high-speed compression damping of the shock absorber ..............73 Tool set ................43 Adjusting the rebound damping of the shock absorber..74 GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION................. 44 Adjusting the spring preload of the shock absorber ....76 Information on first use.............
  • Page 7 TABLE OF CONTENTS Checking the tire air pressure .......... 108 Installing the left fuel tank ......... 139 Checking spoke tension........... 109 Cooling system ............... 141 Removing the underride guard ........110 Checking the coolant level in the compensating tank ..142 Checking the antifreeze and coolant level ......
  • Page 8 TABLE OF CONTENTS STORAGE ................180 Storage................180 Putting into operation after storage ........181 TECHNICAL DATA - ENGINE ..........182 Capacity- engine oil ............183 Capacity - coolant............183 TECHNICAL DATA - ENGINE TIGHTENING TORQUES... 184 TECHNICAL DATA - CHASSIS ..........188 Lighting equipment ............

  • Page 9: Means Of Representation

    All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own safety, have these jobs performed in an authorized KTM workshop! There, your motorcycle will be serviced opti- mally by specially trained experts using the specialist tools required.

  • Page 10: Important Information

    Warranty The work prescribed in the service schedule must be carried out in an authorized KTM workshop only and confirmed in the customer's ser- vice record; otherwise, all warranty claims will be void. No warranty claim can be honored for damage resulting from manipulation and/or other changes to the vehicle.
  • Page 11 Spare parts, accessories For your own safety, only use spare parts and accessory products that have been approved and/or recommended by KTM and have them installed by an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage.
  • Page 12 IMPORTANT INFORMATION – Switch off the engine and remove the ignition key. – Secure the motorcycle against falling over or rolling away using straps or other suitable devices. Environment Motorcycling is a wonderful sport and we naturally hope that you can enjoy it to the full. However, it can also lead to problems with the environment and conflict with other persons.
  • Page 13 IMPORTANT INFORMATION Grades of risks Danger Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken. Warning Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken. Caution Identifies a danger that may lead to minor injuries if the appropriate measures are not taken.

  • Page 14: View Of Vehicle

    VIEW OF VEHICLE View of vehicle, front left side (vehicle differs slightly from photo) 100540-10...
  • Page 15 VIEW OF VEHICLE Clutch lever Seat Seat lock Luggage rack plate Handrail Front brake caliper Underride guard Side stand Shift lever Footrest Center stand Passenger footrest...

  • Page 16: View Of Vehicle, Rear Right Side (Vehicle Differs Slightly From Photo)

    VIEW OF VEHICLE View of vehicle, rear right side (vehicle differs slightly from photo) 100541-10...
  • Page 17 VIEW OF VEHICLE Storage compartment Light switch, turn signal switch, horn button, headlight flasher switch Hazard warning flasher switch Accessories socket Emergency OFF switch, electric starter button Hand brake lever Filler cap Rear brake caliper Foot brake lever Oil dipstick Cooling system compensating tank...

  • Page 18: Location Of Serial Numbers

    LOCATION OF SERIAL NUMBERS Chassis number The chassis number is stamped on the right side of the steering head.  The chassis number is also found on the type label. 100542-10 Type label The type label is located on the right frame tube in the vicinity of the oil tank. ...

  • Page 19: Key Number

    LOCATION OF SERIAL NUMBERS Key number The key number Code number can be found on the KEYCODECARD.  Info You need the key number to order a spare key. Keep the KEYCODECARD in a safe place. Use the orange programming key to activate and deactivate the black ignition key. Keep the orange programming key in a safe place: it must only be used for learning and programming functions.

  • Page 20: Fork Part Number

    LOCATION OF SERIAL NUMBERS Fork part number The fork part number is stamped on the inner side of the fork stub.  100545-10 Shock absorber part number The shock absorber part number is stamped on the upper part of the shock absorber. ...

  • Page 21: Controls

    CONTROLS Clutch lever The clutch lever is fitted on the left side of the handlebar.  The clutch is hydraulically operated and self-adjusting. 100505-10 Hand brake lever The hand brake lever is fitted on the right side of the handlebar. ...

  • Page 22: Light Switch

    CONTROLS Light switch The light switch is fitted on the left side of the handlebar.  Possible states Low beam on – The light switch is turned downwards. In this position, the low beam and tail light are switched on. High beam on –...

  • Page 23: Turn Signal Switch

    CONTROLS Turn signal switch The turn signal switch is fitted on the left side of the handlebar.  Possible states Turn signal off Turn signal, left, on – The turn signal switch is pressed to the left. The turn signal switch automatically returns to the central position after use. Turn signal, right, on –...

  • Page 24: Ignition/Steering Lock

    CONTROLS Ignition/steering lock The ignition/steering lock is in front of the upper triple clamp.  Info The ignition may only be switched on using a black ignition key. Use the orange programming key to activate and deactivate the black ignition key. Possible states Ignition OFF –...

  • Page 25: Emergency Off Switch

    The second black ignition key is activated when the vehicle is shipped. Two additional spare ignition keys (key number on the KEYCODECARD) can be ordered from an authorized KTM workshop, but they must be activated before use. Emergency OFF switch The emergency OFF switch is fitted on the right side of the handlebar.

  • Page 26: Combination Instrument

    CONTROLS Combination instrument 5.11 The combination instrument is installed in front of the handlebar. The combination instrument is divided into 4 function areas. Function buttons  Tachometer  Indicator lamps  Display  400913-10 Combination instrument - function buttons 5.12 You can change the display mode with the MODE button ...

  • Page 27: Combination Instrument - Tachometer

    CONTROLS Combination instrument - tachometer 5.13 The tachometer shows the engine speed in revolutions per minute.  The red marking shows the overspeed range of the engine.  400916-10 Combination instrument - indicator lamps 5.14 The indicator lamps offer additional information about the operating state of the motorcy- cle.

  • Page 28: Combination Instrument - Display

    CONTROLS The oil indicator lamp lights up red – The oil pressure is too low. Warning lamp FI (MIL) lights up/flashes orange – The OBD has detected a critical fault relating to emission or safety. The immobilizer indicator lamp lights up or flashes red – Status or error message for immobilizer/alarm system.

  • Page 29: Combination Instrument - Speedometer

    CONTROLS LEnGth Following the display function test, the wheel circumference LEnGth is shown for one sec- ond. Info 2205 mm equals the circumference of the 21" front wheel with a series production tire. The display then changes to the last selected mode. 400837-01 Combination instrument - speedometer 5.16...

  • Page 30: Combination Instrument - Time

    CONTROLS Condition The motorcycle is standing. – Switch on the ignition by turning the black ignition key to the position ON – Press the MODE button repeatedly until the ODO mode is active. – Keep the MODE button pressed until the display mode changes from km/h to mph or from mph to km/h.

  • Page 31: Setting The Clock

    CONTROLS Setting the clock 5.19 Condition The motorcycle is standing. – Switch on the ignition by turning the black ignition key to the position ON – Press the MODE button repeatedly until the ODO mode is active. – Keep the MODE button and the SET button pressed simultaneously. The time display begins to flash.

  • Page 32: Combination Instrument - Setting/Resetting Trip 1

    CONTROLS Combination instrument - setting/resetting TRIP 1 5.21 Info The TRIP 1 trip counter is always running and counts up to 999.9. The trip counter can be used to measure the distance covered during trips or between two refueling stops. After the value 999.9 is reached, the trip counter starts at 0.0 again.

  • Page 33: Combination Instrument - Trip F Display

    CONTROLS – Switch on the ignition by turning the black ignition key to the position ON – Press the MODE button repeatedly until the TRIP 2 mode is active. – Keep the SET button pressed. The TRIP 2 display is set to 0.0. 400841-01 Combination instrument - TRIP F display 5.23...

  • Page 34: Combination Instrument - Ambient Temperature Display

    CONTROLS Combination instrument - ambient temperature display 5.24 The ambient temperature is displayed in °C or °F.  400893-13 Setting the temperature unit of measure 5.25 Condition The motorcycle is standing. – Switch on the ignition by turning the black ignition key to the position ON –...

  • Page 35: Combination Instrument - Warning Of Slippery Roads

    CONTROLS Combination instrument - warning of slippery roads 5.26 The ice symbol lights up to indicate an increased danger of slippery roads. The ice symbol appears in the display when the ambient temperature drops below the specified value. Temperature 3 °C (37 °F) The ice symbol goes out in the display when the ambient temperature rises above the specified value again.

  • Page 36: Socket For Electrical Accessories

    CONTROLS Socket for electrical accessories 5.28 The socket for electrical accessories is located to the left of the combination instrument.  It is connected to the battery without an additional switch. Socket for electrical accessories Voltage 12 V Maximum current con- 10 A sumption B00116-10...

  • Page 37: Opening The Filler Caps

    CONTROLS Opening the filler caps 5.30 – Lift the cover of the filler cap and insert the ignition key in the lock.  Note Danger of damage Ignition key breakage. – To take pressure off of the ignition key, push down on the filler cap. Damaged igni- tion keys must be replaced.

  • Page 38: Seat Lock

    CONTROLS Seat lock 5.32 The seat lock is located in the left side cover below the seat.  The seat lock unlocks the seat and locks and unlocks the storage compartment. Possible states • Storage compartment locked  • Storage compartment unlocked ...

  • Page 39: Locking The Storage Compartment

    CONTROLS Locking the storage compartment 5.34 – Insert the ignition key into the seat lock. – Turn the ignition key to position  – Remove the ignition key. 100519-10 Opening the storage compartment 5.35 – Unlock the storage compartment. ( p.

  • Page 40: Closing The Storage Compartment

    CONTROLS Closing the storage compartment 5.36 – Push down on the rear of the cover until it audibly engages. Info The storage compartment can be opened again as long as it has not been locked using the seat lock. – Lock the storage compartment.

  • Page 41: Luggage Rack Plate

    CONTROLS Luggage rack plate 5.38 The luggage rack plate is located behind the seat.  The base plate of a luggage system (optional) can be attached to the luggage rack plate. The luggage rack plate may not be loaded with more than the specified weight. Maximum permissible load 8 kg (18 lb.) on luggage rack plate...

  • Page 42: Foot Brake Lever

    CONTROLS Foot brake lever 5.40 Foot brake lever is located in front of the right footrest.  The rear brake is activated using the foot brake lever. 100525-10 Shift lever 5.41 Shift lever is mounted on the left side of the engine. ...

  • Page 43: Side Stand

    CONTROLS The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. 100527-10 Side stand 5.42 Side stand is coupled with the safety start system; see the riding instructions.  Possible states Side stand folded out –...

  • Page 44: Center Stand

    CONTROLS Center stand 5.43 The vehicle is equipped with a center stand in addition to a side stand.  100529-10 Passenger footrests 5.44 The passenger footrests can be folded up and down. Possible states Passenger footrests folded up – For operation without a passenger. •...

  • Page 45: Tool Set

    CONTROLS Tool set 5.45 The tool set is located in the storage compartment under the seat.  The extension can be mounted on several of the wrenches in the tool set.  100531-10...

  • Page 46: General Tips And Hints On Putting Into Operation

    The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle. Warning Danger of accidents Uncontrollable handling characteristic due to non-approved and/or non-recommended tires/wheels. – Only tires/wheels approved by KTM and with the corresponding speed index should be used. Warning Danger of accidents Reduced road grip with new tires. –...

  • Page 47: Running In The Engine

    When using your vehicle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop. You receive a delivery certificate and the service record at vehicle handover.

  • Page 48: Loading The Vehicle

    GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION Loading the vehicle Warning Danger of accidents Unstable riding behavior. – Do not exceed the maximum permitted weight and axle loads. The overall weight consists of: motorcycle operational and with a full tank, driver and passenger with protective clothing and helmet, baggage. Warning Danger of accidents Unstable handling characteristics due to incorrect mounting of suitcase and/or tank rucksack.
  • Page 49 GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION Warning Danger of accidents Unstable handling characteristics due to slipped baggage. – Check the way your baggage is fixed regularly. Warning Danger of burns A hot exhaust system can burn baggage. – Fasten your baggage in such a way that it cannot be burned or singed by the hot exhaust system. –...

  • Page 50: Riding Instructions

    RIDING INSTRUCTIONS Checks before putting into operation Info Make sure that the motorcycle is in perfect technical condition before use. In the interests of riding safety, make a habit of making a general check before you ride. – Check the engine oil level. ( p.

  • Page 51: Starting

    RIDING INSTRUCTIONS Starting Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.
  • Page 52 RIDING INSTRUCTIONS – Turn the emergency OFF switch to the position – Switch on the ignition by turning the black ignition key to the position ON After you switch on the ignition, you can hear the fuel pump working for about two seconds.

  • Page 53: Starting Up

    RIDING INSTRUCTIONS Switching off ABS (990 Adventure) KTM recommends riding with ABS at all times. However, situations may arise in which ABS is not advantageous. Condition Vehicle is standing, engine is running. – Press button for 3 - 5 seconds.
  • Page 54 RIDING INSTRUCTIONS Warning Danger of accidents Distraction from traffic activity by adjustments to the vehicle. – Make all adjustments when the vehicle is at a standstill. Warning Risk of injury The passenger must be capable of sitting correctly on the passenger seat. –...
  • Page 55 If you continue with the coolant temperature warning lamp alight, you may have engine failure. Info If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized KTM workshop.
  • Page 56 RIDING INSTRUCTIONS – When conditions allow (incline, road situation, etc.), you can shift into a higher gear. – Release the throttle while simultaneously pulling the clutch lever, shift into the next gear, release the clutch and open the throttle. Info You can see the positions of the six forward gears in the figure.

  • Page 57: Braking

    Danger of accidents Reduced braking efficiency caused by spongy pressure point of front or rear brake. – Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Failure of brake system.
  • Page 58 RIDING INSTRUCTIONS Warning Danger of accidents Excessively hard braking causes the wheels to lock. – ABS must be switched on to be effective. – When braking, first throttle back and then apply the front and rear brakes at the same time. Info ABS lets you apply the brakes fully during emergency braking and in situations where road grip is compromised, such as on sandy, wet or slippery surfaces, without the danger of the wheels locking.

  • Page 59: Stopping, Parking

    RIDING INSTRUCTIONS – Braking should always be completed before you enter a bend. Change down to a lower gear that is appropriate for your speed. – On long downhill stretches, use the braking effect of the engine. Do this by changing down two gears, but do not race the engine. You will require less braking force and the brakes will not overheat.
  • Page 60 RIDING INSTRUCTIONS Note Material damage Damage and destruction of components from excessive load. – The center stand is only designed for the weight of the motorcycle and luggage. Do not sit on the motorcycle while it is resting on the center stand. The center stand or frame could be damaged and the motorcycle could fall over. –...

  • Page 61: Refueling

    RIDING INSTRUCTIONS Refueling Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. –...
  • Page 62 RIDING INSTRUCTIONS – Switch off the engine. – Lean the vehicle on the side stand. – Open the filler caps. ( p. 35) – Fill the right fuel tank with fuel no higher than level  Guideline Level 75 mm (2.95 in) ...
  • Page 63 RIDING INSTRUCTIONS – Press the SET button for two seconds.  The fuel level warning lamp switches off. TRIP F is set to 0.0 and appears in the  previous display mode. Info If you do not press the SET button , the reset takes place automatically after ...

  • Page 64: Service Schedule

    Check that the electrical equipment is functioning properly. • • • • • • • • Read out the trouble code memory using the KTM diagnostics tool. • • • • Change the engine oil and filter, clean the oil screens. p. 155) • •...
  • Page 65 SERVICE SCHEDULE K10N K75A K150A K300A Clean dust boots of fork legs. ( p. 77) • • • Check the front brake fluid level. ( p. 90) • • • • Bleed the fork legs. ( p. 77) • • •...
  • Page 66 • • • • • • Read out the error memory after the test ride using the KTM diagnostics tool. • • • • Make the necessary service entries in the KTM DEALER.NET and service record. K10N: Once after 1,000 km (621.4 mi)

  • Page 67: Maintenance Work On Frame And Engine

    MAINTENANCE WORK ON FRAME AND ENGINE Jacking up the vehicle on the center stand Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. Note Material damage Damage and destruction of components from excessive load. –...

  • Page 68: Raising The Vehicle Off Of The Center Stand

    MAINTENANCE WORK ON FRAME AND ENGINE Raising the vehicle off of the center stand Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Unlock the steering and move the vehicle forward with both hands on the handlebar. –...

  • Page 69: Mounting The Seat

    MAINTENANCE WORK ON FRAME AND ENGINE Mounting the seat – Hook projection of the seat into the storage compartment, lower the seat at the rear  0 0 1 0 0 2 0 0 3 and push it forward at the same time. The two projections must be inserted into the ...

  • Page 70: Adjusting The Compression Damping Of The Fork

    MAINTENANCE WORK ON FRAME AND ENGINE Adjusting the compression damping of the fork Info The hydraulic compression damping determines the fork suspension behavior. – Remove protection covers  – Turn adjusting screws clockwise until they stop.  Info The adjusting screws are located at the bottom end of the fork legs. Make the same adjustment on both fork legs.

  • Page 71: Adjusting The Rebound Damping Of The Fork

    MAINTENANCE WORK ON FRAME AND ENGINE Info Turn clockwise to increase damping, turn counterclockwise to reduce suspension damping. – Mount protection covers  Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork rebound behavior. –...

  • Page 72: Adjusting The Spring Preload Of The Fork

    MAINTENANCE WORK ON FRAME AND ENGINE (990 Adventure R) Rebound damping Comfort 23 clicks Standard 18 clicks Sport 13 clicks Full payload 13 clicks Info Turn clockwise to increase damping; turn counterclockwise to reduce damping. Adjusting the spring preload of the fork –...

  • Page 73: Compression Damping Of The Shock Absorber

    Adjusting the low-speed compression damping of the shock absorber 9.10 Danger Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.)
  • Page 74 MAINTENANCE WORK ON FRAME AND ENGINE Info The low-speed setting can be seen during the slow to normal compression of the shock absorber. – Turn adjusting screw clockwise with a screwdriver as far as the last perceptible click.  Info Do not loosen nut ...

  • Page 75: Adjusting The High-Speed Compression Damping Of The Shock Absorber

    Danger Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info The high-speed setting can be seen during the fast compression of the shock absorber.

  • Page 76: Adjusting The Rebound Damping Of The Shock Absorber

    Adjusting the rebound damping of the shock absorber 9.12 Danger Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.)
  • Page 77 MAINTENANCE WORK ON FRAME AND ENGINE – Turn adjusting screw clockwise up to the last perceptible click.  Info Do not loosen nut  – Turn back counterclockwise by the number of clicks corresponding to the shock absorber type. Guideline (990 Adventure) Rebound damping 100539-10...

  • Page 78: Adjusting The Spring Preload Of The Shock Absorber

    9.13 Danger Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) – Turn handwheel counterclockwise as far as it will go.

  • Page 79: Bleeding The Fork Legs

    MAINTENANCE WORK ON FRAME AND ENGINE Info The handwheel can be swung out to make settings. Turn clockwise to increase the spring preload; turn counterclockwise to reduce the spring preload. Bleeding the fork legs 9.14 – Jack up the vehicle on the center stand. ( p.

  • Page 80: Checking The Steering Head Bearing Play

    Raise the vehicle off of the center stand. ( p. 66) Checking the steering head bearing play 9.16 Warning Danger of accidents Unstable vehicle handling from incorrect steering head bearing play. – Adjust the steering head bearing play without delay. (Your authorized KTM workshop will be glad to help.)
  • Page 81 MAINTENANCE WORK ON FRAME AND ENGINE Info If the vehicle is operated for a lengthy period with play in the steering head bearing, the bearings and subsequently the bearing seats in the frame are damaged. – Jack up the vehicle on the center stand. ( p.

  • Page 82: Checking For Chain Dirt

    MAINTENANCE WORK ON FRAME AND ENGINE Checking for chain dirt 9.17 – Check the chain for coarse dirt accumulation. » If the chain is very dirty: – Clean the chain. ( p. 80) 400678-01 Cleaning the chain 9.18 Warning Danger of accidents Oil or grease on the tires reduces their grip. –...

  • Page 83: Checking The Chain Tension

    MAINTENANCE WORK ON FRAME AND ENGINE Info The service life of the chain depends largely on its maintenance. – Clean the chain regularly. – Rinse off loose dirt with a soft jet of water. – Remove old grease remains with chain cleaner. Chain cleaner ( p.

  • Page 84: Adjusting The Chain Tension

    MAINTENANCE WORK ON FRAME AND ENGINE – Lean the motorcycle on the side stand. 0 0 B – Shift the transmission to neutral. – Push the chain upwards near the lower chain guard screw and measure chain tension  Info 0 0 A The upper chain section must be taut.
  • Page 85 MAINTENANCE WORK ON FRAME AND ENGINE – Loosen nut  – Loosen nuts  – Adjust the chain tension by turning the adjusting screws on the left and right.  Guideline Chain tension 35… 40 mm (1.38… 1.57 in) Turn adjusting screws on the left and right so that the markings on the left and ...

  • Page 86: Checking The Chain, Rear Sprocket And Engine Sprocket

    MAINTENANCE WORK ON FRAME AND ENGINE Checking the chain, rear sprocket and engine sprocket 9.21 – Check the rear sprocket and engine sprocket for wear. » If the rear sprocket or engine sprocket is worn: – Change the rear sprocket or engine sprocket. Info The rear sprocket, engine sprocket and chain should always be changed together.
  • Page 87 MAINTENANCE WORK ON FRAME AND ENGINE – Jack up the vehicle on the center stand. ( p. 65) – Shift the transmission to neutral. – Pull the lower chain section with specified weight  Guideline Weight, chain wear measurement 15 kg (33 lb.) –...
  • Page 88 MAINTENANCE WORK ON FRAME AND ENGINE – Check the chain sliding guard for wear. » If the chain sliding guard is worn: – Change the chain sliding guard. – Check the chain sliding guard for tightness. » If the chain sliding guard is loose: –...

  • Page 89: Abs / Antilock Brake System (990 Adventure)

    – The ABS will only function correctly if the spare parts used in the brake system and the tires have been approved and/or recommended by KTM. – Maintenance work and repairs must be carried out professionally. (Your autho- rized KTM workshop will be glad to help.)

  • Page 90: Checking The Brake Discs

    Danger of accidents Reduced braking efficiency due to worn brake disc(s). – Change the worn brake disc(s) without delay. (Your authorized KTM workshop will be glad to help.) – Check the thickness of the front and rear brake discs in several places to ensure that it conforms to measurement ...

  • Page 91: Checking The Free Travel Of The Hand Brake Lever

    MAINTENANCE WORK ON FRAME AND ENGINE Checking the free travel of the hand brake lever 9.24 Warning Danger of accidents Brake system failure. – If there is no free travel on the hand brake lever, pressure builds up in the front brake circuit. The front brake can fail due to overheating.

  • Page 92: Checking The Front Brake Fluid Level

    (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will be glad to help.)

  • Page 93: Adding Front Brake Fluid

    If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately. Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will be glad to help.)
  • Page 94 MAINTENANCE WORK ON FRAME AND ENGINE Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. Info Never use DOT 5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for DOT 5 brake fluid.

  • Page 95: Checking The Front Brake Linings

    9.28 Warning Danger of accidents Reduced braking efficiency caused by worn brake linings. – Change worn brake linings immediately. (Your authorized KTM workshop will be glad to help.) Note Danger of accidents Reduced braking efficiency caused by damaged brake discs. – If the brake linings are not changed in time, the steel brake lining carriers grind on the brake disc. The braking effect is greatly reduced and the brake discs are rendered unserviceable.

  • Page 96: Checking The Rear Brake Fluid Level

    (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will be glad to help.)

  • Page 97: Adding Rear Brake Fluid

    If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately. Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will be glad to help.)
  • Page 98 MAINTENANCE WORK ON FRAME AND ENGINE Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. Info Never use DOT 5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for DOT 5 brake fluid.

  • Page 99: Checking The Rear Brake Linings

    9.32 Warning Danger of accidents Reduced braking efficiency caused by worn brake linings. – Change worn brake linings immediately. (Your authorized KTM workshop will be glad to help.) Note Danger of accidents Reduced braking efficiency caused by damaged brake discs. – If the brake linings are not changed in time, the steel brake lining carriers grind on the brake disc. The braking effect is greatly...

  • Page 100: Removing The Front Wheel

    MAINTENANCE WORK ON FRAME AND ENGINE – Check the brake linings for minimum thickness  ≥ 1 mm (≥ 0.04 in) Minimum thickness  » If the minimum thickness is less than specified: – Change the rear brake linings. – Check the brake linings for damage and cracking.
  • Page 101 MAINTENANCE WORK ON FRAME AND ENGINE (990 Adventure) – Remove screw and pull wheel speed sensor out of the hole with sleeve    100603-10 – Loosen screws   – Unscrew screw about six turns and press your hand on the screw to push the wheel ...

  • Page 102: Installing The Front Wheel

    MAINTENANCE WORK ON FRAME AND ENGINE – Remove spacers  100567-10 Installing the front wheel 9.34 Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. – Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. –...
  • Page 103 MAINTENANCE WORK ON FRAME AND ENGINE – Lift the front wheel into the fork, engage the brake discs into the brake calipers and insert the wheel spindle. (990 Adventure) The ABS sensor wheel is located on the left in the direction of travel. –...

  • Page 104: Removing The Rear Wheel

    MAINTENANCE WORK ON FRAME AND ENGINE Removing the rear wheel 9.35 – Jack up the vehicle on the center stand. ( p. 65) – Press the brake caliper by hand on to the brake disc in order to press back the brake pistons.
  • Page 105 MAINTENANCE WORK ON FRAME AND ENGINE – Remove nut . Remove chain adjuster   100569-10 – Pull out wheel spindle only far enough to allow the rear wheel to be pushed forward.  – Push the rear wheel forward as far as possible. Take the chain off of the rear sprocket and place it on chain sprocket guard ...

  • Page 106: Installing The Rear Wheel

    MAINTENANCE WORK ON FRAME AND ENGINE Installing the rear wheel 9.36 Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. – Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. Warning Danger of accidents No braking effect when operating the rear brake.
  • Page 107 MAINTENANCE WORK ON FRAME AND ENGINE – Mount the wheel spindle but do not push it in all the way. – Push the rear wheel as far forward as possible and place the chain on the rear sprocket. – Push the wheel spindle in all the way and mount chain adjuster and nut ...

  • Page 108: Checking The Rear Hub Rubber Dampers

    MAINTENANCE WORK ON FRAME AND ENGINE Checking the rear hub rubber dampers 9.37 Info The engine power is transmitted from the rear sprocket to the rear wheel via 6 rubber dampers. They eventually wear out during operation. If the rubber dampers are not changed in time, the rear sprocket carrier and the rear hub will be damaged. –...

  • Page 109: Checking The Tire Condition

    The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle. Warning Danger of accidents Uncontrollable handling characteristic due to non-approved and/or non-recommended tires/wheels. – Only tires/wheels approved by KTM and with the corresponding speed index should be used. Warning Danger of accidents Reduced road grip with new tires. –...

  • Page 110: Checking The Tire Air Pressure

    DOT marking. The first two digits refer to the week of manufacture and last two digits refer to the year of manufacture. KTM recommends that the tires are changed regardless of the actual wear, at the latest after five years.

  • Page 111: Checking Spoke Tension

    Danger of accidents Instable handling due to incorrect spoke tension. – Ensure that the spoke tension is correct. (Your authorized KTM workshop will be glad to help.) Info A loose spoke can cause wheel imbalance, leading to more loose spokes in a short time.

  • Page 112: Removing The Underride Guard

    MAINTENANCE WORK ON FRAME AND ENGINE – Strike each spoke briefly using a screwdriver blade. Info The frequency of the sound is a function of the spoke length and spoke diame- ter. If spokes of the same length and diameter vibrate with a different tone, this is an indication that the spoke tensions differ.

  • Page 113: Installing The Underride Guard

    MAINTENANCE WORK ON FRAME AND ENGINE Installing the underride guard 9.42 – Position underride guard . Mount and tighten screws   Guideline Loctite ® 243™ Screw, underride guard 25 Nm (18.4 lbf ft) – Swing up the side stand. –...
  • Page 114 MAINTENANCE WORK ON FRAME AND ENGINE – Remove screws . Fold cover down.   100579-10 – Disconnect the negative (minus) cable of the battery.  – Disconnect the positive (plus) cable of the battery.  – Take the battery out of the battery compartment with battery tray ...

  • Page 115: Installing The Battery

    MAINTENANCE WORK ON FRAME AND ENGINE Installing the battery 9.44 – Insert the battery into battery tray  – Slide the battery with the battery tray into the battery compartment. – Connect plus cable  – Connect minus cable  100580-11 –...

  • Page 116: Recharging The Battery

    – Do not discard batteries with the household trash. Dispose of a defective battery in an environmentally compatible manner. Give the battery to your KTM dealer or to a recycling center that accepts used batteries. Warning Environmental hazard Hazardous substances cause environmental damage.
  • Page 117 The battery is maintenance-free, i.e., the acid level does not have to be checked. If the battery is not charged using the KTM battery charger, the battery must be removed for charging. Otherwise, overvoltage may damage electronic components. Charge the battery according to the instructions on the battery casing.
  • Page 118 MAINTENANCE WORK ON FRAME AND ENGINE – Clamp the plus cable of the battery charger to the positive terminal extension  the minus cable to an unpainted location on the engine . Switch on the battery  charger. Battery charger (58429074000) You can also use the battery charger to test rest potential and start potential of the bat- tery, and to test the generator.

  • Page 119: Removing The Right Underride Guard

    MAINTENANCE WORK ON FRAME AND ENGINE Removing the right underride guard 9.46 – Remove screws . Remove the right underride guard   100581-10 Installing the right underride guard 9.47 – Position right underride guard . Mount and tighten screws ...

  • Page 120: Changing The Main Fuse

    MAINTENANCE WORK ON FRAME AND ENGINE Changing the main fuse 9.48 Warning Fire hazard The electrical system can be overloaded by the use of incorrect fuses. – Use only fuses with the prescribed amperage. Never by-pass or repair fuses. Info The main fuse is located in the starter relay under the right underride guard. –...
  • Page 121 MAINTENANCE WORK ON FRAME AND ENGINE (990 Adventure) – Remove the faulty main fuse  Info A defective fuse can be identified by the burned-out fuse wire  A reserve fuse is located in the starter relay.  The main fuse protects all power consumers in the vehicle except for the ABS unit.

  • Page 122: Changing The Abs Fuses (990 Adventure)

    MAINTENANCE WORK ON FRAME AND ENGINE Changing the ABS fuses (990 Adventure) 9.49 Warning Fire hazard The electrical system can be overloaded by the use of incorrect fuses. – Use only fuses with the prescribed amperage. Never by-pass or repair fuses. Info Two fuses for the ABS are located under the right underride guard.

  • Page 123: Changing The Fuses In The Fuse Box

    MAINTENANCE WORK ON FRAME AND ENGINE Changing the fuse of the ABS return pump: – Remove protective cover and remove fuse   Info A spare fuse is located next to the fuse box in the storage compartment. – Install the new fuse. Fuse (58011109140) ( p.
  • Page 124 MAINTENANCE WORK ON FRAME AND ENGINE – Remove fuse box cover  100587-10 – Remove the faulty fuse. Guideline Fuse IGNITION, FUEL PUMP - 10A - ignition, fuel pump, immobilizer, alarm system (optional) Fuse H/L BEAM, POSITION - 15A - high beam, low beam, parking light, license plate lamp Fuse HORN, BRAKE LIGHT - 10A - horn, brake light, hazard warning flasher Fuse FAN - 10A - radiator fan...
  • Page 125 MAINTENANCE WORK ON FRAME AND ENGINE (990 Adventure) – Use spare fuses with the correct rating only. Fuse (58011109110) ( p. 189) Fuse (58011109115) ( p. 189) Info Spare fuses are located next to the fuse box.  The spare fuses are for the ABS.

  • Page 126: Removing The Front Side Cover

    MAINTENANCE WORK ON FRAME AND ENGINE Removing the front side cover 9.51 Info The operations are the same on the left and right sides. – Remove screws  – Carefully swing out the side cover at the top and disconnect the plug-in connectors ...

  • Page 127: Removing The Headlight Mask With The Headlight

    MAINTENANCE WORK ON FRAME AND ENGINE – Position side cover at the fuel tank on the bottom and hold it at an angle.  – Attach the overflow hose of the fuel tank to the connector. – Connect the plug-in connectors of the turn signal cables and swing the side cover up toward the vehicle.

  • Page 128: Installing The Headlight Mask With The Headlight

    MAINTENANCE WORK ON FRAME AND ENGINE – Disconnect plug-in connector  – Place the headlight mask down on a soft cloth to prevent the headlight and trim disc from being damaged. 100591-10 Installing the headlight mask with the headlight 9.54 –...

  • Page 129: Changing The Low Beam Bulb

    MAINTENANCE WORK ON FRAME AND ENGINE – Remove the headlight mask with the headlight. ( p. 125) – Remove rubber cap and disconnect plug-in connector   100594-10 – Detach spring bar and remove the bulb from the headlight.  –...

  • Page 130: Changing The Parking Light Bulb In The Headlight

    MAINTENANCE WORK ON FRAME AND ENGINE – Remove the headlight mask with the headlight. ( p. 125) – Remove rubber cap and connector from the bulb.   100592-10 – Detach spring bar and remove the bulb from the headlight. ...

  • Page 131: Changing The Turn Signal Bulb

    MAINTENANCE WORK ON FRAME AND ENGINE – Remove the headlight mask with the headlight. ( p. 125) – Pull socket out of the headlight and pull bulb out of the socket.   – Insert the new bulb into the socket and insert the socket into the headlight. Parking light (W5W / socket W2.1x9.5d) ( p.

  • Page 132: Changing The Tail Light Bulb

    MAINTENANCE WORK ON FRAME AND ENGINE Turn signal (RY10W / socket BAU15s) ( p. 190) – Check the turn signal to make sure it is functioning properly. – Position the diffuser. Info Hook in projection at recess   – Insert the screw and first turn it counterclockwise until it engages in the thread.

  • Page 133: Changing The Brake Light Bulb

    MAINTENANCE WORK ON FRAME AND ENGINE – Pull bulb sockets out of the tail light.  – Pull bulbs out of the sockets.  – Insert new bulbs into the sockets. Tail light (WR5W / socket W2.1x9.5d) ( p. 190) –...

  • Page 134: Checking The Headlight Setting

    MAINTENANCE WORK ON FRAME AND ENGINE – Turn bulb socket counterclockwise all the way and take it out of the tail light.  – Press bulb carefully into the socket, turn it counterclockwise by about 30°, and pull  it out of the socket. –...

  • Page 135: Adjusting The Headlight Range

    MAINTENANCE WORK ON FRAME AND ENGINE The light-dark boundary must lie exactly on the lower mark when the motorcycle is ready to operate with the rider mounted along with any luggage and a passenger if applicable. » If the boundary between light and dark does not meet specifications: –...
  • Page 136 MAINTENANCE WORK ON FRAME AND ENGINE Loss of a black ignition key (second black ignition key available): The following procedure deactivates all activated black ignition keys that are not included in the procedure. – Turn the emergency OFF switch to the position –...
  • Page 137 MAINTENANCE WORK ON FRAME AND ENGINE The existing black ignition key is reactivated. Loss of both black ignition keys (no black ignition key available): This procedure is important to prevent misuse of the lost black ignition key. – Turn the emergency OFF switch to the position –...

  • Page 138: Removing The Storage Compartment And Hanging It To One Side

    MAINTENANCE WORK ON FRAME AND ENGINE – Switch off the ignition by turning the orange programming key to the OFF position – Pull out the programming key. – Insert the black ignition key in the ignition lock. – Switch on the ignition by turning the black ignition key to the position ON FI Warning lamp (MIL) lights up, switches off, and then starts to flash.

  • Page 139: Installing The Storage Compartment

    MAINTENANCE WORK ON FRAME AND ENGINE – Open the storage compartment. ( p. 37) – Remove screws  – Carefully remove the storage compartment and swing it to the right. Place a cloth between the right fuel tank and the storage compartment to prevent damage. 100616-10 Installing the storage compartment 9.65...

  • Page 140: Removing The Left Fuel Tank

    MAINTENANCE WORK ON FRAME AND ENGINE Removing the left fuel tank 9.66 Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components.

  • Page 141: Installing The Left Fuel Tank

    MAINTENANCE WORK ON FRAME AND ENGINE – Remove screws  – Raise the fuel tank slightly at the front, detach from the upper holder and swing the top away from the vehicle. Info Hold the fuel tank at about the same height as when it is mounted. Before removing the fuel tank entirely, a number of hoses and plug-in connectors need to be detached.
  • Page 142 MAINTENANCE WORK ON FRAME AND ENGINE Warning Danger of poisoning Fuel is poisonous and a health hazard. – Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, contact a doc- tor immediately.

  • Page 143: Cooling System

    MAINTENANCE WORK ON FRAME AND ENGINE Cooling system 9.68 The water pump in the engine forces the coolant to flow.  The pressure in the cooling system resulting from heat is regulated by a valve in the radia- tor cap. This permits the specified coolant temperature without causing any malfunctions. 125 °C (257 °F) 100608-10 Cooling takes place by means of the air stream and a radiator fan...

  • Page 144: Checking The Coolant Level In The Compensating Tank

    MAINTENANCE WORK ON FRAME AND ENGINE A radiator guard is included with the vehicle. The radiator guard should be mounted  when operating the vehicle offroad. It prevents damage to the radiator from flying stones and similar causes. 0 0 4 100640-10 Checking the coolant level in the compensating tank 9.69...

  • Page 145: Checking The Antifreeze And Coolant Level

    MAINTENANCE WORK ON FRAME AND ENGINE – Park the motorcycle on a horizontal surface. – Check the coolant level in the compensating tank  The coolant level must be between MIN and MAX. » If there is no coolant in the compensating tank: –...
  • Page 146 MAINTENANCE WORK ON FRAME AND ENGINE Warning Danger of poisoning Coolant is poisonous and a health hazard. – Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately. Change clothes that have come into contact with coolants.
  • Page 147 MAINTENANCE WORK ON FRAME AND ENGINE – Add coolant to the MAX marking. Alternative 1 Coolant ( p. 201) Alternative 2 Coolant (mixed ready to use) ( p. 201) – Mount the cap of the compensating tank. – Remove radiator cap ...

  • Page 148: Draining The Coolant

    MAINTENANCE WORK ON FRAME AND ENGINE » If the coolant level does not meet specifications: Coolant loss: > 0.50 l (> 0.53 qt.) – Check the cooling system for leaks. Info Do not start up the motorcycle! – Fill/bleed the cooling system. p.

  • Page 149: Filling/Bleeding The Cooling System

    MAINTENANCE WORK ON FRAME AND ENGINE – Place a suitable container under the radiator. – Remove screw  – Remove radiator cap. – Completely drain the coolant. – Mount screw with a new seal ring and tighten it.  Guideline Remaining chassis screws 10 Nm (7.4 lbf ft) 100612-10...
  • Page 150 MAINTENANCE WORK ON FRAME AND ENGINE Condition The front side cover has been removed. – Ensure that the drain plug on the radiator and the water pump cover are tightened. – Remove bleeder screw  100613-10 – Position the vehicle as shown and secure it against rolling. Height difference must ...
  • Page 151 MAINTENANCE WORK ON FRAME AND ENGINE – Pour in coolant until it emerges without bubbles at the vent hole, and then mount and tighten the bleeder screw immediately. Alternative 1 Coolant ( p. 201) Alternative 2 Coolant (mixed ready to use) ( p.

  • Page 152: Removing The Radiator Guard

    MAINTENANCE WORK ON FRAME AND ENGINE – Stop the engine and allow it to cool down. – When the engine is cool, check the coolant level in the radiator and, if necessary, add coolant. – Check the coolant level in the compensating tank and, if necessary, add coolant to marking MAX.

  • Page 153: Installing The Radiator Guard

    MAINTENANCE WORK ON FRAME AND ENGINE – Pull nuts off of the radiator.  Insert the screws into the holes of the radiator guard and mount the nuts. This ensures that all required parts are available when needed. 100642-10 Installing the radiator guard 9.74 –...

  • Page 154: Adjusting The Basic Setting Of The Clutch Lever

    MAINTENANCE WORK ON FRAME AND ENGINE Adjusting the basic setting of the clutch lever 9.75 – Adjust the basic setting of the clutch lever to your hand size by turning adjusting screw  Info Turn the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar.

  • Page 155: Checking The Play In The Throttle Cable

    MAINTENANCE WORK ON FRAME AND ENGINE – Position the cover with the membrane. Mount and tighten the screws. Checking the play in the throttle cable 9.77 – Move the handlebar to the straight-ahead position. Move the throttle grip backwards and forwards to ascertain the play in the throttle cable. Play in throttle cable 3…...

  • Page 156: Adjusting The Play In The Throttle Cable

    Adjusting the play in the throttle cable 9.78 – Move the handlebar to the straight-ahead position. – Use the KTM diagnostics tool to set the throttle stepper motor to the basic position. – Loosen counter nut  – Set the play in the throttle cable by turning adjusting screw ...

  • Page 157: Changing The Engine Oil And Filter, Cleaning The Oil Screens

    MAINTENANCE WORK ON FRAME AND ENGINE – Switch off the engine. – Unscrew oil dipstick , wipe it off with a cloth and screw it back in all the way.  Unscrew the oil dipstick and read off the engine oil level. The engine oil level must be between the MIN and the MAX marking on the dipstick.
  • Page 158 MAINTENANCE WORK ON FRAME AND ENGINE Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. Info Drain the engine oil only when the engine is warm. –...
  • Page 159 MAINTENANCE WORK ON FRAME AND ENGINE – Remove screw on the right fuel tank and remove screws . Remove holder    100625-10 – Raise the vehicle off of the center stand. ( p. 66) – Place the vehicle on the side stand. –...
  • Page 160 MAINTENANCE WORK ON FRAME AND ENGINE – Check seal ring of the oil sieve for damage and correct seating.  – Insert oil sieve into the oil tank.  – Position the oil line. Mount and tighten the screws. Guideline Remaining chassis screws 10 Nm (7.4 lbf ft) –...

  • Page 161: Removing The Oil Filter

    MAINTENANCE WORK ON FRAME AND ENGINE – Position the bracket . Mount and tighten screws   Guideline Remaining chassis screws 25 Nm (18.4 lbf ft) – Mount and tighten screw on the right fuel tank.  Guideline Screw, fuel tank 15 Nm (11.1 lbf ft) 100625-10...
  • Page 162 MAINTENANCE WORK ON FRAME AND ENGINE – Remove screws . Take off oil filter cover with the O-ring.   100632-10 – Pull oil filter out of the oil filter housing.  Circlip pliers reverse (51012011000) – Completely drain the engine oil. –...

  • Page 163: Installing The Oil Filter

    MAINTENANCE WORK ON FRAME AND ENGINE Installing the oil filter 9.83 – Insert oil filter  – Lubricate the O-ring of the oil filter cover. Install oil filter cover  – Mount and tighten the screws. Guideline Remaining engine screws 6 Nm (4.4 lbf ft) 100631-10 Filling up with engine oil...
  • Page 164 MAINTENANCE WORK ON FRAME AND ENGINE Engine oil (1st 2.50 l (2.64 qt.) External Engine oil (SAE quantity) approx. temperature: 5W/40) ( p. 202) < 0 °C (< 32 °F) – Replace the oil dipstick. – Jack up the vehicle on the center stand. ( p.

  • Page 165: Adding Engine Oil

    MAINTENANCE WORK ON FRAME AND ENGINE Adding engine oil 9.85 Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. The engine oil level must be corrected when the engine is warm. – Remove oil dipstick and add engine oil to the MAX marking.

  • Page 166: Ignition Curve Plug-In Connector

    MAINTENANCE WORK ON FRAME AND ENGINE Ignition curve plug-in connector 9.86 Plug-in connector is located under the seat close to where the top of the shock absorber  is attached. By disconnecting the plug-in connector, the ignition curve for fuel with an octane rating below 95 (ROZ 95 / RON 95 / PON 91) is activated.
  • Page 167 MAINTENANCE WORK ON FRAME AND ENGINE – Mount the seat. ( p. 67)

  • Page 168: Immobilizer Blink Code

    IMMOBILIZER BLINK CODE Flash code of immobilizer indica- tor lamp 12 Immobilizer indicator lamp flashes 1x short, 1 second pause, 2x short Error level condition All ignition keys inactive Flash code of immobilizer indica- tor lamp 13 Immobilizer indicator lamp flashes 1x short, 1 second pause, 3x short Error level condition Malfunction, antenna of immobilizer control unit Flash code of immobilizer indica-...
  • Page 169 IMMOBILIZER BLINK CODE Flash code of immobilizer indica- tor lamp 21 Immobilizer indicator lamp flashes 2x short, 1 second pause, 1x short Error level condition Immobilizer control unit not activated Flash code of immobilizer indica- tor lamp 31 Immobilizer indicator lamp flashes 3x short, 1 second pause, 1x short Error level condition Malfunction, encryption query from EFI control unit to immobilizer control unit Flash code of immobilizer indica-...

  • Page 170: Engine Control Blink Code

    ENGINE CONTROL BLINK CODE Flash code of warning lamp FI (MIL) 02 Warning lamp FI (MIL) flashes 2x short Error level condition Circuit ignition pulse generator - malfunction in circuit Flash code of warning lamp FI (MIL) 06 Warning lamp FI (MIL) flashes 6x short Error level condition Throttle valve sensor circuit A - input signal too low Throttle valve sensor circuit A - input signal too high...
  • Page 171 ENGINE CONTROL BLINK CODE Flash code of warning lamp FI (MIL) 12 Warning lamp FI (MIL) flashes 1x long, 2x short Error level condition Coolant temperature sensor - input signal too low Coolant temperature sensor - input signal too high Flash code of warning lamp FI (MIL) 13 Warning lamp FI (MIL) flashes 1x long, 3x short...
  • Page 172 ENGINE CONTROL BLINK CODE Flash code of warning lamp FI (MIL) 18 Warning lamp FI (MIL) flashes 1x long, 8x short Error level condition Lambda sensor cylinder 2, sensor 1 - circuit fault Flash code of warning lamp FI (MIL) 24 Warning lamp FI (MIL) flashes 2x long, 4x short Error level condition Power supply - malfunction in circuit...
  • Page 173 ENGINE CONTROL BLINK CODE Flash code of warning lamp FI (MIL) 37 Warning lamp FI (MIL) flashes 3x long, 7x short Error level condition Ignition coil cylinder 1 - malfunction in circuit Flash code of warning lamp FI (MIL) 38 Warning lamp FI (MIL) flashes 3x long, 8x short Error level condition Ignition coil cylinder 2 - malfunction in circuit Flash code of warning...
  • Page 174 ENGINE CONTROL BLINK CODE Flash code of warning lamp FI (MIL) 49 Warning lamp FI (MIL) flashes 4x long, 9x short Error level condition Motor drive circuit A - circuit fault Flash code of warning lamp FI (MIL) 50 FI Warning lamp (MIL) flashes 5x long Error level condition Motor drive circuit B - circuit fault Flash code of warning...
  • Page 175 ENGINE CONTROL BLINK CODE Flash code of warning lamp FI (MIL) 81 Warning lamp FI (MIL) flashes 8x long, 1x short Error level condition Immobilizer control unit - malfunction in circuit Flash code of warning lamp FI (MIL) 91 Warning lamp FI (MIL) flashes 9x long, 1x short Error level condition CAN bus communication error...

  • Page 176: Troubleshooting

    Reconnect coupling of fuel hose connection. connected – Socket connector of wiring harness Clean the socket connector and treat it with con- oxidized tact spray. – Defect in fuel injection system Read out the fault memory using the KTM diag- nostics tool.
  • Page 177 Air filter very dirty Change the air filter. – Defect in fuel injection system Read out the fault memory using the KTM diag- nostics tool. – Ignition curve for low octane fuel acti- Refuel with fuel with an octane rating of 95 or vated higher.
  • Page 178 Faults Possible cause Action – ABS warning lamp lights up Malfunction in ABS Read out the ABS fault memory using the KTM diagnostics tool. (990 Adventure) – High oil consumption Engine oil level too high Check the engine oil level. ( p.

  • Page 179: Cleaning

    CLEANING Cleaning motorcycle 13.1 Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electrical components, socket connects, throttle cables, and bearings, etc., and can damage or destroy these parts. Warning Environmental hazard Hazardous substances cause environmental damage.
  • Page 180 CLEANING Warning Danger of accidents Reduced braking efficiency due to wet or dirty brakes. – Clean or dry dirty or wet brakes by riding and braking gently. – After cleaning, ride the vehicle a short distance until the engine warms up, and then apply the brakes. Info The heat produced causes water at inaccessible positions in the engine and on the brakes to evaporate.

  • Page 181: Protective Treatment For Winter Operation

    PROTECTIVE TREATMENT FOR WINTER OPERATION Protective treatment for winter operation 14.1 Info If you use the motorcycle in winter, you must expect salt on the roads. You should therefore take precautions against aggressive road salt. If the vehicle was operated in road salt, clean it with cold water. Warm water would enhance the corrosive effects of salt. –...

  • Page 182: Storage

    STORAGE Storage 15.1 Info If you want to garage the motorcycle for a longer period, take the following actions. Before storing the motorcycle, check all parts for function and wear. If service, repairs or replacements are necessary, you should do this during the storage period (less workshop overload). In this way, you can avoid long workshop waiting times at the start of the new season.

  • Page 183: Putting Into Operation After Storage

    STORAGE Putting into operation after storage 15.2 – Raise the vehicle off of the center stand. ( p. 66) – Recharge the battery. p. 114) – Install the battery. p. 113) – Set the clock. ( p. 29) – Refuel. ( p.

  • Page 184: Technical Data - Engine

    TECHNICAL DATA - ENGINE Design 2-cylinder 4-stroke Otto motor, 75° V arrangement, water-cooled Displacement 999 cm³ (60.96 cu in) Stroke 62.4 mm (2.457 in) Bore 101 mm (3.98 in) Compression ratio 11.5:1 Control DOHC, 4 valves per cylinder, chain-driven Valve - diameter Exhaust 33 mm (1.3 in) Intake...

  • Page 185: Capacity- Engine Oil

    TECHNICAL DATA - ENGINE 5th gear 24:27 6th gear 27:26 Mixture preparation Electronic fuel injection Ignition system Contactless controlled fully electronic ignition with digital ignition adjustment Generator 12 V, 450 W Spark plug NGK LKAR8BI9 Spark plug electrode gap 0.8 mm (0.031 in) Cooling Water cooling, permanent circulation of coolant by water pump Cold start device...

  • Page 186: Technical Data - Engine Tightening Torques

    TECHNICAL DATA - ENGINE TIGHTENING TORQUES – Hose clip, intake flange 1.5 Nm (1.11 lbf ft) ® Oil jet 6 Nm (4.4 lbf ft) Loctite 243™ – Remaining engine screws 6 Nm (4.4 lbf ft) ® Screw, bearing retainer 6 Nm (4.4 lbf ft) Loctite 243™...
  • Page 187 TECHNICAL DATA - ENGINE TIGHTENING TORQUES – Screw, valve cover 10 Nm (7.4 lbf ft) – Screw, water pump cover 10 Nm (7.4 lbf ft) ® Screw, water pump wheel 10 Nm (7.4 lbf ft) Loctite 243™ ® Stud, cylinder head in cylinder Loctite 243™...
  • Page 188 TECHNICAL DATA - ENGINE TIGHTENING TORQUES Nut, cylinder head on chain shaft Step 1 lubricated with engine oil 25 Nm (18.4 lbf ft) Step 2 38 Nm (28 lbf ft) – Plug, clutch lubrication 15 Nm (11.1 lbf ft) – Stud, cylinder head in engine case 20 Nm (14.8 lbf ft) –...
  • Page 189 TECHNICAL DATA - ENGINE TIGHTENING TORQUES ® Nut, primary gear M33LHx1.5 130 Nm (95.9 lbf ft) Loctite 243™...

  • Page 190: Technical Data - Chassis

    TECHNICAL DATA - CHASSIS Frame Lattice frame made of chrome molybdenum steel tubing, powder- coated Fork WP Suspension Up Side Down 4860 MXMA PA Shock absorber WP Suspension PDS 5018 DCC PA Suspension travel (990 Adventure) Front 210 mm (8.27 in) Suspension travel (990 Adventure R) Front 265 mm (10.43 in)
  • Page 191 TECHNICAL DATA - CHASSIS Tire air pressure, solo Front 2.4 bar (35 psi) Rear 2.6 bar (38 psi) Tire air pressure with passenger/full payload Front 2.4 bar (35 psi) Rear 2.8 bar (41 psi) Secondary drive ratio 16:42 Chain 5/8 x 5/16” X‑ring Steering head angle 63.4°...

  • Page 192: Lighting Equipment

    TECHNICAL DATA - CHASSIS Fuse 58011109130 30 A Fuse 58011109140 40 A Lighting equipment 18.1 Low beam H7 / socket PX26d 12 V 55 W High beam H3 / socket PK22s 12 V 55 W Parking light W5W / socket W2.1x9.5d 12 V Instrument lights and indicator lamps Turn signal...

  • Page 193: Tires

    Alternative tires to max.: 160 km/h (99.4 mph) Continental TKC 80 Continental TKC 80 Additional information is available in the Service section under: http://www.ktm.com Capacity - fuel 18.3 Total fuel tank capacity, approx. 20 l (5.3 US gal) Super unleaded (ROZ 95 / RON 95 / PON 91) ( p.

  • Page 194: Technical Data - Fork

    TECHNICAL DATA - FORK 990 Adventure 19.1 Fork part number 14.18.7E.24 WP Suspension Up Side Down 4860 MXMA PA Fork Compression damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Rebound damping Comfort 23 clicks Standard 18 clicks Sport...

  • Page 195: 990 Adventure R

    TECHNICAL DATA - FORK Air chamber length mm (3.94 +1.18 −20 −0.79 Fork oil per fork leg 655 ml (22.15 fl. oz.) Fork oil (SAE 5) ( p. 203) 990 Adventure R 19.2 Fork part number 14.18.7E.25 Fork WP Suspension Up Side Down 4860 MXMA PA Compression damping Comfort 20 clicks...
  • Page 196 TECHNICAL DATA - FORK Medium (standard) 4.8 N/mm (27.4 lb/in) Hard 5.0 N/mm (28.6 lb/in) Fork length 935 mm (36.81 in) +1.18 Air chamber length mm (3.94 −20 −0.79 Fork oil per fork leg 655 ml (22.15 fl. oz.) Fork oil (SAE 5) ( p.

  • Page 197: Technical Data - Shock Absorber

    TECHNICAL DATA - SHOCK ABSORBER 990 Adventure 20.1 Shock absorber part number 12.18.7E.08 WP Suspension PDS 5018 DCC PA Shock absorber Compression damping, low-speed Comfort 25 clicks Standard 20 clicks Sport 15 clicks Full payload 15 clicks Compression damping, high-speed Comfort 2 turns Standard...

  • Page 198: 990 Adventure R

    TECHNICAL DATA - SHOCK ABSORBER Soft 140 N/mm (799 lb/in) Medium (standard) 150 N/mm (857 lb/in) Spring length 225 mm (8.86 in) Gas pressure 10 bar (145 psi) Static sag 25 mm (0.98 in) Fitted length 372 mm (14.65 in) Shock absorber oil ( p.
  • Page 199 TECHNICAL DATA - SHOCK ABSORBER Sport 10 clicks Full payload 10 clicks Spring preload - Preload Adjuster Comfort 4 turns Standard 4 turns Sport 8 turns Full payload 10 turns Spring rate Soft 130 N/mm (742 lb/in) Medium (standard) 140 N/mm (799 lb/in) Hard 150 N/mm (857 lb/in) Spring length...

  • Page 200: Technical Data - Chassis Tightening Torques

    TECHNICAL DATA - CHASSIS TIGHTENING TORQUES – Screw, side stand switch 2 Nm (1.5 lbf ft) – Screw, cable guide, wheel speed sensor, 3 Nm (2.2 lbf ft) rear – Screw, filler cap 5 Nm (3.7 lbf ft) ® Screw, foot brake lever stub 6 Nm (4.4 lbf ft) Loctite 243™...
  • Page 201 TECHNICAL DATA - CHASSIS TIGHTENING TORQUES – Screw, fuel tap 6 Nm (4.4 lbf ft) – Screw, heat guard on manifold 8 Nm (5.9 lbf ft) ® Screw, magnetic holder on side stand 6 Nm (4.4 lbf ft) Loctite 243™ ®...
  • Page 202 TECHNICAL DATA - CHASSIS TIGHTENING TORQUES – Remaining chassis screws 45 Nm (33.2 lbf ft) – Screw, handlebar support 20 Nm (14.8 lbf ft) ® Screw, side stand 35 Nm (25.8 lbf ft) Loctite 243™ ® Screw, side stand bracket 45 Nm (33.2 lbf ft) Loctite 243™...

  • Page 203: Substances

    – Guideline – Use only brake fluid that complies with the specified standards (see specifications on the container) and that possesses the corre- ® sponding properties. KTM recommends Castrol and Motorex products. Supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 ®...
  • Page 204 SAE ( p. 207) (SAE 10W/50) Guideline – Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corresponding ® properties. KTM recommends Motorex products. Fully synthetic engine oil Supplier ® Motorex –...
  • Page 205 – ISO VG (15) Guideline – Use only hydraulic fluid that complies with the specified standards (see specifications on the container) and that possesses the corre- ® sponding properties. KTM recommends Motorex products. Supplier ® Motorex – Hydraulic Fluid 75...
  • Page 206 SUBSTANCES Super unleaded (ROZ 95 / RON 95 / PON 91) According to – DIN EN 228 (ROZ 95 / RON 95 / PON 91)

  • Page 207: Auxiliary Substances

    AUXILIARY SUBSTANCES Chain cleaner Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Chain Clean 611 Chain lube for road use Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Chain Lube 622 Strong Cleaning and preserving materials for metal, rubber and plastic Guideline –...
  • Page 208 AUXILIARY SUBSTANCES Long-life grease Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Fett 2000 Motorcycle cleaner Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Moto Clean 900 Universal oil spray Guideline – ® KTM recommends Motorex products.

  • Page 209: Standards

    STANDARDS JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Ear- lier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specification. Whereas long service intervals are demanded for automobile engines, high performance at high engine speeds are in the foreground for motorcycle engines.

  • Page 210: Index

    INDEX Brake linings INDEX front brake, checking ......93 ABS ......... 87 rear brake, checking .
  • Page 211 INDEX function buttons ......24 Engine oil indicator lamps ......25 adding .
  • Page 212 INDEX Front wheel High beam bulb installing ........100 changing .
  • Page 213 INDEX Motorcycle Rear hub rubber dampers cleaning ........177 checking .
  • Page 214 INDEX removing ........124 engine ....... 182-183 engine tightening torques .
  • Page 215 INDEX loading ........46 raising off of center stand ..... . . 66 View of vehicle front left side .
  • Page 216 *3211514en* 3211514en 10/2009 Photo: Mitterbauer KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com...

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