OWNER’S MANUAL 2006 990 SUPER DUKE ART. NR. 3.211.83 EN 10/2005 KTM Group Partner KTM Sportmotorcycle AG A–5230 Mattighofen www.ktm.
IMPORTANT » 1 We strongly suggest that you read this manual carefully and completely before going on your first ride. It contains a great deal of information and advice which will help you use and handle your bike properly. In your own interest, please pay particular attention to notices that are marked as follows: – IGNORING THESE INSTRUCTIONS, CAN ENDANGER YOUR BODY AND YOUR LIFE.
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 LIMITED WARRANTY AND LIMITED GUARANTEE INFORMATION » The 990 Super Duke is designed and constructed for normal use on public roads but not for use on race courses or offroad terrain. The service, care and operating instructions for the engine and chassis specified in the owner's manual must be observed to ensure that the bike runs smoothly and to avoid premature wear.
INDEX » IMPORTANT . . . . . . . . . . . . . . . . . . . . . . INTRODUCTION . . . . . . . . . . . . . . . . . . . IMPORTANT LIMITED WARRANTY AND LIMITED GUARANTEE INFORMATION . . . SERIAL NUMBER LOCATIONS . . . . . . . . . Chassis number, Type label . . . . . . . . . . Engine number, engine type . . . . . . . . . OPERATION INSTRUMENTS . . . . . . . . . . Clutch lever . . . . . . . . . . . . . . . . . . . . Hand brake lever . . . . . . . . . . . . . . . . . Multi-functional digital speedometer . . Display . .
INDEX » General information on KTM disk brakes . . . . . . . . Adjusting the basic position of the hand brake lever Checking the front brake fluid level . . . . . . . . . . . Refilling front brake fluid . . . . . . . . . . . . . . . . . . Checking the front brake pads . . . . . . . . . . . . . . . Changing the basic position of the foot brake lever . Checking the rear brake fluid level . . . . . . . . . . . . Refilling rear brake fluid . . . . . . . . . . . . . . . . . . . Checking the rear brake pads . . .
SERIAL NUMBER LOCATIONS » 6 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. Enter this number on page 1.
OPERATION INSTRUMENTS » 7 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 chassis and engine). The clutch is hydraulically actuated and adjusts itself automatically. A 1 Hand brake lever The hand brake lever [2] is mounted on the handlebar on the right and actuates the front wheel brake.
OPERATION INSTRUMENTS » 1 2 3 8 Multi-functional digital speedometer The universal instrument is divided into 3 parts. Use the MODE and SET [1] button to change the display and the basic settings in the display. Display [2] shows all of the information that may be of interest to you. 5 display modes can be selected with the MODE button. The indicator lamps [3] provide additional information on the motorcycle's running condition.
OPERATION INSTRUMENTS » CLOCK 9 CLOCK You will recognize the CLOCK display by the blinking dots between the hours and minutes. It displays the speed, temperature of the cooling liquid and the clock. To switch to the next display mode, press the MODE button. ODO ODO The speed, temperature of the cooling liquid and the total kilometers or miles traveled are shown in the ODO mode. To switch to the next display mode, press the MODE button.
OPERATION INSTRUMENTS » 1 1 2 10 sec 10 Setting options in the display KILOMETERS OR MILES. You can have the speed and distance shown in kilometers or miles in the display. The display can be adapted to the respective country on long-distance trips. To switch from kilometers to miles, switch on the ignition and press the MODE [1] button for approx. 10 seconds. The km/h display will switch to mph. The speed and the stored distances will be converted and displayed in miles.
OPERATION INSTRUMENTS » 2 11 RESETTING TRIP 2 The trip meter 2 runs continuously and counts up to 999.9. It can be used similarly to TRIP 1 or together with a switch available as an accessory (see below) for trips according to a roadbook. To return the trip meter 2 to zero, switch on the ignition, change to the TRIP 2 mode and press the SET button.
OPERATION INSTRUMENTS » 12 Cooling liquid temperature display 1 120°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) 2 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 liquid has reached a temperature of approx. 40°C (104°F). 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.
OPERATION INSTRUMENTS » 13 Indicator lamps The green indicator lamp will blink in the blinker rhythm when the blinker is switched on. NOTE: The indicator lamp will blink slower when a blinker is broken. The green indicator lamp will light up when the gearbox is in an idling position. The blue indicator lamp will light up when the high beams are switched on. The red warning light will light up when the cooling liquid has reached a temperature of approx. 120°C (248°F).
OPERATION INSTRUMENTS » 14 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. Turn the handlebar to the left, then turn the ignition key to the left. The ignition key can be withdrawn in position and . 2 Combination switch The rocker switch LIGHTS [1] actuates the high beam or low beam.
OPERATION INSTRUMENTS » 15 Emergency OFF tip switch, light switch, starter tip switch 1 2 3 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). The engine cannot be started in position (ignition circuit and starter circuit are interrupted).
OPERATION INSTRUMENTS » 16 Seat lock, removing the seat 1 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. 2 4 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. Press down on the seat near the holding strap while sliding it forwards.
OPERATION INSTRUMENTS » 17 Tool set The tool set [1] is located in the storage compartment under the seat. 1 Helmet lock 3 2 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. THE HELMET LOCK IS PROVIDED TO SECURE THE HELMET TO THE MOTORCYCLE WHEN PARKED. DO NOT ATTACH THE HELMET OR OTHER OBJECTS TO THE STEEL ROPE WHILE DRIVING. YOU CAN EASILY LOSE CONTROL OF THE MOTORCYCLE.
OPERATION INSTRUMENTS » 18 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 Maintenance work). 2,3,4,5,6 N 1 Side stand Fold the side stand [1] forward to the stop with your foot and put the weight of the motorcycle on the stand.
OPERATION INSTRUMENTS » 19 Footrests The passenger footrests [1] fold up. 1 Compression damping of fork 2 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. More information is provided in the chapter „Adjusting the fork and shock absorber“.
OPERATION INSTRUMENTS » 20 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“. 1 Damping action during compression of shock absorber 3 2 The shock absorber's damping action during compression travel (compression damping) can be adjusted. This allows you adjust the shock absorber's damping behavior to match your driving style and the payload.
OPERATION INSTRUMENTS » 21 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.
GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE » Instructions for initial operation – Make sure the work for the „pre-delivery inspection“ was performed by your authorized KTM workshop. The DELIVERY CERTIFICATE and SERVICE MANUAL will be handed over when you pick up your vehicle. – Read these operating instructions carefully before your first ride. – Enter the chassis, engine and key numbers on page 1. – Familiarize yourself with the operating elements.
GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE » – NEVER LEAVE YOUR MOTORCYCLE WITHOUT SUPERVISION IF THE ENGINE IS RUNNING. – THE TIRES MUST BE DESIGNED FOR A SPEED OF OVER 240 KPH (SPEED SYMBOL ZR) AND MUST BE RELEASED BY KTM. – NEW TIRES HAVE A SMOOTH SURFACE, WHICH MEANS THAT THEY MUST BE RUN IN TO ACHIEVE FULL GRIP.
DRIVING INSTRUCTIONS » 24 Check the following before each start When you start, the motorcycle must be in perfect mechanical condition. For safety reasons, you should make a habit of performing an overall check of your motorcycle before each start. The following checks should be performed: 1 FUEL Check the fuel quantity in the tanks. 2 CHAIN Check the tension and condition of the chain. A loose chain can fall off the sprockets and a worn-out chain can tear.
DRIVING INSTRUCTIONS » 25 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. 9 BAGGAGE, PAYLOAD Never exceed the maximum total weight (380 kg, 838 lbs) and the motorcycle's wheel loads.
DRIVING INSTRUCTIONS » 26 Starting the engine 1 Switch on emergency OFF switch [1]. 2 Switch on ignition (turn ignition key [2] into position ). NOTE: You will hear the operation of the fuel pump for approx. 2 seconds after switching on the ignition. The FI indicator lamp will also light up during this time and the engine should not be started. 3 Switch transmission to idle (green indicator lamp N [3] lights up). 4 Do not accelerate; operate starter button [5].
DRIVING INSTRUCTIONS » IF THE ENGINE IS DOES NOT CRANK WHEN YOU ACTUATE THE STARTER TIP SWITCH: – the transmission is switched to idle – Check if the emergency OFF switch is on – Check if the ignition is on – the headlight is on (Light switch in position). – If this is not the case, the battery is discharged – If the lights are on, proceed as described in the „Trouble-shooting“ section or contact a KTM dealer.
DRIVING INSTRUCTIONS » – WHILE RIDING YOUR MOTORCYCLE, NEVER SWITCH THE IGNITION LOCK TO POSITIONS AND . – DO NOT TRY TO CHANGE THE SETTINGS OF THE MULTI-FUNCTIONAL SPEEDOMETER WHILE DRIVING. YOUR ATTENTION WILL BE DISTRACTED FROM THE TRAFFIC AND MAY CAUSE YOU TO LOSE CONTROL OF YOUR MOTORCYCLE. – THE PASSENGER MUST HOLD ON TO THE DRIVER OR THE HOLDING STRAP ON THE SEAT WHILE RIDING AND KEEP HIS/HER FEET ON THE PASSENGER FOOTRESTS. – REGULARLY MAKE SURE THAT THE BAGGAGE AND CASES ARE TIGHTLY FASTENED.
DRIVING INSTRUCTIONS » – ON SALT-SPRAYED OR DIRTY ROADS BRAKE ACTION MAY BE DELAYED AS WELL. FIRST, THE BRAKES MUST BE BRAKED CLEAN. – REMEMBER THAT THE STOPPING DISTANCE WILL BE LONGER IF YOU ARE CARRYING A PASSENGER OR BAGGAGE. – WHEN YOU BRAKE, THE BRAKE DISCS, BRAKE PADS, BRAKE CALIPER AND BRAKE FLUID HEAT UP. THE HOTTER THESE PARTS GET, THE WEAKER THE BRAKING EFFECT. IN EXTREME CASES, THE ENTIRE BRAKING SYSTEM CAN FAIL.
DRIVING INSTRUCTIONS » 30 Fuel MAX In the condition at delivery, the LC8 engine requires unleaded fuel with at least RON 95 (USA = Premium RON 91, see technical specifications – engine). After refueling, it will take approx. 8 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. NOTE: Press the SET key for 2 seconds to immediately turn off the fuel warning lamp.
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PERIODIC MAINTENANCE » ADD-ON-PARTS FUEL INJECTION ENGINE 990 SUPER DUKE 2006 A clean motorcycle can be checked more quickly which saves money! 32 1st Service after 1000 km every 7500 km or once a year every 15000 km or every 2 years Change engine oil and oil filter z z z Clean oil screens of engine and oil tank z z z Clean magnetic drain plugs of engine and oil tank z z z Check oil lines for damage and kink-less arrangement z z z z Renew spark plugs Check and adjust valve clearance
PERIODIC MAINTENANCE » 990 SUPER DUKE 2006 A clean motorcycle can be checked more quickly which saves money! 33 1st Service after 1000 km every 7500 km or once a year z Replace the graphite gasket in the rear exhaust manifold slide BRAKES ADD-ON-PARTS Check actuating cables for damage, smooth operation, and kink-less arrangement,adjust and lubricate z Check the oil level in the hydraulic clutch reservoir z z z z z Check air filter, renew if necessary, clean air filter box Check cables for dama
PERIODIC MAINTENANCE » WHEELS 990 SUPER DUKE 2006 A clean motorcycle can be checked more quickly which saves money! 34 1st Service after 1000 km every 7500 km or once a year every 15000 km or every 2 years Check rim joint z z z Check tire condition and inflation pressure z z z Check chain, sprockets and chain guides for wear, force fit and tension z z z Check bolts on pinion and chain sprocket for locking devices and a tight fit z z z Lubricate chain z z z z z Check wheel bearing
PERIODIC MAINTENANCE » 35 990 SUPER DUKE 2006 VITAL CHECKS AND CARE PROCEDURES TO CONDUCTED BY THE OWNER OR THE MECHANIC Check oil level before each start z Check brake fluid level z Check brake pads for wear z Check lighting system for proper operation z Check horn for proper operation z after every cleaning every 1000 km z Lubricate actuating cables and nipples Bleed fork legs z Clean chain z z Lubricate chain Check chain tension z Check tire pressure and wear z Check coolant level
MAINTENANCE WORK ON CHASSIS AND ENGINE » 36 ALL MAINTENANCE AND ADJUSTMENT WORK MARKED WITH AN ASTERISK * REQUIRES SPECIAL TECHNICAL SKILLS. IN YOUR OWN INTEREST, HAVE THIS WORK PERFORMED BY AN AUTHORIZED KTM WORKSHOP, WHERE YOUR MOTORCYCLE WILL BE SERVICED BY SPECIALLY TRAINED TECHNICIANS. – 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.
MAINTENANCE WORK ON CHASSIS AND ENGINE » 37 Driving Sport Maximum Payload Driving Comfort BASIC SETTING FORK WP 4860 ROMA 990 SUPER DUKE Basic Setting Adjusting the fork and shock absorber Compression adjuster (clicks) 20 15 10 15 Rebound adjuster (clicks) 20 15 10 15 Spring preload (turns) 5 5 5 There are a number of ways to adjust the fork and shock absorber to match the chassis to your driving style and the payload.
MAINTENANCE WORK ON CHASSIS AND ENGINE » 38 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 direction will decrease the preload. 1 turn will change the preload by 1 mm. Changing the preload will not affect the rebound damping adjustment, although adjusting screw [1 will turn at the same time.
MAINTENANCE WORK ON CHASSIS AND ENGINE » 39 STANDARD ADJUSTMENT LOW-SPEED: – Turn adjusting screw [1] clockwise as far as it will go. – Turn 20 clicks in a counterclockwise direction. 1 STANDARD ADJUSTMENT HIGH-SPEED: – Turn adjusting screw (wrench size 17 mm) clockwise as far as it will go. – Turn 2 turns in a counterclockwise direction. THE DAMPING UNIT OF THE SHOCK ABSORBER IS FILLED WITH HIGH-COMPRESSION NITROGEN. NEVER TRY TO TAKE THE SHOCK ABSORBER APART OR TO DO ANYMAINTENANCE WORK YOURSELF.
MAINTENANCE WORK ON CHASSIS AND ENGINE » 40 Checking the chain tension Place the motorcycle on the side stand. Switch the transmission to neutral and push the chain up. The distance between the chain and the swing arm should be 7 mm when the upper part of the chain [1] is tensioned (see drawing). Correct the chain tension if necessary.
MAINTENANCE WORK ON CHASSIS AND ENGINE » 41 Chain maintenance For long chain life, good maintenance is very important. X-ring chains require only modest maintenance. The best way is to use lots of water, but never use brushes or solvents. After letting the chain dry, you can use a special X-ring chain spray (Motorex Chainlube 622).
MAINTENANCE WORK ON CHASSIS AND ENGINE » 2 42 General information on KTM disk brakes 1 3 BRAKE CALIPERS: The front brake calipers [1] have 4 brake pistons each and are firmly connected to the fork legs. The front brake disks are designed as „floating“ brake disks, i.e. they are not firmly connected to the front wheel. The lateral balance ensures that the brake pads always have the best possible contact to the brake disk.
MAINTENANCE WORK ON CHASSIS AND ENGINE » 43 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. If you do not have any DOT 5.1 for refilling, you may use DOT 4 brake fluid. However, you should replace it as soon as possible by DOT 5.1. Never use DOT 5 braking fluid.
MAINTENANCE WORK ON CHASSIS AND ENGINE » 44 Adjusting the basic position of the hand brake lever The basic position of the hand brake lever can be modified by turning the adjusting screw [1]. This lets you adapt the position of the pressure point (the resistance you feel on the hand brake lever when the brake pads are pressed against the brake disk) to fit any hand. 1 min. 3 mm AT THE HAND BRAKE LEVER, FREE TRAVEL MUST AT LEAST BE 3 MM (0.12 IN).
MAINTENANCE WORK ON CHASSIS AND ENGINE » 45 – ACTUATE THE FRONT BRAKE UNTIL YOU FEEL THE POINT OF PRESSURE. – NEVER USE DOT5 BRAKE FLUID! IT IS BASED ON SILICONE OIL AND OF A PURPLE COLOR. SEALS AND BRAKE HOSES MUST BE ESPECIALLY ADAPTED TO IT. – STORE BRAKE FLUID OUT OF REACH OF CHILDREN. – BRAKE FLUID CAN CAUSE SKIN IRRITATION. AVOID CONTACT WITH SKIN AND EYES. IF YOU GET BRAKE FLUID IN YOUR EYES, RINSE WITH PLENTY OF WATER AND CONSULT A DOCTOR.
MAINTENANCE WORK ON CHASSIS AND ENGINE » 46 Changing the basic position of the foot brake lever * 6 mm 2 1 Loosen the counternut [1] and turn the push rod [2] until the foot brake lever is in the right position. Tighten the counternut again. For the best possible connection, the push rod should be screwed at least 6 turns (6 mm) into the heim joint (see drawing). If the push rod is not screwed in far enough, the connection can brake and cause the rear brake to fail in extreme cases.
MAINTENANCE WORK ON CHASSIS AND ENGINE » 47 – ACTUATE THE REAR BRAKE UNTIL YOU FEEL THE POINT OF PRESSURE. – NEVER USE DOT5 BRAKE FLUID! IT IS BASED ON SILICONE OIL AND OF A PURPLE COLOR. SEALS AND BRAKE HOSES MUST BE ESPECIALLY ADAPTED TO IT. – STORE BRAKE FLUID OUT OF REACH OF CHILDREN. – BRAKE FLUID CAN CAUSE SKIN IRRITATION. AVOID CONTACT WITH SKIN AND EYES.
MAINTENANCE WORK ON CHASSIS AND ENGINE » 48 Dismounting and remounting the front wheel * Special stands are required to dismount the wheels to make sure the motorcycle is securely fixed. The front stand only adequately fixes the motorcycle together with the rear stand. The stands shown in the illustration can be found in the KTM Power Parts catalog. First mount the rear stand (see Dismounting and remounting the rear wheel), then the front stand.
MAINTENANCE WORK ON CHASSIS AND ENGINE » 4 A 49 Before you remount the front wheel, clean and grease the shaft seal rings [5] and the bearing surface [A] of the distance bushings and mount the distance bushings (wide distance bushing in the left shaft seal ring). When mounting the distance bushing, be careful not to press the sealing lips towards the inside. position the front wheel according to the running direction shown by the arrows [B] on the rim.
MAINTENANCE WORK ON CHASSIS AND ENGINE » 50 Dismounting and mounting the rear wheel * 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.
MAINTENANCE WORK ON CHASSIS AND ENGINE » 51 – IF YOU DON’T HAPPEN TO HAVE A TORQUE WRENCH AT HAND, MAKE SURE YOU HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POSSIBLE. A LOOSE WHEEL SPINDLE MAY LEAD TO AN UNSTABLE DRIVING BEHAVIOR OF YOUR MOTORCYCLE. – AFTER MOUNTING THE REAR WHEEL, KEEP OPERATING THE FOOTBRAKE UNTIL THE PRESSURE POINT RETURNS. – IT IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND GREASE, OTHERWISE THE BRAKING EFFECT WOULD BE STRONGLY REDUCED.
MAINTENANCE WORK ON CHASSIS AND ENGINE » TIRES – AIR PRESSURE 990 Super Duke front rear Road, driver only 2.4 bar 34 psi 2.4 bar 34 psi Road, with passenger 2.4 bar 34 psi 2.6 bar 37 psi maximum payload 2.6 bar 37 psi 2.4 bar 34 psi – DO NOT MOUNT TIRES WHICH HAVE NOT BEEN APPROVED BY KTM. OTHER TIRES COULD HAVE ADVERSE EFFECTS ON THE WAY YOUR MOTORCYCLE RIDES. – USE TIRES OF THE SAME BRAND AND TYPE FOR THE FRONT AND REAR WHEELS. – FOR YOUR OWN SAFETY REPLACE DAMAGED TIRES IMMEDIATELY.
MAINTENANCE WORK ON CHASSIS AND ENGINE » 53 Removing and remounting the battery * 1 2 2 3 3 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. Push the cables to the side. Remove the screws [3] and fold the battery cover [4] down. First disconnect the negative terminal, then the positive terminal from the battery.
MAINTENANCE WORK ON CHASSIS AND ENGINE » 54 Charging the battery The battery discharges every day, even if it is not used. Always disconnect the battery when charging. Charge the battery as described in the instructions [1] on the battery housing. Do not exceed the amperage and charging time. Quick charging at a high amperage has an adverse effect on the service life. 1 Always use special charging devices to charge maintenance-free batteries, e.g. the KTM charging device (item no. 58429074000).
MAINTENANCE WORK ON CHASSIS AND ENGINE » 55 Main fuse The main fuse protects all of the motorcycle's electric power consumers. The main fuse is located on the left under the front spoiler. 1 2 4 3 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.
MAINTENANCE WORK ON CHASSIS AND ENGINE » 56 Fuses for individual power consumers A fuse box is mounted under the seat containing additional fuses that protect the individual electric power consumers. The power consumers and the corresponding capacities are listed on the cover of the fuse box [1]. Spare fuses [2] of 10 and 15 amperes are located next to the fuse box. 1 Replace a blown fuse only with an equivalent one.
MAINTENANCE WORK ON CHASSIS AND ENGINE » 57 Replacing the headlight lamp * Remove the screws [1] on the left and right and tilt the headlight mask down towards the front. 1 1 2 NEVER TOUCH THE GLASS OF THE BULB WITH YOUR FINGERS. THE GLASS OF THE BULB MUST REMAIN ABSOLUTELY FREE FROM GREASE. HEAT WILL OTHERWISE CAUSE THE GREASE TO EVAPORATE AND SETTLE DOWN ON THE REFLECTOR. 4 3 A 5 BULB FOR HIGH BEAM [A]: Remove the rubber cap [2] and pull off the connector [3].
MAINTENANCE WORK ON CHASSIS AND ENGINE » 58 Adjusting the headlight range The payload can make it necessary to correct the headlight range. The headlight range can be adjusted with the adjusting screw [1]. Turning in a clockwise direction will increase the headlight range, turning in a counterclockwise direction will reduce the headlight range. 1 CONTROL: Make a mark on a light colored wall behind a horizontal surface, at the height corresponding to the center of the headlight.
MAINTENANCE WORK ON CHASSIS AND ENGINE » 1 59 BULB FOR THE TAILLIGHT: Remove the bulb socket [1] from the housing and pull the bulb out of the socket. Insert a new bulb and press the bulb socket all the way into the taillight housing. Mount the seat. Replacing the flasher bulbs Remove the screw on the back of the turn signal, carefully fold the lens [2] towards the motorcycle and remove. Turn the cap [3 approx. 15° in a counterclockwise direction and remove.
MAINTENANCE WORK ON CHASSIS AND ENGINE » 60 Cooling system The water pump in the engine ensures a forced circulation of the cooling liquid. When the engine is cold, the cooling liquid only circulates in the cylinders and cylinder heads. The thermostat will open when the engine reaches approx. 75°C (167°F) and the cooling liquid will also be pumped through the aluminum radiator. Cooling is by means of the air stream. The lower the speed, the lower the cooling effect.
MAINTENANCE WORK ON CHASSIS AND ENGINE » 61 A mixture of 50% antifreeze and 50% distilled water is used as the cooling liquid. However, the anti-freeze protection must be at least -25° C (-13° F). Aside from antifreezing protection, this mixture also provides great corrosion protection which is why it must not be replaced by pure water. 4 – FOR THE COOLING SYSTEM, USE ONLY HIGH-GRADE ANTIFREEZER (MOTOREX ANTIFREEZE). USING LOWERGRADE ANTIFREEZE AGENTS, CAN CAUSE CORROSION AND COOLANT FOAMING.
MAINTENANCE WORK ON CHASSIS AND ENGINE » 62 Checking the cooling liquid level in the radiator * Hold the radiator cap [1] with a cloth, carefully turn in a counterclockwise direction and remove. The radiator should be completely filled with cooling liquid; no air should be 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. 2 1 IF POSSIBLE, CHECK THE COOLING LIQUID LEVEL WHEN THE ENGINE IS COLD.
MAINTENANCE WORK ON CHASSIS AND ENGINE » 63 Remove the bleeder screw [5] on the left side of the radiator. 5 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. Completely fill the radiator with cooling liquid. Mount the radiator cap and move the motorcycle into a horizontal position again.
MAINTENANCE WORK ON CHASSIS AND ENGINE » 64 Changing the basic position of the clutch lever The basic position of the clutch lever can be modified by turning the adjusting screw [1]. This lets you adjust the best clutch lever position for any hand size. To adjust, pull the clutch lever towards the front. Turning the adjusting screw in a clockwise direction will move the clutch lever away from the driver.
MAINTENANCE WORK ON CHASSIS AND ENGINE » 1 65 Adjusting the handlebar tilt Loosen the screws [1]. Adjust the handlebar and tighten the screws to 20 Nm. Make sure the handlebar instruments do not touch the fuel tank when the handlebar is completely turned.
MAINTENANCE WORK ON CHASSIS AND ENGINE » 66 Engine oil JASO T903 MA TEMPERATUR 0°C 32°F 5W/40 10W/50 Automobile engine oil used to be used for four-stroke motorcycles before there were separate motorcycle specifications. Different technical developments made it necessary to have a separate specification for four-stroke motorcycles - the JASO T903 MA standard. Whereas car engines require long changing intervals, motorcycle engines require a higher power output at higher speeds.
MAINTENANCE WORK ON CHASSIS AND ENGINE » 67 Refilling engine oil To refill engine oil, take off the right spoiler [1] by removing the screws [2]. 1 2 2 Also remove the screws [3] and take off the spoiler. 3 3 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. Mount the plug and check the engine for leaks. Finally, mount the spoilers.
MAINTENANCE WORK ON CHASSIS AND ENGINE » 68 Changing the engine oil and the oil filter, cleaning the oil screen * NOTE: The LC8 engine has a dry-sump lubrication system. The engine oil is pumped from the oil sump in the engine case to the oil tank. The engine oil must also be drained from the oil tank during an oil change. Since many parts must be demounted for an oil change, we recommend having the engine oil changed by an authorized KTM workshop.
MAINTENANCE WORK ON CHASSIS AND ENGINE » 69 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. 8 7 6 7 Carefully pull the oil screen [9] out of the oil tank. 9 Thoroughly clean the drain plugs, the cover and both oil screens. Clean all rubber seal rings and check for damage. Replace if necessary.
MAINTENANCE WORK ON CHASSIS AND ENGINE » 70 Mount the oil drain plug on the engine with a new seal ring and tighten to 20 Nm. Slide the oil screen [1] into the guides in the oil pump housing with the TOP mark facing up. Make sure the form ring is in place and mount the cap [2]. Tighten the screws to 10 Nm. 2 1 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. 3 ONLY USE ORIGINAL KTM OIL FILTERS.
MAINTENANCE WORK ON CHASSIS AND ENGINE » 71 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. Switch off the engine and check the oil level (see Checking the engine oil level). 6 Check the engine and the oil tank for oil leakage.
TROUBLESHOOTING » 72 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.
TROUBLESHOOTING » 73 TROUBLE CAUSE REMEDY Engine cranks but doesn’t start. Operating error Pay attention to starting off information (see driving instructions).
TROUBLESHOOTING » 74 TROUBLE CAUSE REMEDY Engine overheats Blown fan fuse Replace fuse FAN Defect fan or thermoswitch for fan Contact an authorized KTM workshop.
TROUBLESHOOTING » 75 TROUBLE CAUSE REMEDY The battery is discharged The ignition (power consumer) hasn’t been switched off Recharge the battery according to the relevant instructions. The battery isn’t charged by the generator Voltage regulator and generator should be checked by an authorized KTM workshop. No values are visible in the multi-functional digital speedometer display. Blown fuse Replace fuse HORN BRAKELIGHT SPEEDO.
TROUBLESHOOTING » 76 The blink code indicates which component is affected by an error. This allows the error to be identified if no diagnosis tool is available.
CLEANING » 77 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 COMPONENTS, PLUGS, CABLES, BEARINGS, ETC. WHICH CAN CAUSE MALFUNCTIONING OR CAN LEAD TO PREMATURE WEAR OF THESE COMPONENTS. – Before you wash your motorcycle, close the muffler openings. – Use warm water with a commercial detergent and sponge.
STORAGE » 78 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). – Change the engine oil and the oil filter (old engine oil contains aggressive impurities). – Check the quantity of antifreeze and cooling liquid. – Remove and charge the battery (see Charging the battery chapter).
TECHNICAL SPECIFICATIONS – CHASSIS » CHASSIS 990 SUPER DUKE Frame Tubular chrome-molybdenum-steel space frame Fork WP Suspension – Up Side Down 4860 ROMA Spring travel front 135 mm (5.3 in) Rear suspension WP Suspension 4618 BAVP Spring travel rear 160 mm (6.3 in) Front brake Disk brake, 2 perforated brake disks Ø 320 mm (12.6 in), fixed brake calipers Rear brake Scheibenbremse, gelochte Bremsscheibe Ø 240 mm (9.
TECHNICAL SPECIFICATIONS – CHASSIS » Ground clearance, unloaded 165 mm (6.5 in) Dry weight 184 kg (406.2 lbs) Max. axle load, front 200 kg (441.5 lbs) Max. axle load, rear 220 kg (485.6 lbs) Max. total weight 380 kg (838.8 lbs) BASIC SETTING FORK WP 4860 ROMA 990 SUPER DUKE BASIC SETTING SHOCK ABSORBER WP 4618 BAVP 990 SUPER DUKE Maximum Payload 855 mm (33.6 in) Driving Sport 1438 ± 10 mm (56.6 ± 0.4 in) Seat height, unloaded Basic Setting Wheel base Driving Comfort 66.
TECHNICAL SPECIFICATIONS – CHASSIS » 81 TIGHTENING TORQUES – CHASSIS 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.
TECHNICAL SPECIFICATIONS – CHASSIS » 82 TIGHTENING TORQUES – CHASSIS HH bolts for side stand fixture - side stand bracket M10 Loctite 243 + 25 Nm HH bolts for side stand mounting M10 Loctite 243 + 35 Nm HH bolt for spring rest on side stand M8 Loctite 243 + 25 Nm HH bolt for side stand switch M4 Loctite 243 + 2 Nm Drain plug on oil tank M12x1.
TECHNICAL SPECIFICATIONS – ENGINE » 83 ENGINE 990 LC8 Design Liquid-cooled, 2-cylinder 4-stroke engine with 75° V arrangement with balancer shaft and electric starter Displacement 999 cc Bore / Stroke 101/62.4 mm Compression ratio 11.5:1 Fuel unleaded fuel with at least RON 95 (USA: Premium RON 91) * Valve timing 4 valves controlled over bucket tappet and 2 camshafts, camshaft drive with gears/chain Valve diameter Intake: 38 mm Exhaust: 33 mm Valve clearance, cold Intake: 0.10 - 0.
TECHNICAL SPECIFICATIONS – ENGINE » 84 ENGINE 990 LC8 Ignition system breakerless transistorized electronic ignition system with digital ignition advance Ignition timing Map-controlled via TPS Map-controlled via TPS 12V 450W at 6000 rpm Spark plug NGK DCPR 8 E Electrode distance 0.8 mm Cooling system liquid cooled, permanent circulation of cooling liquid through water pump Cooling liquid 2.1 liters (0.
HEAD WORD INDEX » Accessories and payload . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting compression damping of fork . . . . . . . . . . . . . . Adjusting rebound damping of fork . . . . . . . . . . . . . . . . . Adjusting the basic position of the hand brake lever . . . . . Adjusting the fork and shock absorber . . . . . . . . . . . . . . Adjusting the handlebar tilt . . . . . . . . . . . . . . . . . . . . . . Adjusting the headlight range . . . . . . . . . . . . . . . . . . . . .
HEAD WORD INDEX » Important . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Important limited warranty and limited guarantee information Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Indicator lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instructions for initial operation . . . . . . . . . . . . . . . . . . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Jump start . . . . .
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BEDIENUNGSANLEITUNG 2006 990 SUPER DUKE ART. NR. 3.211.83 DE 10/2005 KTM Group Partner KTM Sportmotorcycle AG A–5230 Mattighofen www.ktm.
