Gebruiksaanwijzing /service van het product 990 SUPER DUKE, 990 SUPER DUKE R van de fabrikant KTM
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990 SUPER DUKE 990 SUPER DUKE R KTM Sportmotorcycle AG A–5230 Mattighofen www.ktm.at 11/2006 FOTO: MITTERBAUER KTM Group Partner ART. NR. 3.211.151 EN OWNER’S MANUAL 2007.
INTRODUCTION » All information contained is without obligation. KTM-Sportmotorcycle AG particularly reserves the right to modify any equipment, technical specifications, prices, colors, shapes, mater.
IMPORTANT INFORMATION » INTENDED PURPOSE The 990 Super Duke is designed to resist the usual wear and tear of paved roads but is not designed for race courses or off-road use. The 990 Super Duke R is designed to resist the usual wear and tear of paved roads or race courses but is not designed for off-road use.
IMPORTANT INFORMATION » W ARRANTY The service work specified in the „Lubrication and Maintenance Schedule“ must be performed by an authorized KTM workshop. This is the only place that has the qualified technicians and the special tools required for the 990 Super Duke / R.
INDEX » 4 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 IMPOR T ANT INFORMA TION . . . . . . . . . . . . . . . . . . . . . . . . . .2 SERIAL NUMBER LOCA TIONS . . . . . . . . . . . . . . . . . . . . . . . .6 Chassis number , T ype label .
INDEX » 5 Checking the front brake pads . . . . . . . . . . . . . . . . . . . . .45 Checking the rear brake fluid level . . . . . . . . . . . . . . . . . .46 Checking the rear brake pads . . . . . . . . . . . . . . . . . . . . . .46 Dismounting and remounting the front wheel .
Chassis number, Type label The chassis number is stamped on the right side of the steering head tube. Enter this num- ber in the field on page no 1. The type label is located on the right frame tube under the seat.
Clutch lever The clutch lever [1] is fitted on the left hand side of the handle bar . The adjusting screw [A] is used to change the original position of the clutch lever (see maintenance work on chas- sis and engine). The clutch is hydraulically actuated and adjusts itself automatically .
OPERATION INSTRUMENTS » 8 1 2 Combined instrument The combined instrument is divided into 4 parts. Function buttons: to select the display modes and basic settings in the display T achometer: display.
OPERATION INSTRUMENTS » 9 1 2 3 SPEED [1] The speed can be displayed in kilometers per hour (km/h) or miles per hour (mph). CHANGING THE SPEED DISPLA Y FROM KM/H - MPH or MPH - KM/H Switch on the ignition and press the MODE button more than 10 seconds in the ODO mode.
OPERATION INSTRUMENTS » 10 1 2 FROST W ARNING [1] The frost symbol will start to blink regardless of the mode if the ambient temperature drops below 3°C (37.5°F). ODO [2] Displays the total kilometers or miles traveled. This figure will not be cleared if the battery is disconnected.
OPERATION INSTRUMENTS » 11 3 2 1 TRIP 1 [1] The trip meter 1 is always active and counts up to 999.9. It is used to measure the length of the trip or the distance between 2 refueling stops. TO RESET TRIP 1 T o reset the trip meter 1 to zero, switch on the ignition, select the TRIP 1 display mode and press the SET button more than 2 seconds.
Tachometer The tachometer [3] shows the engine speed in revolutions per minute. Do not run the engine beyond the orange mark at 9500 rpm. The speed limiter will set in at 9600 rpm, drastically reducing the engine power above this rotational speed. Cooling liquid temperature display The temperature display [1] is shown in 12 bars.
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.
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 T o switch the ignition to position turn the ignition key to position and firmly press it into the lock.
Starter tip switch, Emergency OFF tip switch The emergency off switch [1] is provided for emergency situations and should not be used to switch off the engine. The engine is ready for operation in position (ignition circuit and starter circuit are switched on).
Seat lock, removing the seat The seat lock [1] can be locked with the ignition key . T o 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.
Tool set The tool set [1] is located in the storage compartment under the seat. Helmet lock The steel rope [2] in the tool bag can be used to secure a helmet. T o secure, remove the seat, run the rope through the helmet, attach both ends to the hook [3] and mount the seat.
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).
Footrests The passenger footrests [1] fold up. Compression damping of fork The fork's damping action during compression travel (compression damping) can be adjusted. This allows you adjust the damping behavior to match your driving style and the payload.
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“.
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 .
Instructions for initial operation – Make sure the work for the „pre-delivery inspection“ was performed by your author- ized KTM workshop. The DELIVERY CER- TIFICA TE and SERVICE MANUAL will be handed over when you pick up your vehicle. – Read these operating instructions care- fully before your first ride.
– 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.
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.
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.
Starting the engine 1 Switch on emergency OFF switch [1] . 2 Switch on ignition (turn ignition key [2] into position ). NOTE: Y ou 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 can- not be started.
IF THE ENGINE IS DOES NOT CRANK WHEN YOU ACTUA TE THE ST ARTER TIP SWITCH: – whether you accelerated while starting – the transmission is switched to idle – Check if the emergency OFF switch is .
– While riding your motorcycle, never switch the ignition lock to positions and . – Do not try to change the settingsof the combined instrument while driving. Y our attention will be distracted from the traf- fic and this may cause you to lose con- trol of your motorcycle.
DRIVING INSTRUCTIONS » 29 – 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 pas- senger or baggage. – When you brake, the brake discs, brake pads, brake caliper and brake fluid heat up.
Fuel In the condition at delivery , the LC8 engine requires unleaded fuel with at least RON 95 (USA = Premium PON 91, see technical specifications – engine). After refueling, it will take approx. 3 minutes for the fuel warning lamp to switch off and for TRIP F to automatically reset to 0 and return to the previous display mode.
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PERIODIC MAINTENANCE SCHEDULE » 990 SUPER DUKE / R 2007 A clean motorcycle can be checked more quickly which saves money! 1st Service after 1000 km every 7500 km or once a year every 15000 km or ever.
PERIODIC MAINTENANCE SCHEDULE » 990 SUPER DUKE / R 2007 A clean motorcycle can be checked more quickly which saves money! 1st Service after 1000 km every 7500 km or once a year every 15000 km or ever.
PERIODIC MAINTENANCE SCHEDULE » 34 IF MOTORCYCLE IS USED FOR COMPETITION 7500 KM SERVICE SHOULD BE CARRIED OUT AFTER EVER Y RACE! Service intervalls should never be exceeded by more than 500 km.
PERIODIC MAINTENANCE SCHEDULE » 990 SUPER DUKE / R 2007 VITAL CHECKS AND CARE PROCEDURES TO CONDUCTED BY THE OWNER OR THE MECHANIC before each start after every cleaning every 1000 km Check oil level.
– Do not clean the motorcycle with a power washer otherwise water will get into the bearings, electric socket connectors, etc. – Use special KTM screws with the correct thread length to fasten the spoiler to the tank. Mounting other screws or longer screws could puncture the tank and cause fuel to leak out.
Adjusting the fork and shock absorber There are a number of ways to adjust the fork and shock absorber to match the chassis to your driving style and the payload.
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). T urning in a clockwise direction will increase the preload, turning in a counterclockwise direc- tion will decrease the preload.
ST ANDARD ADJUSTMENT LOW -SPEED: – T urn adjusting screw [1] clockwise as far as it will go. – T urn 20 clicks in a counterclockwise direction. ST ANDARD ADJUSTMENT HIGH-SPEED: – T urn adjusting screw (wrench size 17 mm) clockwise as far as it will go.
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).
Chain maintenance Maintenance of the X-ring chain is reduced to a minimum. Rinse off any heavy dirt with plenty of water . Residual used grease must be removed prior to lubrication (Motorex Chain Clean 611). After drying, use a chain spray specially designed for X-ring chains (Motorex Chainlube 622).
General information on KTM disk brakes BRAKE CALIPERS: The front brake calipers [1] have 4 brake pistons and are radially bolted to the fork legs. The front brake disks are designed as „floating“ brake disks, i.e. they are not firmly con- nected to the front wheel.
BRAKE FLUID: W e recommend that you use Motorex DOT 5.1 brake fluid when you refill or change the brake fluid. DOT 5. 1 brake fluid has a wet boiling point of 180°C / 356°F (25°C / 45°F higher than DOT 4) and is safer for high performance applications.
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.
Checking the front brake pads The brake pads can be inspected from the rear . The linings must be at least 1 mm (0.04 in) thick. At their most worn point brake pad linings should not be thinner than 1 mm, otherwise they could lead to brake failure. For your own safety don’t put off having your brake pads changed.
Checking the rear brake pads The brake pads can be inspected from the rear . The thickness of the linings may not be less than 1 mm (0.04 in). At their most worn point brake pad linings should not be thinner than 1 mm, otherwise they could lead to brake failure.
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MAINTENANCE WORK ON CHASSIS AND ENGINE » 48 2 3 3 2 1 6 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.
MAINTENANCE WORK ON CHASSIS AND ENGINE » 49 4 A 5 B C C T ake the left [4] and right distance bushing out of the shaft seal rings. – Do not operate the hand brake when the front wheel has been dismounted. – Be careful not to damage the brake disks when you lay the front wheel down.
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.
– If you don’t happen to have a torque wrench at hand, make sure you have the tighten- ing torque corrected by a KTM dealer as soon as possible. A loose wheel spindle may lead to an unstable driving behavior of your motorcycle. – After mounting the rear wheel, keep operating the footbrake until the pressure point returns.
Battery The battery is located in the front spoiler in front of the engine and is maintenance-free. It is not necessary to check the electrolyte level or to refill water . Simply keep the battery poles clean and slightly grease them with an acid-free grease if necessary .
Removing and remounting the battery The battery only needs to be removed if the motorcycle is being immobilized. Remove the screws [1] on both sides, loosen the screws [2] 2 turns and remove the front spoiler towards the front. Push the cables to the side.
MAINTENANCE WORK ON CHASSIS AND ENGINE » 54 VOL T 1 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 instruc- tions [1] on the battery housing.
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 . 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.
Fuses for individual power consumers A fuse box is mounted under the seat containing additional fuses that protect the individ- ual electric power consumers. The power consumers are listed numerically on the cover of the fuse box [1] and allocated as described below .
Replacing the headlight lamp Remove the screws [1] on the left and right and tilt the headlight mask down towards the front. Never touch the glass of the bulb with your fingers. The glass of the bulb must remain absolutely free from grease. Heat will otherwise cause the grease to evaporate and settle down on the reflector .
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] . T urning in a clockwise direction will increase the headlight range, turning in a counterclockwise direction will reduce the headlight range.
BULB FOR THE T AILLIGHT : Remove the bulb socket [2] 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.
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 .
A mixture of 50% antifreeze and 50% distilled water is used as the cooling liquid. How- ever , the anti-freeze protection must be at least -25° C (-13° F). Aside from antifreezing pro- tection, this mixture also provides great corrosion protection which is why it must not be replaced by pure water .
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.
T o 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 .
Adjusting the handlebar tilt Loosen the screws [2] . 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 com- pletely turned.
MAINTENANCE WORK ON CHASSIS AND ENGINE » 65 How to change the handlebar position (Super Duke R) The upper triple clamp includes 2 bores arranged at a distance of 15 mm (0.6 in) from one another . Accordingly , you can mount the handlebar in 2 different positions.
Engine oil Automobile engine oil used to be used for four -stroke motorcycles before there were sepa- rate motorcycle specifications. Different technical developments made it necessary to have a separate specification for four -stroke motorcycles - the JASO T903 MA standard.
Refilling engine oil T o refill engine oil, take off the right spoiler [1] by removing the screws [2] . Also remove the screws [3] and take off the spoiler . Unscrew the plug [4] and refill engine oil. W ait 20 seconds and check the oil level again. The quantity of oil between the MIN and MAX marks is 0.
Changing the engine oil and the oil filter, cleaning the oil screen Y ou may only change the engine oil yourself after the warranty period has expired. The war- ranty will become void if you change the oil yourself during the warranty period. NOTE: The LC8 engine has a dry-sump lubrication system.
Remove the drain plug [6] on the oil tank and allow the oil to drain into a receptacle. Remove the screws [7] and tilt the oil return valve [8] to the side. Carefully pull the oil screen [9] out of the oil tank. Thoroughly clean the drain plugs, the cover and both oil screens.
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 fac- ing up. Make sure the form ring is in place and mount the cap [2] . T ighten the screws to 10 Nm.
Remove the right spoiler (see Refilling the engine oil) and unscrew the plug [6] . Add 2.5 liters (0.7 USgal) of fully synthetic engine oil meeting the JASO MA standard (e.g. Motorex Power Synt 4T) and remount the plug. Start the engine and allow to run warm in neutral until 4 bars on the temperature indicator light up.
If you have your motorcycle serviced as set forth in this manual, no malfunctioning is to be expected. Nevertheless, if an error does arise, we recommend that you look for the error according to the following chart. Please note that you cannot perform all of the work yourself.
TROUBLESHOOTING » TROUBLE CAUSE REMEDY Engine cranks but doesn’t start. Operating error Blown fuse for the fuel pump Clutch not attached to the fuel line The plug and socket connector on the wiring.
TROUBLESHOOTING » 74 TROUBLE CAUSE REMEDY Engine overheats Blown fan fuse Defect fan or thermoswitch for fan Air in the cooling system Replace fuse 5 Contact an authorized KTM workshop.
TROUBLESHOOTING » TROUBLE CAUSE REMEDY The battery is discharged The ignition (power consumer) has- n’t been switched off The battery isn’t charged by the generator Recharge the battery according to the relevant instructions. V oltage regulator and generator should be checked by an authorized KTM workshop.
TROUBLESHOOTING » 76 BLINK CODE SIGNAL / COMPONENT ERROR DESCRIPTION ENGINE 12 Coolant temperature sensor Output signal too low /high Continues to run 13 Air temperature sensor Output signal too low .
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 elec tric compo- nents, plugs, cables, bearings, etc.
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).
TECHNICAL SPECIFICATIONS – CHASSIS » CHASSIS 990 SUPER DUKE / R 2007 Frame T ubular chrome-molybdenum-steel space frame Fork WP Suspension – U p S ide D own 4860 ROMA Spring travel front 135 mm (5.3 in) Rear suspension WP Suspension 4618 BA VP Spring travel rear Super Duke: 160 mm (6.
TECHNICAL SPECIFICATIONS – CHASSIS » CHASSIS 990 SUPER DUKE / R 2007 Battery maintenance-free battery 12V 11.2 Ah Steering head angle Super Duke: 66.1° Super Duke R: 67.3° Wheel base 1450 ± 10 mm (57 ± 0.4 in) Seat height, unloaded Super Duke: 850 mm (33.
TIGHTENING TORQUES – CHASSIS 2007 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.
TECHNICAL SPECIFICATIONS – CHASSIS » TIGHTENING TORQUES – CHASSIS 2007 HH bolts for side stand fixture - side stand bracket M10 Loctite 243 + 25 Nm HH bolts for side stand mounting M10 Loctite 24.
TECHNICAL SPECIFICATIONS – ENGINE » ENGINE 990 LC8 2007 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.
TECHNICAL SPECIFICATIONS – ENGINE » ENGINE 990 LC8 2007 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 IR KR8BI Electrode distance 0.
Accessories and payload . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 Adjusting compression damping of fork . . . . . . . . . . . . . . . . .37 Adjusting rebound damping of fork . . . . . . . . . . . . . . . . . . . .37 Adjusting the basic position of the hand brake lever .
How to change the handlebar position (Super Duke R) . . . . . .65 Ignition lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 Important information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Index . . . . .
CONSUMER INFORMATION FOR USA ONLY » 87 REPORTING SAFETY DEFECTS If you believe that your vehicle has a defect which could cause an accident resulting in injury or death, you should immediatel y inform the National Highway T raffic Safety Administration (NHTSA) in addition to notifying KTM North America, Inc.
CONSUMER INFORMATION FOR USA ONLY » 88 under seat on fuel tank R/S on fuel tank L/S on steering head tube on fuel tank Sticker positions: 345 on frame tube R/S under seat on frame tube R/S 7 on frame.
CONSUMER INFORMATION FOR USA ONLY » [3] Suspension setting [5] T echnical information [8] Before you go for the first ride [7] V ehicle emission [2] T ype label CAN [6] Noise emission [1] EA VP [4] C.
USE THIS SPACE FOR NOTES » 90.
990 SUPER DUKE 990 SUPER DUKE R KTM Sportmotorcycle AG A–5230 Mattighofen www.ktm.at 11/2006 FOTO: MITTERBAUER KTM Group Partner ART. NR. 3.211.151 DE BEDIENUNGSANLEITUNG 2007.
Een belangrijk punt na aankoop van elk apparaat KTM 990 SUPER DUKE, 990 SUPER DUKE R (of zelfs voordat je het koopt) is om de handleiding te lezen. Dit moeten wij doen vanwege een paar simpele redenen:
Als u nog geen KTM 990 SUPER DUKE, 990 SUPER DUKE R heb gekocht dan nu is een goed moment om kennis te maken met de basisgegevens van het product. Eerst kijk dan naar de eerste pagina\'s van de handleiding, die je hierboven vindt. Je moet daar de belangrijkste technische gegevens KTM 990 SUPER DUKE, 990 SUPER DUKE R vinden. Op dit manier kan je controleren of het apparaat aan jouw behoeften voldoet. Op de volgende pagina's van de handleiding KTM 990 SUPER DUKE, 990 SUPER DUKE R leer je over alle kenmerken van het product en krijg je informatie over de werking. De informatie die je over KTM 990 SUPER DUKE, 990 SUPER DUKE R krijgt, zal je zeker helpen om een besluit over de aankoop te nemen.
In een situatie waarin je al een beziter van KTM 990 SUPER DUKE, 990 SUPER DUKE R bent, maar toch heb je de instructies niet gelezen, moet je het doen voor de hierboven beschreven redenen. Je zult dan weten of je goed de alle beschikbare functies heb gebruikt, en of je fouten heb gemaakt die het leven van de KTM 990 SUPER DUKE, 990 SUPER DUKE R kunnen verkorten.
Maar de belangrijkste taak van de handleiding is om de gebruiker bij het oplossen van problemen te helpen met KTM 990 SUPER DUKE, 990 SUPER DUKE R . Bijna altijd, zal je daar het vinden Troubleshooting met de meest voorkomende storingen en defecten #MANUAl# samen met de instructies over hun opplosinge. Zelfs als je zelf niet kan om het probleem op te lossen, zal de instructie je de weg wijzen naar verdere andere procedure, bijv. door contact met de klantenservice of het dichtstbijzijnde servicecentrum.
