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Summary of Contents for KTM Super Duke 990s
- Page 1 BEDIENUNGSANLEITUNG2005 990 SUPER DUKE OWNER’S MANUAL MANUALE D’USO MANUEL D’UTILISATION MANUAL DE INSTRUCCIONES ART. NR. 3.211.57...
- Page 2 KTM may stop manufacturing cer- tain models without previous notice. KTM shall not be held liable for any deviations of availability and/or ability to deliver, illustrations, descriptions, printing and/or other errors. The illustrated models partly con- tain extra equipment, which is not applied to standard models.
- Page 3 Take special care to follow the recommended run in, inspection, and maintenance intervals. Heeding these guidelines will significantly increase the life of your motorcycle. To ensure that all work to your KTM is performed properly and to avoid warranty conflicts, KTM recommends that you always have your KTM serviced by a recognized and qualified KTM dealer.
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Page 4: Important Limited Warranty And Limited Guarantee Information
The service work described in the "Lubrication and maintenance chart" must be carried out by an author- ized KTM workshop and confirmed in the service manual, otherwise your warranty will become void. The fuels and lubricants specified in the owner's manual or those of an equal quality must be used in accordance with the maintenance schedule. -
Page 5: Table Of Contents
GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE ......14 Instructions for initial operation ....14 Running in the LC8 engine . -
Page 6: Serial Number Locations
SERIAL NUMBER LOCATIONS OPERATION INSTRUMENTS » Chassis number, Type label The chassis number is stamped on the right side of the steering head tube. Enter this number in the field on page no 1. 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. -
Page 7: Multi-Functional Digital Speedometer
Display [2] shows all of the information that may be of interest to you. 5 dis- play modes can be selected with the MODE button. The indicator lamps [3] provide additional information on the motorcycle's running condition. Display... -
Page 8: Resetting Trip 2 Clock
OPERATION INSTRUMENTS 10 sec » Setting options in the display KILOMETERS OR MILES. You can have the speed and distance shown in kilometers or miles in the dis- play. The display can be adapted to the respective country on long-distance trips. -
Page 9: Cooling Liquid Temperature Display
OPERATION INSTRUMENTS 120°C (248°F) 110°C (230°F) 100°C (212°F) 70°C (158°F) 60°C (140°F) 50°C (122°F) 40°C (104°F) » Cooling liquid temperature display The temperature display [1] is shown in 7 bars. The more bars that light up, the hotter the cooling liquid. When the lowest bar lights up, the cooling liq- uid has reached a temperature of approx. -
Page 10: Ignition Lock
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 and firmly press it into the lock. Turn the handlebar all the way to the left, then turn the ignition key to the left. -
Page 11: Filler Cap
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 [3] on the bottom of the seat behind the dollies [4] on the subframe. Press down on the seat near the holding strap while sliding it forwards. -
Page 12: Helmet Lock
Fold the side stand [4] forward to the stop with your foot and put the weight of the motorcycle on the stand. Make sure it is standing securely on a firm surface. The side stand is linked to the safety start system; follow the driving instructions. -
Page 13: Footrests
» 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. -
Page 14: Damping Action During Compression Of Shock Absorber
The damping rate can be adjusted in the low and high-speed range (Dual Compression Control). The designation low and high-speed refers to the move- ment of the shock absorber and not to the motorcycle's driving speed. The adjusting screw [1] for the low-speed range can be adjusted with a screwdriver. -
Page 15: General Tips And Warnings For Starting The Motorcycle
– Do not make any alterations to the motorcycle and always use ORIGINAL KTM SPARE PARTS. Spare parts from other man- ufacturers can impair the safety of the motorcycle. – Motorcycles are sensitive to changes in the weight distribu- tion. -
Page 16: Driving Instructions
If the level of brake fluid falls below the minimum value, this indicates a leak in the braking system or completely worn out brake pads. Arrange for the braking system to be checked by a KTM specialist, as com- plete failure of the braking system can be avoided. -
Page 17: Starting The Engine
ENGINE IS RUNNING, IMMEDIATELY SWITCH OFF THE ENGINE. 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 TRYING AGAIN. -
Page 18: Starting Off
Only accelerate to the extent that road and weather conditions allow. Be especially careful when you accelerate in curves. Abrupt open- ing of the throttle can cause the motorcycle to go out of control and also increases fuel consumption. By shifting down, use the brakes if necessary and close throttle at the same time. -
Page 19: Stopping And Parking
Apply the brakes fully and put the engine into neutral. To stop the engine, switch off the ignition. Fold the side stand forward to the stop with your foot, put the weight of the motorcycle on the stand and park the bike on a firm sur- face. Lock the motorcycle. -
Page 21: Periodic Maintenance
Check clutch linings Check clutch pressure booster system Check rubber boot 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... - Page 22 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! IMPORTANT RECOMENDED MAINTENANCE PROCEDURES TO BE PERFORMED BASED ON A SEPARATE SUPPLEMENT ORDER...
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Page 23: Maintenance Work On Chassis And Engine
– DO NOT CLEAN THE MOTORCYCLE WITH A POWER WASHER OTHERWISE WATER WILL GET INTO THE BEARINGS, ELECTRIC SOCKET CON- NECTORS, 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. -
Page 24: Adjusting The Spring Preload On The Fork
(Dual Compression Control). Low and high speed refers to the movement of the shock absorber during com- pression and not to the speed of the motorcycle. The low and high-speed technology overlaps. The low-speed setting is primarily for slow to normal shock absorber compres- sion rates. -
Page 25: Rebound Damping Of Shock Absorber
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 POS- SIBLE. A LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAVIOR OF YOUR MOTORCYCLE. -
Page 26: Chain Maintenance
OF CONTROL. – THE CHAIN DOES NOT HAVE A CHAIN JOINT FOR SAFETY REASONS. ALWAYS HAVE THE CHAIN REPLACED IN AN AUTHORIZED KTM WORKSHOP WHERE THE SERVICE TECHNICANS HAVE THE REQUIRED RIVETING TOOL. – NEVER MOUNT A NORMAL CHAIN JOINT. -
Page 27: General Information On Ktm Disk Brakes
In this case, consult an authorized KTM dealer immediately. BRAKE FLUID: KTM fills the brake systems with Motorex Brake Fluid DOT 5.1 brake fluid, one of the best brake fluids that is currently available. We recommend that you continue to use it. DOT 5.1 brake fluid is based on glycol ether and of an amber color. -
Page 28: Adjusting The Basic Position Of The Hand Brake Lever
SYSTEM HAS A LEAK OR THE BRAKE PADS ARE COMPLETELY WORN DOWN. IN THIS CASE, CONSULT AN AUTHORIZED KTM DEALER IMMEDIATELY. – HAVE THE BRAKE FLUID CHANGED AT AN AUTHORIZED KTM WORKSHOP EVERY 2 YEARS. Refilling front brake fluid * It is not necessary to refill brake fluid under normal conditions (see General information on KTM disk brakes). -
Page 29: Changing The Basic Position Of The Foot Brake Lever
SYSTEM HAS A LEAK OR THE BRAKE PADS ARE COMPLETELY WORN DOWN. IN THIS CASE, CONSULT AN AUTHORIZED KTM DEALER IMMEDIATELY. – HAVE THE BRAKE FLUID CHANGED AT AN AUTHORIZED KTM WORKSHOP EVERY 2 YEARS. Refilling rear brake fluid * It is not necessary to refill brake fluid under normal conditions (see General information on KTM disk brakes). -
Page 30: Dismounting And Remounting The Front Wheel
Finally, tighten the clamping screws on both fork leg axle passages to 15 Nm. – IF YOU DO NOT HAVE A TORQUE WRENCH TO MOUNT THE WHEEL, HAVE THE TORQUES CORRECTED BY AN AUTHORIZED KTM WORKSHOP AS SOON AS POS- SIBLE. A LOOSE AXLE PASSAGE CAN CAUSE THE MOTORCYCLE'S HANDLING PERFORMANCE TO BECOME INSTABLE. -
Page 31: Dismounting And Remounting The Rear Wheel
– IF YOU DON’T HAPPEN TO HAVE A TORQUE WRENCH AT HAND, MAKE SURE YOU HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POSSIBLE. A LOOSE WHEEL SPINDLE MAY LEAD TO AN UNSTABLE DRIV- ING BEHAVIOR OF YOUR MOTORCYCLE. -
Page 32: Tires, Air Pressure
Proper pressure ensures opti- mum driving comfort and extends the life of your tires. – DO NOT MOUNT TIRES WHICH HAVE NOT BEEN APPROVED BY KTM. OTHER TIRES COULD HAVE ADVERSE EFFECTS ON THE WAY YOUR MOTORCYCLE RIDES. -
Page 33: Removing And Remounting The Battery
DESTROY THE RECTIFIER-REGULATOR. Charging the battery Note: a battery charger, item no. 58429074000, is available from your KTM dealer. You can also use the battery charger to test the off load voltage, starta- bility of the battery and the generator capacity. -
Page 34: Main Fuse
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. -
Page 35: Replacing The Headlight Lamp
BULB FOR THE PARKING LIGHT: Since a number of parts need to be removed to replace the parking light bulb, we recommend that you have the lamp replaced at an authorized KTM workshop. Adjusting the headlight range The payload can make it necessary to correct the headlight range. -
Page 36: Replacing The Brake Light And Taillight Bulbs
Replacing the flasher bulbs Remove the screw on the back of the turn signal, carefully fold the lens [3] towards the motorcycle and remove. Turn the cap [4] approx. 15° in a coun- terclockwise direction and remove. Slightly depress the bulb, turn it approx. 30° counterclockwise and pull it out of the socket. -
Page 37: Cooling System
ATURE IS 120°C (248°F) AND THE IGNITION IS ON. IF THE FAN IS NOT WORK- ING, AND THERE APPEARS TO BE SUFFICIENT COOLING LIQUID, THE ONLY THING YOU CAN DO IS TO DRIVE ON TO YOUR NEAREST AUTHORIZED KTM WORKSHOP AT THE LEAST POSSIBLE ENGINE LOAD. -
Page 38: Checking The Cooling Liquid Level In The Radiator
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. -
Page 39: Changing The Basic Position Of The Clutch Lever
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 USE ORIGINAL KTM HYDRAULIC OIL (AVAILABLE FROM YOUR AUTHORIZED KTM WORK- SHOP) TO MAKE SURE YOUR CLUTCH OPERATES SMOOTHLY. -
Page 40: Engine Oil
Only use fully synthetic engine oils that meet the JASO MA quality require- ments (see information on the can). KTM recommends Motorex Power Synt 4T in the 10W/50 viscosity (for tem- peratures over 0°C, 32°F) or 5W/40 (for temperatures under 0°C, 32°F). -
Page 41: Changing The Engine Oil And The Oil Filter, Cleaning The Oil Screen
KTM workshop. During the guaranty period, the oil change must be performed by an author- ized KTM mechanic. Otherwise, the guarantee will become void. The engine oil change is to be carried out when the engine is still warm. - Page 42 Insert a new oil filter [3] in the engine case, grease the O-ring and mount the oil filter cover together with the O-ring. Tighten the screws to 6 Nm. ONLY USE ORIGINAL KTM OIL FILTERS. THE ENGINE CAN BE DAMAGED IF OTHER FILTERS ARE USED.
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Page 43: Troubleshooting
If you have your motorcycle serviced as set forth in this manual, no malfunctioning is to be expected. Nevertheless, if an error does arise, we recommend that you look for the error according to the following chart. Please note that you cannot perform all of the work yourself. If you are not sure, contact your KTM dealer. TROUBLE... - Page 44 Replace fuse CLOCK and set the clock. Recharge the battery according to the relevant instructions. Voltage regulator and generator should be checked by an authorized KTM workshop. Replace fuse HORN BRAKELIGHT SPEEDO. Check the pickup cable for damage, visit an authorized KTM workshop...
- Page 45 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 Pulse generator Throttle sensor Sensor for 2nd throttle valve Intake manifold air pressure for sensor rear cylinder Output signal too low /high Intake manifold air pressure sensor for front cylinder Output signal too low /high Coolant temperature sensor Air temperature sensor...
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Page 46: Cleaning
(e.g. Motorex 900) and cleaned with a brush. – After the motorcycle has been rinsed with a soft water jet, it should be dried by air pressure and a cloth. Then take a short drive until the engine has reached the working temperature and also use the brakes. -
Page 47: Technical Specifications - Chassis
TECHNICAL SPECIFICATIONS – CHASSIS CHASSIS Frame Fork Spring travel front Rear suspension Spring travel rear Front brake Rear brake Tires, front Air pressure Tires, rear Air pressure Fuel tank capacity Gear ratio – rear wheel Chain Lighting Battery Steering head angle Wheel base Seat height, unloaded Ground clearance, unloaded... -
Page 48: Technical Data - Chassis
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES – CHASSIS Collar bolt on front wheel spindle Collar nut wheel spindle rear AH bolt shock absorber top/bottom Collar nut for swing arm bolt AH bolts on subframe AH bolts on back of footrest support Engine carrier bolts HH clamp bolts on top triple clamp HH clamp bolts on bottom triple clamp... -
Page 49: Technical Specifications - Engine
TECHNICAL SPECIFICATIONS – ENGINE ENGINE Design Displacement Bore / Stroke Compression ratio Fuel Valve timing Valve diameter Valve clearance, cold Crankcase bearing Conrod bearing Piston pin bearing Piston Piston rings Engine lubrication Engine oil Quantity of engine oil Primary drive Clutch Transmission Gear ratio... -
Page 50: Head Word Index
Fuel ........18 Fuses for individual power consumers General information on KTM disk brakes General tips and warnings for starting the motorcycle .14 Hand brake lever . - Page 52 KTM Group Partner KTM-Sportmotorcycle AG A–5230 Mattighofen www.ktm.at...
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