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OWNER’S MANUAL 2008 990 SUPER DUKE 990 SUPER DUKE R ART. NR. 3.211.249 EN...
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INTRODUCTION We would like to congratulate you on your purchase of a KTM motorcycle. You are now the owner of a state-of-the-art sport motorcycle that guarantees to bring you lots of fun and enjoyment, provided that you clean and maintain it appropriately.
» IMPORTANT INFORMATION INTENDED PURPOSE The 990 Super Duke is designed to resist the usual wear and tear of paved roads but is not designed for race courses or off-road use. The 990 Super Duke R is designed to resist the usual wear and tear of paved roads or race courses but is not designed for off-road use. OWNER'S MANUAL Carefully read the entire Owner's Manual before you start riding your motorcycle, even if this will take a little time.
SPARE PARTS, ACCESSORIES For your own safety, only use spare parts and accessories approved by KTM. KTM shall not assume any liability for other products or consequential damage resulting from the use of such products.
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Compression damping of fork ..... .19 General information on KTM disk brakes ....42 Rebound damping of fork .
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» INDEX Checking the front brake pads .....45 cleaning the oil screen ......68 Checking the rear brake fluid level .
» 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 [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).
» OPERATION INSTRUMENTS Combined instrument The combined instrument is divided into 4 parts. Function buttons: to select the display modes and basic settings in the display Tachometer: displays the engine speed Indicator lamps: provide additional information on the motorcycle operating condition Display: shows the speed, cooling liquid temperature, time, ambient temperature, distance traveled (ODO), trip master 1 (TRIP 1), trip master 2 (TRIP 2),...
» OPERATION INSTRUMENTS SPEED [1] The speed can be displayed in kilometers per hour (km/h) or miles per hour (mph). CHANGING THE SPEED DISPLAY FROM KM/H - MPH or MPH - KM/H Switch on the ignition and press the MODE button more than 10 seconds in the ODO mode. CLOCK [2] The dots between the hours and minutes will blink in the CLOCK display.
» OPERATION INSTRUMENTS FROST WARNING [1] The frost symbol will start to blink regardless of the mode if the ambient temperature drops below 3°C (37.5°F). ODO [2] Displays the total kilometers or miles traveled. This figure will not be cleared if the battery is disconnected.
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» OPERATION INSTRUMENTS TRIP 1 [1] The trip meter 1 is always active and counts up to 999.9. It is used to measure the length of the trip or the distance between 2 refueling stops. TO RESET TRIP 1 To reset the trip meter 1 to zero, switch on the ignition, select the TRIP 1 display mode and press the SET button more than 2 seconds.
» OPERATION INSTRUMENTS Cooling liquid temperature display The temperature display [1] is shown in 12 bars. The more bars that light up, the hotter the heiß / hot / caldo / chaud / caliente cooling liquid. When the upper bar lights up 120°C (248°F), all of the bars will start to blink and the red warning lamp [2] will light up.
The error can be identified by means of a blink code (see Trouble shoot- ing). The red warning lamp will light up if the voltage in the on-board electrics drops below 10 volts. Immediately drive to the nearest authorized KTM workshop and have the electrical system checked.
» 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 and firmly press it into the lock.
» OPERATION INSTRUMENTS Starter tip switch, Emergency OFF 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).
» OPERATION INSTRUMENTS Seat lock, removing the seat The seat lock [1] can be locked with the ignition key. To 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. To mount the seat, place it on the motorcycle and position the hooks [2] on the bottom of the seat behind the dollies [3] on the subframe.
» OPERATION INSTRUMENTS 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. To secure, remove the seat, run the rope through the helmet, attach both ends to the hook [3] and mount the seat.
» 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 [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.
» OPERATION INSTRUMENTS 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 adjusted.
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» 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 [1] is located on the bottom of the shock absorber. More information is provided in the chapter "Adjusting the fork and shock absorber.“...
1000 km, you may push it to its 9500 ized KTM workshop. The DELIVERY CER- is overheated. rpm limit , i.e. up to the orange zone indi- TIFICATE and SERVICE MANUAL will –...
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240 KPH (speed symbol ZR) and – Never leave your motorcycle without super- the braking distance; adapt your driving must be released by KTM. vision if the engine is running. speed accordingly. – New tires have a smooth surface, which –...
Arrange for the braking system to be checked by a KTM specialist, as com- plete failure of the braking system can be avoided.
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» DRIVING INSTRUCTIONS 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.
If the engine is not switched off, engine damage will occur within a short period of time. Check the engine oil level or contact a ktm workshop. – Maximum period for continuous starting: 5 seconds. Wait at least 5 seconds before try- ing again.
Let clutch lever go again ceed as described in the „Trouble- and carefully open throttle. Do not shift gears shooting“ section or contact a KTM and accelerate carefully in curves. dealer. Only accelerate to the extent that road and weather conditions allow.
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Check the engine oil level or con- SCALDING HAZARD! Do not drive on, trol of your motorcycle. tact an authorized KTM workshop. until there is sufficient liquid in the col- – The frost symbol * in the combined instru- –...
First, the brakes the braking effect. In extreme cases, the looked over by a KTM dealer. must be braked clean. entire braking system can fail. – Remember that the stopping distance –...
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» DRIVING INSTRUCTIONS Fuel In the condition at delivery, the LC8 engine requires unleaded fuel with at least RON 95 (USA = Premium PON 91, see technical specifications – engine). After refueling, it will take approx. 3 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.
Clean the oil jet for the clutch lubrication 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...
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» PERIODIC MAINTENANCE SCHEDULE 1st Service every every after 990 SUPER DUKE / R 2008 7500 km 15000 km 1000 km A clean motorcycle can be checked more quickly which saves money! once a year every 2 years 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 Check the oil level in the hydraulic clutch reservoir...
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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 / R 2008...
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» PERIODIC MAINTENANCE SCHEDULE 990 SUPER DUKE / R 2008 VITAL CHECKS AND CARE PROCEDURES TO CONDUCTED BY THE OWNER OR THE MECHANIC before after every each start every cleaning 1000 km Check oil level Check brake fluid level Check brake pads for wear Check lighting system for proper operation Check horn for proper operation Lubricate actuating cables and nipples...
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– 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.
» MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting the fork and shock absorber Super Duke Super Duke R There are a number of ways to adjust the fork and shock absorber to match the chassis to your driving style and the payload. BASIC SETTING We have provided a table with pragmatical values to help you tune up your motorcycle.
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» MAINTENANCE WORK ON CHASSIS AND ENGINE 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). Turning in a clockwise direction will increase the preload, turning in a counterclockwise direc- tion will decrease the preload.
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» MAINTENANCE WORK ON CHASSIS AND ENGINE STANDARD ADJUSTMENT LOW-SPEED: – Turn adjusting screw [1] 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 tightening torque corrected by a KTM dealer as soon as possible. A loose axle may lead to an unstable driving behavior of your motorcycle.
– 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. – Never mount a normal chain joint.
Brake pads available in the accessory trade are often not authorized for operation of your KTM motorcycle in road traffic. The brake pads design and friction 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 original equipment, it cannot be warranted that they are authorized for use in road traffic.
DOT 4 brake fluid. Do not, in any event, use DOT 5 brake fluid. It is based on silicone oil and is dyed purple. KTM motorcycle gaskets and brake hoses are not designed for DOT 5 brake fluid.
– If the brake fluid level drops below the minimum either the brake system has a leak or the brake pads are completely worn down. In this case, consult an authorized KTM dealer immediately.
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» MAINTENANCE WORK ON CHASSIS AND ENGINE Checking the front brake pads The brake pads can be inspected from the rear. The linings must be at least 1 mm (0.04 min. in) thick. 1 mm At their most worn point brake pad linings should not be thinner than 1 mm, otherwise they could lead to brake failure.
– If the brake fluid level drops below the minimum either the brake system has a leak or the brake pads are completely worn down. In this case, consult an authorized KTM dealer immediately.
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» MAINTENANCE WORK ON CHASSIS AND ENGINE Changing the seat height (Super Duke R) The seat height of the mono-seat can be raised by 7 or 15 mm (0.3 or 0.6 in). The parts required are supplied with the bike. Remove the seat and the screws [B].
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, then the front stand. Make sure the stands rest on solid ground and are correctly mounted.
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– If you do not have a torque wrench to mount the wheel, have the torques corrected by an authorized KTM workshop as soon as possible. A loose wheel spindle can cause the motorcycle's handling performance to become instable and cause it to crash.
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 tighten- ing torque corrected by a KTM dealer as soon as possible. A loose wheel spindle may lead to an unstable driving behavior of your motorcycle.
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– Do not mount tires which have not been on wet surfaces. roughened. Tires will not display their full approved by KTM. Other tires could have – If air pressure is too low, abnormal wear grip characteristics until they are properly adverse effects on the way your motorcy- and overheating of the tire can result.
» MAINTENANCE WORK ON CHASSIS AND ENGINE 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.
To charge the battery while mounted, always use the KTM battery charger (Item no. 58429074000) to ensure that the electric system is not damaged by excess voltage. Always remove the battery if using other battery chargers! You can also use this charging device to test the off-load voltage and startability of the battery and generator.
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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 equivalent fuse. Visit an authorized KTM workshop if a new fuse blows again after it is inserted.
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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”.
» MAINTENANCE WORK ON CHASSIS AND ENGINE 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 absolutely free from grease.
» MAINTENANCE WORK ON CHASSIS AND ENGINE USA design: The parking light [E] is located in the upper part of the headlight in the USA design. Bulb [F] (see Technical specifications – Chassis / Lighting) with high and low beams is mounted in the lower part of the headlight.
» MAINTENANCE WORK ON CHASSIS AND ENGINE Replacing the brake light and taillight bulbs NOTE: Only mount red light bulbs in a smoked brake tail light. Remove the seat. BULB FOR BRAKE LIGHT: Turn the bulb socket [1] approx. 30° in a counterclockwise direction and pull it out of the taillight housing.
If the fan is not working, and there appears to be sufficient cool- ing liquid, the only thing you can do is to drive on to your nearest authorized KTM work- shop at the least possible engine load.
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, allow- ing any excess pressure to escape (danger of scalding).
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» MAINTENANCE WORK ON CHASSIS AND ENGINE Remove the bleeder screw [5] 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.
If necessary, add SAE 10 biodegradable hydraulic oil (Motorex clutch fluid 75), available from your authorized 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.
» MAINTENANCE WORK ON CHASSIS AND ENGINE How to change the handlebar position (Super Duke R) The upper triple clamp includes 2 bores arranged at a distance of 15 mm (0.6 in) from one another. Accordingly, you can mount the handlebar in 2 different positions. The steering angle is reduced if the handlebar is mounted in the rear position.
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 [1] by removing the screws [2]. Also remove the screws [3] and take off the spoiler. Unscrew the plug [4] 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.
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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.
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» MAINTENANCE WORK ON CHASSIS AND ENGINE 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.
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O-ring. Tighten the screws to 6 Nm. Only use original ktm oil filters. The engine can be damaged if other filters are used. Mount the oil drain plug on the oil tank with a new seal ring and tighten to 20 Nm.
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» MAINTENANCE WORK ON CHASSIS AND ENGINE Remove the right spoiler (see Refilling the engine oil) and unscrew the plug [6]. Add 2.5 liters (0.7 USgal) of fully synthetic engine oil meeting the JASO MA standard (e.g. Motorex Power Synt 4T) and remount the plug. Start the engine and allow to run warm in neutral until 4 bars on the temperature indicator light up.
If you have your motorcycle serviced as set forth in this manual, no malfunctioning is to be expected. Nevertheless, if an error does arise, we recommend that you look for the error according to the following chart. Please note that you cannot perform all of the work yourself. If you are not sure, contact your KTM dealer. TROUBLE...
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Error in the injection system Visit an authorized KTM workshop Engine will not reach full power Air filter/fuel filter heavily soiled Have the air filter/fuel filter replaced at an authorized KTM workshop Error in the injection system Visit an authorized KTM workshop...
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Engine overheats Blown fan fuse Replace fuse 5 Defect fan or thermoswitch for fan Contact an authorized KTM workshop. Air in the cooling system Bleed the cooling system (see Maintenance work) FI lamp is blinking / lights up Error in the injection system...
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Blown fuse Replace fuse 3 bined instrument display. The speed indication on the Pickup cable is damaged or con- Check the pickup cable for damage, visit an authorized KTM combined instrument is not tacts on the cable connector have workshop working oxidized The blink code indicates which component is affected by an error.
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» 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 ERROR DESCRIPTION ENGINE Coolant temperature sensor Output signal too low /high Continues to run Air temperature sensor Output signal too low /high...
» CLEANING 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 washer or a strong water jet, otherwise the pressure will allow water to enter the electric compo- nents, plugs, cables, bearings, etc.
» STORAGE 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). –...
..........12V PR21W (socket BAW15s) ..Super Duke R: LED USA: stoplight ........12V 21W (socket BA15s) ....Super Duke R: LED flashers ..........12V RY10W (socket BAU15s) licens plate illumination ......12V 5W (socket W2,1x9,5d) * further tire releases are available on the Internet at www.ktm.com...
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» TECHNICAL SPECIFICATIONS – CHASSIS CHASSIS 990 SUPER DUKE / R 2008 Battery maintenance-free battery 12V 11.2 Ah Steering head angle Super Duke: 66.1° Super Duke R: 67.3° Wheel base 1450 ± 10 mm (57 ± 0.4 in) Seat height, unloaded Super Duke: 850 mm (33.5 in) Super Duke R: 860 mm (33.9 in) Ground clearance, unloaded...
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» TECHNICAL SPECIFICATIONS – CHASSIS TIGHTENING TORQUES – CHASSIS 2008 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...
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» TECHNICAL SPECIFICATIONS – CHASSIS TIGHTENING TORQUES – CHASSIS 2008 AH bolts for side stand bracket - engine Loctite 243 + 45 Nm HH bolts for side stand fixture - side stand bracket Loctite 243 + 25 Nm HH bolts for side stand mounting Loctite 243 + 35 Nm HH bolt for spring rest on side stand Loctite 243 + 25 Nm...
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» TECHNICAL SPECIFICATIONS – CHASSIS TIGHTENING TORQUES – CHASSIS 2008 Other bolts on chassis 10 Nm 25 Nm 45 Nm Other collar nuts on chassis 15 Nm 30 Nm 50 Nm...
» TECHNICAL SPECIFICATIONS – ENGINE ENGINE 990 SUPER DUKE 2008 990 SUPER DUKE R 2008 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...
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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).
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....44 General information on KTM disk brakes ....42 Checking the front brake pads .
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» HEAD WORD INDEX Holding strap ........17 Starting the engine .
NOISE EMISSION WARRANTY KTM Sportmotorcycle AG warrants that this exhaust system, at the time of sale, meets all applicable U.S. EPA Federal noise standards. This warranty extends to the first per- son who buys this exhaust system for purposes other than resale, and to all subsequent buyers.
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» CONSUMER INFORMATION FOR USA ONLY Sticker positions: 3 4 5...
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» CONSUMER INFORMATION FOR USA ONLY [1] EAVP [3] Suspension setting Super Duke [3] Suspension setting Super Duke R [4] Chain tension [6] Noise emission [5] Technical information [2] Type label CAN [7] Vehicle emission [8] Before you go for the first ride [9] Type label USA...
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3211249en 3211249en 11/2007 FOTO: MITTERBAUER KTM Group Partner KTM Sportmotorcycle AG A–5230 Mattighofen www.ktm.at...
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