KTM 2010 990 Super Duke Owner's Manual
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KTM 2010 990 Super Duke Owner's Manual

KTM 2010 990 Super Duke Owner's Manual

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OWNER'S MANUAL
2010
990 Super Duke EU
990 Super Duke AUS/UK
990 Super Duke FR
990 Super Duke R EU
990 Super Duke R AUS/UK
990 Super Duke R FR
Art. no. 3211522en

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Summary of Contents for KTM 2010 990 Super Duke

  • Page 1 OWNER'S MANUAL 2010 990 Super Duke EU 990 Super Duke AUS/UK 990 Super Duke FR 990 Super Duke R EU 990 Super Duke R AUS/UK 990 Super Duke R FR Art. no. 3211522en...
  • Page 3 KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as misprints and other errors.
  • Page 4 Reproduction, even in part, as well as copying of all kinds, 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 Setting kilometers or miles ..........27 TABLE OF CONTENTS MEANS OF REPRESENTATION ..........7 Combination instrument - time .......... 28 IMPORTANT INFORMATION ........... 8 Setting the clock .............. 28 VIEW OF VEHICLE..............12 Combination instrument - ODO display ....... 29 View of vehicle, front left side (vehicle differs slightly from photo) ................
  • Page 6 TABLE OF CONTENTS Starting ................47 Checking the chain for dirt ..........75 Starting up ..............48 Cleaning the chain............76 Shifting, riding ..............49 Checking the chain tension ..........77 Braking ................52 Adjusting the chain tension ..........78 Stopping, parking .............
  • Page 7 TABLE OF CONTENTS Removing the spoiler ............106 Draining the engine oil and filter, cleaning the oil screens ..............143 Installing the spoiler ............107 Filling up with engine oil ..........147 Removing the battery ..........109 Adding engine oil ............149 Installing the battery ..........
  • Page 8 TABLE OF CONTENTS AUXILIARY SUBSTANCES........... 188 STANDARDS..............190 INDEX ................191...

  • 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 by 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 by 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...
  • 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 Note Fire hazard Some vehicle components become very hot when the vehicle is operated. – Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from being run.
  • 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) B00152-10...
  • Page 15 VIEW OF VEHICLE Combination instrument Rear mirror Clutch lever Filler cap Seat Compression damping of the shock absorber Shock absorber spring preload Shift lever Engine number Oil rising pipe...

  • 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) B00151-10...
  • Page 17 VIEW OF VEHICLE Seat lock Light switch, headlight flasher switch, turn signal switch, horn button Emergency OFF switch, electric starter button Hand brake lever Fork spring preload, fork rebound damping Chassis number Fork compression damping Type label Foot brake lever Brake fluid reservoir Shock absorber rebound damping...

  • Page 18: Location Of Serial Numbers

    LOCATION OF SERIAL NUMBERS Chassis number/type label Chassis number is embossed in the steering head at the right.  Type label is located on the upper frame tube on the right.  B00153-10...

  • Page 19: Key Number

    LOCATION OF SERIAL NUMBERS Key number Key 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. 100179-10 Engine number The engine number is stamped on the left side of the engine under the engine sprocket. ...

  • 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.  B00155-10 Shock absorber part number The shock absorber part number is stamped on the top of the shock absorber above the ...

  • 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. B00157-10 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 Left turn signal on – The turn signal switch is pressed to the left. The turn signal switch automatically returns to the central position after use. Right turn signal on –...

  • Page 24: Ignition/Steering Lock

    CONTROLS Ignition/steering lock The ignition/steering lock is in front of the upper triple clamp. Possible states Ignition OFF – In this position, the ignition circuit is interrupted, a running engine stops, and a non-running engine will not start. The ignition key can be removed.

  • Page 25: Electric Starter Button

    CONTROLS Electric starter button The electric starter button is fitted on the right side of the handlebar.  Possible states • Electric starter button in basic position pressed – The electric starter is actuated in this position. • Electric starter button 700552-11 Combination instrument 5.10...

  • Page 26: Combination Instrument - Function Buttons

    CONTROLS Combination instrument - function buttons 5.11 You can change the display mode with the MODE button  Possible display modes are the distance traveled (ODO), trip master 1 (TRIP 1), trip mas- ter 2 (TRIP 2) and the ambient temperature. Press the SET button to reset the trip master 1 function (TRIP 1) and trip master 2 func- ...

  • Page 27: Combination Instrument - Indicator Lamps

    CONTROLS Combination instrument - indicator lamps 5.13 The indicator lamps offer additional information about the operating state of the motorcy- cle. Possible states The turn signal indicator lamp flashes green simultaneously with the turn signal – The turn signal is switched on. The idle speed indicator lamp lights up green –...

  • Page 28: Combination Instrument - Display

    CONTROLS Combination instrument - display 5.14 When you switch on the ignition, all display segments light up for one second as a function test. 400892-01 LEnGth Following the display function test, the LEnGth wheel circumference is shown for one sec- ond.

  • Page 29: Combination Instrument - Speedometer

    CONTROLS Combination instrument - speedometer 5.15 The speed is shown in kilometers per hour km/h or in miles per hour mph.  400838-10 Setting kilometers or miles 5.16 Info If you change the unit, the value ODO is retained and converted accordingly. Making the setting according to the country.

  • Page 30: Combination Instrument - Time

    CONTROLS – Switch on the ignition by turning the ignition key to the ON position. – 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: Combination Instrument - Odo Display

    CONTROLS – Switch on the ignition by turning the ignition key to the ON position. – 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 2

    CONTROLS – Switch on the ignition by turning the ignition key to the ON position. – Press the MODE button repeatedly until the TRIP 1 mode is active. – Keep the SET button pressed. The TRIP 1 display is set to 0.0. 400840-01 Combination instrument - setting/resetting TRIP 2 5.21...

  • Page 33: Combination Instrument - Trip F Display

    CONTROLS Combination instrument - TRIP F display 5.22 If the fuel level drops to the reserve mark, the display automatically changes to TRIP F and starts to count from 0.0, regardless of the previous display mode. Info Parallel to the TRIP F display, the fuel warning light switches on. 400842-01 Combination instrument - ambient temperature display 5.23...

  • Page 34: Setting The Temperature Units

    CONTROLS Setting the temperature units 5.24 Condition The motorcycle is stationary. – Switch on the ignition by turning the ignition key to the ON position. – Press the MODE button repeatedly until the ambient temperature is active. – Keep the MODE button pressed until the display mode changes from °C to °F or from °F to °C.

  • Page 35: Combination Instrument - Coolant Temperature Indicator

    CONTROLS Combination instrument - coolant temperature indicator 5.26 The temperature display consists of 12 bars. The more bars that light up, the hotter the coolant. When the upper bar lights up, all bars in the display begin to flash and the temper- ature warning lamp lights up.

  • Page 36: Opening The Filler Cap

    CONTROLS Opening the filler cap 5.27 – 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 37: Closing The Filler Cap

    CONTROLS Closing the filler cap 5.28 Warning Fire hazard Fuel is highly flammable, poisonous and harmful to your health. – When closing the filler cap, ensure that it is closed correctly. Change cloth- ing that came into contact with fuel. Immediately clean skin that came into contact with fuel using soap and water.

  • Page 38: Seat Lock (Super Duke)

    CONTROLS Seat lock (Super Duke) 5.29 Seat lock is located at the rear of the seat.  It can be locked with the ignition key. B00165-10 Seat lock (Super Duke R) 5.30 The seat lock is behind the seat.  It can be locked with the ignition key.

  • Page 39: Supporting Strap (Super Duke)

    CONTROLS Supporting strap (Super Duke) 5.31 Supporting strap is mounted on the seat.  The supporting strap is provided for the passenger to hold on to. B00164-10 Baggage lugs (Super Duke) 5.32 Baggage lugs are located on the underside of the seat. ...

  • Page 40: Tool Set

    CONTROLS Tool set 5.33 The tool set is located in the storage compartment under the seat.  B00166-10 Helmet lock 5.34 Warning Danger of accidents Impairment of ride behavior and vehicle operation if a helmet or helmet lock is attached to the vehicle. –...

  • Page 41: Passenger Footrests (Super Duke)

    CONTROLS Passenger footrests (Super Duke) 5.35 The passenger footrests can be folded up and down. Possible states Passenger footrests folded up – For operation without a passenger. • Passenger footrests folded down – For operation with a passenger. • B00167-01 Shift lever 5.36 Shift lever...

  • Page 42: Foot Brake Lever

    CONTROLS The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gear.  B00169-11 Foot brake lever 5.37 Foot brake lever is located in front of the right footrest.  The rear brake is activated using the foot brake lever.

  • Page 43: Side Stand

    CONTROLS Side stand 5.38 Side stand is coupled with the safety start system; see the riding instructions.  Possible states Side stand folded out – The vehicle can be leaned on the side stand. The safety start • system is active. Side stand folded in –...

  • Page 44: Tips 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 45: Running In The Engine

    TIPS ON PUTTING INTO OPERATION – 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. – Before your first trip, read the entire operating instructions carefully.
  • Page 46 TIPS ON PUTTING INTO OPERATION Warning Danger of accidents Unstable handling characteristics due to incorrect mounting of suitcase and/or tank rucksack. – Mount and secure suitcase and tank rucksack according to the manufacturer's instructions. Warning Danger of accidents Unstable handling characteristics at high speed. –...
  • Page 47 TIPS ON PUTTING INTO OPERATION – If you are carrying baggage, make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight distri- bution between the front and rear wheels. – Do not exceed the maximum permissible total weight and the axle loads.

  • Page 48: 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 49: 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 50: Starting Up

    RIDING INSTRUCTIONS – Press the emergency OFF switch into the position – Switch on the ignition by turning the ignition key to the ON position. After you switch on the ignition, you can hear the fuel pump working for about two seconds.

  • Page 51: Shifting, Riding

    RIDING INSTRUCTIONS Shifting, riding Warning Danger of accidents Abrupt load alterations can cause the vehicle to get out of control. – Avoid abrupt load alterations and sudden braking actions, and adapt your speed to the road conditions. Warning Danger of accidents If you change down at high engine speed, the rear wheel can lock up. –...
  • Page 52 RIDING INSTRUCTIONS Warning Danger of accidents Reduced road grip with cold tires. – On every journey, take the first miles carefully at moderate speed until the tires reach operating temperature and optimal road grip is ensured. Warning Danger of accidents Reduced road grip with new tires. –...
  • Page 53 Info If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized KTM workshop. – When conditions allow (incline, road situation, etc.), you can shift into a higher gear.

  • Page 54: 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 55: Stopping, Parking

    RIDING INSTRUCTIONS Warning Danger of accidents Longer stopping distance due to higher overall weight. – Take the longer stopping distance into account when carrying a passenger and baggage. Warning Danger of accidents Delayed brake action on salted roads. – There may be salt deposits on the brake discs. In order to restore the normal braking efficiency, you will need to remove the deposits from the discs by carefully applying the brakes.
  • Page 56 RIDING INSTRUCTIONS – Always place the vehicle on a firm and even surface. Note Fire hazard Some vehicle components become very hot when the vehicle is operated. – Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from being run.

  • Page 57: 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 58 RIDING INSTRUCTIONS – Switch off the engine. – Open the filler cap. ( p. 34) – Fill the fuel tank with fuel up to the lower edge of the fuel filler.  Total fuel tank 18.5 l Super unleaded (ROZ 95 / RON 95 / capacity, approx.

  • Page 59: 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. 142) • •...
  • Page 60 Final inspection: Check the vehicle of roadworthiness and take a test ride. • • • • Read out the fault memory after a test ride using the KTM diagnostics tool. • • • • Make the service entries in the KTM DEALER.NET and service record.
  • Page 61 SERVICE SCHEDULE K10N: Once after 1,000 km (621.4 mi) K75A: Every 7,500 km (4,660 mi) or annually K150A: Every 15,000 km (12,428 mi), every 2 years or after every sporting use K300A: Every 30,000 km (18,641 mi) or every 4 years...

  • Page 62: Maintenance Work On Frame And Engine

    MAINTENANCE WORK ON FRAME AND ENGINE Jacking up motorcycle at the front Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Jack up the motorcycle at the rear. ( p.

  • Page 63: Jacking Up Motorcycle At The Rear

    MAINTENANCE WORK ON FRAME AND ENGINE Jacking up motorcycle at the rear Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Insert the work stand adapter in the rear of the work stand. Work stand adapter (61029055120) Work stand rear (61029055100) –...

  • Page 64: Fork/Shock Absorber

    MAINTENANCE WORK ON FRAME AND ENGINE Fork/shock absorber The fork and the shock absorber offer many options of adapting the suspension to your rid- ing style and the payload. Info To help you adapt the vehicle, we have summarized our findings in Table .
  • Page 65 MAINTENANCE WORK ON FRAME AND ENGINE – Turn adjusting screws clockwise all the way.  Info The adjusting screws are located at the bottom end of the fork legs. Make the same adjustment on both fork legs. – Turn back counterclockwise by the number of clicks corresponding to the fork type. Guideline (Super Duke) Compression damping...

  • Page 66: Adjusting The Rebound Damping Of The Fork

    MAINTENANCE WORK ON FRAME AND ENGINE Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork rebound behavior. An optimally adjusted rebound damping brakes the springing energy and enables a fast, vibration-free resetting of the fork to the zero position.

  • Page 67: Adjusting The Spring Preload Of The Fork

    MAINTENANCE WORK ON FRAME AND ENGINE Info Turn clockwise to increase damping; turn counterclockwise to reduce damping. Adjusting the spring preload of the fork Info Spring preload determines the initial fork position. The best spring preload setting is achieved when it is set for the weight of the rider and that of any baggage and a passenger, thus ensuring an ideal compromise between maneuverability and stability.

  • Page 68: Bleeding The Fork Legs

    MAINTENANCE WORK ON FRAME AND ENGINE (Super Duke R) Spring preload - Preload Adjuster Comfort 5 turns Standard 5 turns Sport 5 turns Info Turn clockwise to increase preload, turn counterclockwise to reduce spring preload. Changing the spring preload has no influence on the rebound damping although the adjusting screws turn during the adjustment work.

  • Page 69: 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 low-speed setting can be seen during the slow to normal compression of the shock absorber.
  • Page 70 MAINTENANCE WORK ON FRAME AND ENGINE – Turn adjusting screw clockwise with a screwdriver 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.

  • Page 71: 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 72: Adjusting The Rebound Damping 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 adjusting screw clockwise up to the last perceptible click.

  • Page 73: Adjusting The Spring Preload Of The Shock Absorber

    MAINTENANCE WORK ON FRAME AND ENGINE (Super Duke R) Rebound damping Comfort 12 clicks Standard 10 clicks Sport 8 clicks Info Turn clockwise to increase damping; turn counterclockwise to reduce damping. Adjusting the spring preload of the shock absorber 9.14 Warning Danger of accidents Modifications to the suspension settings can seriously alter the vehicle's ride behavior.
  • Page 74 MAINTENANCE WORK ON FRAME AND ENGINE – Loosen locking ring  – Turn adjusting ring until the spring is no longer under tension.  Hook wrench (T106S) – Measure the overall spring length without a load. – Tension the spring by turning adjusting ring to the prescribed value.

  • Page 75: Steering Damper (Super Duke R)

    MAINTENANCE WORK ON FRAME AND ENGINE Steering damper (Super Duke R) 9.15 The steering damper suppresses shocks to the steering arising from acceleration on uneven ground at high speed or when the load is temporarily taken from the front wheel. The steering damper is adjusted to suit the riding style and the road conditions.

  • Page 76: Handlebar Position (Super Duke R)

    MAINTENANCE WORK ON FRAME AND ENGINE Info Do not change the adjustment of the steering damper during the journey! After adjusting the steering damper, check the steering for smooth operation, making sure that the handlebar can be moved from extreme left to extreme right without a tendency to lock.

  • Page 77: Checking The Chain For Dirt

    MAINTENANCE WORK ON FRAME AND ENGINE Guideline Screw, handlebar support 45 Nm (33.2 lbf ft) Info Position the handlebar supports evenly on the left and right. – Position the handlebar. Info Ensure that the cables and lines are routed correctly. –...

  • Page 78: Cleaning The Chain

    MAINTENANCE WORK ON FRAME AND ENGINE Cleaning the chain 9.20 Warning Danger of accidents Oil or grease on the tires reduces their grip. – Remove oil and grease with a suitable cleaning material. Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. –...

  • Page 79: Checking The Chain Tension

    MAINTENANCE WORK ON FRAME AND ENGINE Checking the chain tension 9.21 Warning Danger of accidents Danger caused by incorrect chain tension. – If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bearings in transmission and rear wheel) are under additional load.

  • Page 80: Adjusting The Chain Tension

    MAINTENANCE WORK ON FRAME AND ENGINE Adjusting the chain tension 9.22 Warning Danger of accidents Danger caused by incorrect chain tension. – If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bearings in transmission and rear wheel) are under additional load.
  • Page 81 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 7 mm (0.28 in) Turn adjusting screws on the left and right so that the markings on the left and ...

  • Page 82: Checking The Chain, Rear Sprocket And Engine Sprocket

    MAINTENANCE WORK ON FRAME AND ENGINE Checking the chain, rear sprocket and engine sprocket 9.23 – Check the rear sprocket and engine sprocket for wear. » If the rear sprocket or engine sprocket is worn: – Replace the rear sprocket or engine sprocket. Info The rear sprocket, engine sprocket and chain should always be changed together.
  • Page 83 MAINTENANCE WORK ON FRAME AND ENGINE – Shift into neutral, and pull the lower chain section with the specified weight  Guideline Weight, chain wear measurement 15 kg (33 lb.) – Measure the distance of 18 chain links in the lower chain section. ...

  • Page 84: Checking The Front 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 brake disc in several places to see if it conforms to measure- ment ...

  • Page 85: Checking The Rear Brake Disc

    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 brake disc in several places to see if it conforms to measure- ment ...

  • Page 86: Adjusting The Basic Position Of The Hand Brake Lever

    (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 87: 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 88: Brake Linings

    Clean up overflowed or spilt brake fluid immediately with water. Brake linings 9.29 The brake linings fitted by KTM have been tested over long periods and guarantee optimal braking characteristics. The type names of the brake linings are entered in the homologation documents.

  • Page 89: Checking The Front Brake Linings

    Brake linings available in accessories shops are often untested and unapproved for use on KTM vehicles. The structure and friction coefficient of the brake linings, and therefore the brake power, can vary considerably from the original KTM brake linings. If brake linings other than those supplied as originals are used, there is no guarantee that they correspond to the original homologation.

  • Page 90: Checking The Rear Brake Fluid Level

    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.) – Stand the vehicle upright.
  • Page 91 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.) Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 92: Checking The Rear Brake Linings

    9.33 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 93: 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 94: Installing The Front Wheel

    MAINTENANCE WORK ON FRAME AND ENGINE – Loosen screws   – Unscrew screw about six turns and press your hand on the screw to push the wheel  spindle out of the fork stub. Remove screw  Warning Danger of accidents Reduced braking efficiency caused by damaged brake discs.
  • Page 95 MAINTENANCE WORK ON FRAME AND ENGINE – Check the wheel bearing for damage and wear. » If the wheel bearing is broken or worn: – Replace the wheel bearing. – Grease and mount the left and right spacers and the shaft seal rings. Long-life grease ( p.

  • Page 96: Removing The Rear Wheel

    MAINTENANCE WORK ON FRAME AND ENGINE Guideline Screw, front brake caliper M10x1.25 45 Nm Loctite ® 243™ (33.2 lbf ft) – Remove the fixation of the hand brake lever. – Take the front from the work stand. ( p. 60) –...

  • Page 97: Installing The Rear Wheel

    MAINTENANCE WORK ON FRAME AND ENGINE – Push the rear wheel forward as far as possible and take the chain off the rear sprocket. – Withdraw the wheel spindle. – Pull the rear wheel backward until the brake caliper support hangs free between the brake disc and the wheel rim.
  • Page 98 MAINTENANCE WORK ON FRAME AND ENGINE – Check the wheel bearing for damage and wear. » If the wheel bearing is broken or worn: – Replace the wheel bearing. – Remove bushing and bushing . Clean and grease the roll surfaces of the bushing ...

  • Page 99: Checking Rear Hub Shock Absorbers

    MAINTENANCE WORK ON FRAME AND ENGINE – Engage the counter bearing of the brake caliper support and swingarm. Lay the chain  on the rear sprocket and mount the wheel spindle. – Mount chain adjuster and nut   Info Mount the left and right chain adjusters in the same position.

  • Page 100: 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.
  • Page 101 MAINTENANCE WORK ON FRAME AND ENGINE Warning Danger of accidents Reduced road grip with new tires. – New tires have a smooth rolling surface and therefore cannot provide full road grip. The entire rolling surface must be rough- ened in the first 200 kilometers (124.3 miles) by moderate riding at alternating angles. The full grip levels are not achieved until the tires have been run in.

  • Page 102: 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 be changed after 5 years at the latest, regard- less of the actual state of wear.

  • Page 103: Removing The Front Spoiler

    MAINTENANCE WORK ON FRAME AND ENGINE – Mount the dust cap. Info The rubber seal in the dust cap prevents air from leaking out of the tire if the valve is faulty. Removing the front spoiler 9.41 – Remove screws with the washer.

  • Page 104: Removing The Seat

    MAINTENANCE WORK ON FRAME AND ENGINE Removing the seat 9.43 (Super Duke) – Insert the ignition key in the seat lock and turn it clockwise.  – Raise the rear of the seat, push it towards the rear, and remove it upwards. B00165-10 (Super Duke R) –...

  • Page 105: Mounting The Seat

    MAINTENANCE WORK ON FRAME AND ENGINE Mounting the seat 9.44 (Super Duke) – Hook the tabs of the seat onto the fuel tank, lower the rear and push forward.  The two hooks must engage in the subframe.  – Turn the ignition key counterclockwise in the seat lock and withdraw it.

  • Page 106: Seat Height (Super Duke R)

    MAINTENANCE WORK ON FRAME AND ENGINE Seat height (Super Duke R) 9.45 The seat height of the mono seat can be adjusted. Seat height, unloaded 860… 875 mm (33.86… 34.45 in) The seat can be set to three different positions. In this way, the seat can be installed in the position most comfortable for the rider.

  • Page 107: Mounting The Helmet Lock On The Vehicle

    MAINTENANCE WORK ON FRAME AND ENGINE – Remove the four screws  Info 0 0 3 The required parts are included. – If needed, position spacers of the same length between seat and seat support    – Mount and tighten screws of a suitable length.

  • Page 108: Removing The Spoiler

    MAINTENANCE WORK ON FRAME AND ENGINE – Remove the seat. ( p. 102) – Position the steel cable from the tool set with one loop on the lug  Steel cable (60012015000) – Guide the steel cable through the helmet opening. –...

  • Page 109: Installing The Spoiler

    MAINTENANCE WORK ON FRAME AND ENGINE – Remove screws   – Take off the spoiler. B00197-10 Installing the spoiler 9.49 Info The operations are the same on the left and right sides.
  • Page 110 MAINTENANCE WORK ON FRAME AND ENGINE – Position the spoiler. – Mount and tighten screws   Guideline Screw, spoiler 6 Nm (4.4 lbf ft) B00197-10...

  • Page 111: Removing The Battery

    MAINTENANCE WORK ON FRAME AND ENGINE Removing the battery 9.50 Warning Risk of injury Battery acid and battery gases cause serious cauterization. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. – Avoid contact with battery acid and battery gases. –...

  • Page 112: Installing The Battery

    MAINTENANCE WORK ON FRAME AND ENGINE – Disconnect negative cable of the battery.  – Disconnect the positive (plus) cable of the battery.  – Take the battery out of the battery compartment.  Info Never operate the motorcycle with a discharged battery or without a battery. In both cases, electrical components and safety equipment can be damaged.

  • Page 113: Recharging The Battery

    Environmental hazard Battery parts and acid are harmful to the environment. – 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.
  • Page 114 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 Even when there is no load on the battery, it discharges steadily. The charge state and the type of charge are very important for the service life of the battery.

  • Page 115: Changing The Main Fuse

    MAINTENANCE WORK ON FRAME AND ENGINE – Connect the battery charger to the battery. Switch on the battery charger. Battery charger (58429074000) You can also use the battery charger to test the rest potential and start potential of the battery, and to test the alternator. With this device, you cannot overcharge the battery. Info Never remove lid ...
  • Page 116 MAINTENANCE WORK ON FRAME AND ENGINE Info The main fuse protects all power consumers of the vehicle. The main fuse is located next to the battery under the front spoiler. – Switch off all power consumers and switch off the engine. –...

  • Page 117: Changing The Fuses Of Individual Power Consumers

    MAINTENANCE WORK ON FRAME AND ENGINE Changing the fuses of individual power consumers 9.54 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 fuse box containing the fuses of individual power consumers is located under the seat.
  • Page 118 MAINTENANCE WORK ON FRAME AND ENGINE – Check the fuses. Info A defective fuse can be identified by the burned-out fuse wire  – Remove the faulty fuse. Guideline Fuse 1 - 10A - ignition Fuse 2 - 15A - high beam, low beam, parking light, tail light, license plate lamp B00196-10 Fuse 3 - 10A - horn, brake light, turn signal Fuse 4 - 10A - radiator fan...

  • Page 119: Changing The Parking Light Bulb

    MAINTENANCE WORK ON FRAME AND ENGINE Changing the parking light bulb 9.55 Note Damage to reflector Reduced luminance. – Grease on the lamp will evaporate due to the heat and be deposited on the reflector. Clean the lamp and keep it free of grease before mounting.

  • Page 120: Changing The Low Beam Bulb

    MAINTENANCE WORK ON FRAME AND ENGINE – Mount and tighten screw  – Check that the lighting is functioning properly. B00206-10 Changing the low beam bulb 9.56 Note Damage to reflector Reduced luminance. – Grease on the lamp will evaporate due to the heat and be deposited on the reflector. Clean the lamp and keep it free of grease before mounting.
  • Page 121 MAINTENANCE WORK ON FRAME AND ENGINE – Cover the fender with a cloth. – Swing the headlight mask forward. B00199-01 – Remove rubber cap  – Disconnect plug-in connector  B00200-10 – Detach spring bar  – Remove headlight bulb ...

  • Page 122: Changing The High Beam Bulb

    MAINTENANCE WORK ON FRAME AND ENGINE – Position the spring bar. – Connect plug-in connector  – Mount rubber cap  B00200-10 – Position the headlight mask. Mount and tighten screws  Guideline Remaining chassis screws 10 Nm (7.4 lbf ft) –...
  • Page 123 MAINTENANCE WORK ON FRAME AND ENGINE – Switch off all power consumers and switch off the engine. – Remove screws  B00198-10 – Cover the fender with a cloth. – Swing the headlight mask forward. B00199-01...
  • Page 124 MAINTENANCE WORK ON FRAME AND ENGINE – Remove rubber cap  – Disconnect plug-in connector  B00203-10 – Detach spring bar  – Remove headlight bulb  – Position the new headlight bulb in the headlight housing. High beam (H3/socket PX22s) ( p.

  • Page 125: Changing The Turn Signal Bulb

    MAINTENANCE WORK ON FRAME AND ENGINE – Position the headlight mask. Mount and tighten screws  Guideline Remaining chassis screws 10 Nm (7.4 lbf ft) – Check that the lighting is functioning properly. B00198-10 Changing the turn signal bulb 9.58 Note Damage to reflector Reduced luminance.

  • Page 126: Changing The Brake Light Bulb (Super Duke)

    MAINTENANCE WORK ON FRAME AND ENGINE Changing the brake light bulb (Super Duke) 9.59 Note Damage to reflector Reduced luminance. – Grease on the lamp will evaporate due to the heat and be deposited on the reflector. Clean the lamp and keep it free of grease before mounting.

  • Page 127: Changing The Tail Light Bulbs (Super Duke)

    MAINTENANCE WORK ON FRAME AND ENGINE Changing the tail light bulbs (Super Duke) 9.60 Note Damage to reflector Reduced luminance. – Grease on the lamp will evaporate due to the heat and be deposited on the reflector. Clean the lamp and keep it free of grease before mounting.

  • Page 128: Changing The License Plate Lamp

    MAINTENANCE WORK ON FRAME AND ENGINE Changing the license plate lamp 9.61 (Super Duke) – Remove screws  B00212-10 – Pull holder carefully out of the bracket.  – Remove the bulb. – Position a new light bulb in the holder. License plate lamp (W5W/socket W2.1x9.5d) ( p.
  • Page 129 MAINTENANCE WORK ON FRAME AND ENGINE – Position the license plate holder. – Mount and tighten screws  B00212-10 (Super Duke R) – Remove screw  B00214-10 – Carefully pull holder out of the license plate lamp.  B00215-10...
  • Page 130 MAINTENANCE WORK ON FRAME AND ENGINE – Remove bulb  – Position a new light bulb in the holder. License plate lamp (W5W/socket W2.1x9.5d) ( p. 173) – Carefully position the holder with the bulb in the license plate lamp. B00216-10 –...

  • Page 131: Checking The Headlight Setting

    MAINTENANCE WORK ON FRAME AND ENGINE Checking the headlight setting 9.62 – Park the vehicle on a horizontal surface in front of a light-colored wall and make a mark at the level of the center of the headlight. 0 0 A –...

  • Page 132: Cooling System

    MAINTENANCE WORK ON FRAME AND ENGINE – Turn screw to adjust the headlight range.  Guideline For a motorcycle with rider, and with luggage and a passenger if applicable, the light/dark boundary must be exactly on the lower mark (applied in: Checking headlight adjustment).

  • Page 133: Checking The Antifreeze And Coolant Level

    MAINTENANCE WORK ON FRAME AND ENGINE Cooling takes place by means of the air stream and a radiator fan, which is controlled by a thermoswitch. The lower the speed, the less the cooling effect. Dirty cooling fins also reduce the cooling effect.
  • Page 134 MAINTENANCE WORK ON FRAME AND ENGINE Info Remove the right side only. – Remove radiator cap and plug from the compensating tank.   – Check the coolant antifreeze. −25… −45 °C (−13… −49 °F) » If the coolant antifreeze does not meet specifications: –...

  • Page 135: Checking The Coolant Level In The Compensating Tank

    MAINTENANCE WORK ON FRAME AND ENGINE – Check the coolant level in the radiator. The radiator must be completely filled. » If the coolant level does not meet specifications: – Correct the coolant level and determine the reason for the coolant loss. Alternative 1 Coolant ( p.
  • Page 136 MAINTENANCE WORK ON FRAME AND ENGINE Condition The engine is cold. The radiator is completely full. – Stand the motorcycle on a horizontal surface. – Check the coolant level in the compensating tank  The coolant level must be between min and max. »...

  • Page 137: Draining The Coolant

    MAINTENANCE WORK ON FRAME AND ENGINE – Fill/bleed the cooling system. p. 136) Draining the coolant 9.67 Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down.

  • Page 138: Filling/Bleeding The Cooling System

    MAINTENANCE WORK ON FRAME AND ENGINE – Place a suitable container under the engine. – Remove screw  – Tilt the vehicle slightly to the right. – Completely drain the coolant. – Mount screw with a new seal ring and tighten it. ...
  • Page 139 MAINTENANCE WORK ON FRAME AND ENGINE – Position the vehicle as shown and secure it against rolling. Height difference must  be reached. Guideline Height difference 50 cm (19.7 in)  Info To make sure that all of the air can escape from the cooling system, raise the 0 0 A front of the vehicle.

  • Page 140: Adjusting The Basic Position Of The Clutch Lever

    MAINTENANCE WORK ON FRAME AND ENGINE 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 141: Checking/Correcting The Fluid Level Of The Hydraulic Clutch

    MAINTENANCE WORK ON FRAME AND ENGINE – Adjust the basic setting of the clutch lever to your hand size by turning adjusting screw  100116-10 Checking/correcting the fluid level of the hydraulic clutch 9.70 Info The fluid level rises with increasing wear of the clutch lining disc. Do not use brake fluid.

  • Page 142: Checking The Play In The Throttle Cable

    MAINTENANCE WORK ON FRAME AND ENGINE Checking the play in the throttle cable 9.71 – 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 143: Adjusting The Play In The Throttle Cable

    Adjusting the play in the throttle cable 9.72 – 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 144: Changing The Engine Oil And Filter, Cleaning The Oil Screens

    MAINTENANCE WORK ON FRAME AND ENGINE – Switch off the engine. – Park the motorcycle on a horizontal surface in a vertical position (not on the side stand). Info After switching off the engine, wait one minute before checking the level. –...

  • Page 145: Draining The Engine Oil And Filter, Cleaning The Oil Screens

    MAINTENANCE WORK ON FRAME AND ENGINE Draining the engine oil and filter, cleaning the oil screens 9.75 Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden. – Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water. Warning Environmental hazard Hazardous substances cause environmental damage.
  • Page 146 MAINTENANCE WORK ON FRAME AND ENGINE – Remove screws and cover   – Pull oil screen out of the engine case with pliers. B00226-10 – Place a suitable container under the engine. – Remove oil drain plug  – Fully drain the engine oil out of the oil tank.
  • Page 147 MAINTENANCE WORK ON FRAME AND ENGINE – Remove screws . Take off oil filter cover with the O-ring.   – Pull oil filter out of the oil filter housing.  Circlip pliers reverse (51012011000) – Completely drain the engine oil. –...
  • Page 148 MAINTENANCE WORK ON FRAME AND ENGINE – Position oil line . Mount and tighten screws   Guideline Remaining engine screws 10 Nm (7.4 lbf ft) – Mount oil drain plug with the magnet and new seal and tighten.  Guideline Oil drain plug with magnet M12x1.5...

  • Page 149: Filling Up With Engine Oil

    MAINTENANCE WORK ON FRAME AND ENGINE Filling up with engine oil 9.76 Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. – Remove the spoiler. ( p. 106) Info Remove the right side only. –...
  • Page 150 MAINTENANCE WORK ON FRAME AND ENGINE 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 151: Adding Engine Oil

    MAINTENANCE WORK ON FRAME AND ENGINE Adding engine oil 9.77 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 the spoiler. ( p.

  • Page 152: Engine Control Blink Code

    ENGINE CONTROL BLINK CODE Blink code FI of warning lamp (MIL) 02 Warning lamp FI (MIL) flashes 2x short Error level condition Circuit ignition pulse generator - circuit fault Blink code FI of warning lamp (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 153 ENGINE CONTROL BLINK CODE Blink code FI of warning lamp (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 Blink code FI of warning lamp (MIL) 13 Warning lamp FI (MIL) flashes 1x long, 3x short...
  • Page 154 ENGINE CONTROL BLINK CODE Blink code FI of warning lamp (MIL) 18 Warning lamp FI (MIL) flashes 1x long, 8x short Error level condition Lambda sensor cylinder 2, sensor 1 - circuit fault Blink code FI of warning lamp (MIL) 24 Warning lamp FI (MIL) flashes 2x long, 4x short Error level condition Power supply - circuit fault...
  • Page 155 ENGINE CONTROL BLINK CODE Blink code FI of warning lamp (MIL) 37 Warning lamp FI (MIL) flashes 3x long, 7x short Error level condition Ignition coil cylinder 1 - circuit fault Blink code FI of warning lamp (MIL) 38 Warning lamp FI (MIL) flashes 3x long, 8x short Error level condition Ignition coil cylinder 2 - circuit fault Blink code FI of warning...
  • Page 156 ENGINE CONTROL BLINK CODE Blink code FI of warning lamp (MIL) 49 Warning lamp FI (MIL) flashes 4x long, 9x short Error level condition Motor drive circuit A - circuit fault Blink code FI of warning lamp (MIL) 50 Warning lamp FI (MIL) flashes 5x long Error level condition Motor drive circuit B - circuit fault Blink code FI of warning...
  • Page 157 ENGINE CONTROL BLINK CODE Blink code FI of warning lamp (MIL) 81 Warning lamp FI (MIL) flashes 8x long, 1x short Error level condition Immobilizer control unit - circuit fault Blink code FI of warning lamp (MIL) 91 Warning lamp FI (MIL) flashes 9x long, 1x short Error level condition Malfunction in CAN bus communication...

  • Page 158: Troubleshooting

    Clean the socket connector and treat it with con- dized tact spray. – Defect in fuel injection system Read out the fault memory using the KTM diag- nostics tool. – Engine has too little power Air filter very dirty Change the air filter.
  • Page 159 Possible cause Action – Engine has too little power Defect in fuel injection system Read out the fault memory using the KTM diag- nostics tool. – Engine overheats Too little coolant in cooling system Check the cooling system for leaks.
  • Page 160 TROUBLESHOOTING Faults Possible cause Action – Turn signal, brake light and horn are Fuse 3 blown Change the fuses of individual power consumers. not functional p. 115) – Battery discharged Ignition not switched off when vehicle Recharge the battery. p. 111) was parked –...

  • Page 161: Cleaning

    CLEANING Cleaning motorcycle 12.1 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 162 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, applying the brakes occasionally. Info The heat produced causes water at inaccessible positions in the engine and on the brakes to evaporate.

  • Page 163: Protective Treatment For Winter Operation

    PROTECTIVE TREATMENT FOR WINTER OPERATION Conserving for winter operation 13.1 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 164: Storage

    Storage temperature of battery without direct sunshine 0… 35 °C (32… 95 °F) – The storage place should be dry and not subject to large temperature differences. Info KTM recommends jacking up the motorcycle. – Jack up the motorcycle at the rear. ( p. 61) –...

  • Page 165: Putting Into Operation After Storage

    STORAGE Info Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion. Avoid running the engine for a short time only. Since the engine cannot warm up properly, the water vapor produced during combustion condenses and causes valves and exhaust system to rust. Putting into operation after storage 14.2 –...

  • Page 166: 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 (Super Duke) 11.5:1 Compression ratio (Super Duke R) 12.2:1 Control DOHC, 4 valves per cylinder, chain-driven Valve - diameter (Super Duke)

  • Page 167: Capacity- Engine Oil

    TECHNICAL DATA - ENGINE 1st gear 14:36 2nd gear 16:30 3rd gear 20:30 4th gear 21:27 5th gear 23:26 6th gear 25:26 Mixture preparation Electronic fuel injection Ignition system Contactless controlled fully electronic ignition with digital ignition adjustment Alternator 12 V, 450 W Spark plug (Super Duke) NGK KR8DI Spark plug (Super Duke R)

  • Page 168: Capacity - Coolant

    TECHNICAL DATA - ENGINE Capacity - coolant 15.2 Coolant 2.10 l (2.22 qt.) Coolant ( p. 184) Coolant (mixed ready to use) ( p. 184)

  • Page 169: 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 170 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 171 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 172 TECHNICAL DATA - ENGINE TIGHTENING TORQUES ® Nut, primary gear M33LHx1.5 130 Nm (95.9 lbf ft) Loctite 243™...

  • Page 173: Technical Data - Chassis

    TECHNICAL DATA - CHASSIS Frame Lattice frame made of chrome molybdenum steel tubing, powder- coated Fork WP Suspension Up Side Down 4860 ROMA PA Shock absorber WP Suspension 4618 BAVP DCC Suspension travel (Super Duke) Front 135 mm (5.31 in) Rear 160 mm (6.3 in) Suspension travel (Super Duke R)
  • Page 174 TECHNICAL DATA - CHASSIS Tire air pressure with passenger/full payload Front 2.4 bar (35 psi) Rear 2.6 bar (38 psi) Secondary drive ratio 16:38 Chain 5/8 x 5/16” X‑ring Steering head angle (Super Duke) 66.1° Steering head angle (Super Duke R) 67.3°...

  • Page 175: Lighting Equipment

    TECHNICAL DATA - CHASSIS Lighting equipment 17.1 Low beam H7/socket PX26d 12 V 55 W High beam H3/socket PX22s 12 V 55 W Parking light W5W/socket W2.1x9.5d 12 V Instrument lights and indicator lamps Turn signal RY10W/socket BAU15s 12 V 10 W Tail light (Super Duke) WR5W/socket W2.1x9.5d...

  • Page 176: Tires

    120/70 ZR 17 M/C 58W TL 180/55 ZR 17 M/C 73W TL Pirelli DRAGON SUPERCORSA PRO Pirelli DRAGON SUPERCORSA PRO Additional information is available in the Service section under: http://www.ktm.com Capacity - fuel 17.3 Total fuel tank capacity, approx. 18.5 l (4.89 US gal) Super unleaded (ROZ 95 / RON 95 / PON 91) ( p.

  • Page 177: Technical Data - Fork

    TECHNICAL DATA - FORK Super Duke 18.1 Fork part number 14.18.7E.13 WP Suspension Up Side Down 4860 ROMA PA Fork Compression damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Rebound damping Comfort 20 clicks Standard 15 clicks Sport...

  • Page 178: Super Duke R

    TECHNICAL DATA - FORK Air chamber length 110±10 mm (4.33±0.39 in) Fork oil per fork leg 567 ml (19.17 fl. oz.) Fork oil (SAE 5) ( p. 186) Super Duke R 18.2 Fork part number 14.18.7J.31 Fork WP Suspension Up Side Down 4860 ROMA PA Compression damping Comfort 23 clicks...
  • Page 179 TECHNICAL DATA - FORK Air chamber length 100±20 mm (3.94±0.79 in) Fork oil per fork leg 527 ml (17.82 fl. oz.) Fork oil (SAE 5) ( p. 186)

  • Page 180: Technical Data - Shock Absorber

    TECHNICAL DATA - SHOCK ABSORBER Super Duke 19.1 Shock absorber part number 15.18.7E.01 WP Suspension 4618 BAVP DCC Shock absorber Compression damping, low-speed Comfort 25 clicks Standard 20 clicks Sport 10 clicks Full payload 10 clicks Compression damping, high-speed Comfort 2 turns Standard 1.5 turns...

  • Page 181: Super Duke R

    TECHNICAL DATA - SHOCK ABSORBER Soft 160 N/mm (914 lb/in) Medium (standard) 170 N/mm (971 lb/in) Hard 180 N/mm (1,028 lb/in) Spring length 185 mm (7.28 in) Gas pressure 10 bar (145 psi) Static sag 20… 25 mm (0.79… 0.98 in) Fitted length 387 mm (15.24 in) Shock absorber fluid...
  • Page 182 TECHNICAL DATA - SHOCK ABSORBER Spring preload Comfort 6 mm (0.24 in) Standard 6 mm (0.24 in) Sport 6 mm (0.24 in) Spring rate Soft 160 N/mm (914 lb/in) Medium (standard) 170 N/mm (971 lb/in) Hard 180 N/mm (1,028 lb/in) Spring length 185 mm (7.28 in) Gas pressure...

  • Page 183: Technical Data - Chassis Tightening Torques

    TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ® Screw, side stand switch 2 Nm (1.5 lbf ft) Loctite 243™ – Remaining chassis screws 5 Nm (3.7 lbf ft) – Screw, chain sliding guard 5 Nm (3.7 lbf ft) – Screw, fuel level indicator 3 Nm (2.2 lbf ft) –...
  • Page 184 TECHNICAL DATA - CHASSIS TIGHTENING TORQUES – Remaining chassis nuts 30 Nm (22.1 lbf ft) – Remaining chassis screws 25 Nm (18.4 lbf ft) – Screw, bottom triple clamp 15 Nm (11.1 lbf ft) – Screw, exhaust clamp on main silencer 35 Nm (25.8 lbf ft) –...
  • Page 185 TECHNICAL DATA - CHASSIS TIGHTENING TORQUES – Screw, top triple clamp 12 Nm (8.9 lbf ft) – Screw, upper subframe 25 Nm (18.4 lbf ft) – Engine carrying screw 45 Nm (33.2 lbf ft) – Remaining chassis nuts 50 Nm (36.9 lbf ft) –...

  • Page 186: Substances

    – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that possesses the correspond- ® ing properties. KTM recommends Castrol and Motorex products. Supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 ®...
  • Page 187 SAE ( p. 190) (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 188 – ISO VG (15) Guideline – Use only hydraulic oil that complies with the specified standard (see specifications on the container) and that possesses the corre- ® sponding properties. KTM recommends Motorex products. Supplier ® Motorex – Hydraulic Fluid 75...
  • Page 189 SUBSTANCES Super unleaded (ROZ 95 / RON 95 / PON 91) According to – DIN EN 228 (ROZ 95 / RON 95 / PON 91)

  • Page 190: 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 191 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 192 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 193 INDEX Brake linings ........INDEX front brake, checking ......87 Accessories .
  • Page 194 INDEX ODO display ....... . . 29 Engine oil speed display ....... . 27 adding .
  • Page 195 INDEX Front wheel installing ........92 License plate lamp removing .
  • Page 196 INDEX Seat height ........adjusting ........104 Parking .
  • Page 197 INDEX Tail lamp bulbs changing ........125 Warning of slippery roads .
  • Page 198 *3211522en* 3211522en 12/2009 Photo: Mitterbauer KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com...

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