KTM 2010 990 Super Duke R Owner'S Manual Download Page 93

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MAINTENANCE WORK ON FRAME AND ENGINE

B00186-01

–

Check the brake linings for minimum thickness



Minimum thickness



≥

1 mm (

≥

0.04 in)

» If the minimum thickness is less than specified:

–

Change the rear brake linings.

–

Check the brake linings for damage and cracking.
» If damage or wear is encountered:

–

Change the rear brake linings.

9.34

Removing the front wheel

–

Jack up the motorcycle at the rear. (

p. 61)

–

Jack up the motorcycle at the front. (

p. 60)

B00244-10

–

Remove the screws



from both brake calipers.

–

Press back the brake linings with a light lateral tilting of the brake calipers on the brake
disc. Pull the brake calipers carefully back from the brake discs and hang them to one
side.

Info

Do not pull the hand brake lever when the brake calipers are removed.

Summary of Contents for 2010 990 Super Duke R

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 2: ......

Page 3: ...o print However it is never possible to exclude small deviations arising from further development in design and construction All specifications are non binding KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifications prices colors forms materials services designs equipment etc without prior notice and without specifying reasons to adapt these to local con...

Page 4: ...ds 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 Issued by TÜV Management Service KTM Sportmotorcycle AG 5230 Mattighofen Austria ...

Page 5: ...strument display 26 Combination instrument speedometer 27 Setting kilometers or miles 27 Combination instrument time 28 Setting the clock 28 Combination instrument ODO display 29 Combination instrument setting resetting TRIP 1 29 Combination instrument setting resetting TRIP 2 30 Combination instrument TRIP F display 31 Combination instrument ambient temperature display 31 Setting the temperature ...

Page 6: ...g damper Super Duke R 73 Handlebar position Super Duke R 74 Adjusting the handlebar position x Super Duke R 74 Checking the chain for dirt 75 Cleaning the chain 76 Checking the chain tension 77 Adjusting the chain tension 78 Checking the chain rear sprocket and engine sprocket 80 Checking the front brake discs 82 Checking the rear brake disc 83 Adjusting the basic position of the hand brake lever ...

Page 7: ...lever 138 Checking correcting the fluid level of the hydraulic clutch 139 Checking the play in the throttle cable 140 Adjusting the play in the throttle cable x 141 Checking the engine oil level 141 Changing the engine oil and filter cleaning the oil screens x 142 Draining the engine oil and filter cleaning the oil screens x 143 Filling up with engine oil x 147 Adding engine oil 149 ENGINE CONTROL...

Page 8: ...TABLE OF CONTENTS 6 AUXILIARY SUBSTANCES 188 STANDARDS 190 INDEX 191 ...

Page 9: ...tanding 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 Identifies a page reference more information is provided on the specified page Formats used The typographical formats used in this document are explained below Specific name Identifies a...

Page 10: ...ded in the owner s manual Poor adjustment and tuning of the engine and suspension can lead to damage and breakage of components Using the motorcycle in extreme conditions such as very muddy or wet roads can lead to above average wear of components such as the transmission train or the brakes For this reason it may be necessary to service or replace worn parts before the limit specified in the ser ...

Page 11: ... Website http www ktm com Work rules Special tools are necessary for some of the work These are not included with the vehicle and can be ordered under the number in paren theses Ex valve spring mounter 59029019000 During assembly non reusable parts e g self locking screws and nuts seals and seal rings O rings pins lock washers must be replaced by new parts If a thread lock e g Loctite is used for ...

Page 12: ...sport and we naturally hope that you can enjoy it to the full However it can also lead to problems with the environment and conflict with other persons Responsible behavior in handling the motorcycle can help to avoid such problems and con flicts To protect the future of motorcycle sport make sure that you use your motorcycle legally display environmental consciousness and respect the rights of ot...

Page 13: ...damage if the appropriate measures are not taken Warning Identifies a danger that will lead to environmental damage if the appropriate measures are not taken Owner s manual Be sure to read this owner s manual carefully and completely before taking your first ride It contains useful information and tips to help you operate and handle your motorcycle Only then will you find out how to best customize...

Page 14: ...VIEW OF VEHICLE 12 3 1 View of vehicle front left side vehicle differs slightly from photo B00152 10 ...

Page 15: ...VEHICLE 13 1 Combination instrument 2 Rear mirror 3 Clutch lever 4 Filler cap 5 Seat 6 Compression damping of the shock absorber 7 Shock absorber spring preload 8 Shift lever 9 Engine number 10 Oil rising pipe ...

Page 16: ...VIEW OF VEHICLE 14 3 2 View of vehicle rear right side vehicle differs slightly from photo B00151 10 ...

Page 17: ...urn signal switch horn button 3 Emergency OFF switch electric starter button 4 Hand brake lever 5 Fork spring preload fork rebound damping 6 Chassis number 7 Fork compression damping 8 Type label 9 Foot brake lever 10 Brake fluid reservoir 11 Shock absorber rebound damping ...

Page 18: ...LOCATION OF SERIAL NUMBERS 16 4 1 Chassis number type label B00153 10 Chassis number is embossed in the steering head at the right Type label is located on the upper frame tube on the right ...

Page 19: ...179 10 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 4 3 Engine number B00154 10 The engine number is stamped on the left side of the engine under the engine sprocket ...

Page 20: ... number B00155 10 The fork part number is stamped on the inner side of the fork stub 4 5 Shock absorber part number B00156 10 The shock absorber part number is stamped on the top of the shock absorber above the adjusting ring on the engine side ...

Page 21: ...ver is fitted on the left side of the handlebar The clutch is hydraulically operated and self adjusting 5 2 Hand brake lever B00158 10 The hand brake lever is fitted on the right side of the handlebar The front brake is engaged using the hand brake lever ...

Page 22: ... light are switched on High beam on The light switch is turned upwards In this position the high beam and tail light are switched on 5 4 Headlight flasher switch B00160 10 The headlight flasher switch is fitted on the left side of the handlebar Possible states Headlight flasher switch in basic position Headlight flasher switch pressed The headlight flasher switch high beam is oper ated in this pos...

Page 23: ...s to the central position after use Right turn signal on The turn signal switch is pressed to the right The turn signal switch automatically returns to the central position after use To switch off the turn signal press the turn signal switch towards the switch case 5 6 Horn button B00159 12 The horn button is fitted on the left side of the handlebar Possible states Horn button in basic position Ho...

Page 24: ...ion circuit is closed and the engine can be started Steering locked In this position the ignition circuit is interrupted and the steering locked The ignition key can be removed 5 8 Emergency OFF switch B00161 10 The emergency OFF switch is fitted on the right side of the handlebar Possible states Emergency OFF switch on This position is necessary for operation as it closes the ignition circuit Eme...

Page 25: ...Electric starter button in basic position Electric starter button pressed The electric starter is actuated in this position 5 10 Combination instrument 400972 10 The combination instrument is installed in front of the handlebar The combination instrument is divided into 4 function areas Function buttons Tachometer Indicator lights Display ...

Page 26: ...O 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 tion TRIP 2 to 0 0 Button has no function 5 12 Combination instrument tachometer 400974 10 The tachometer shows the engine speed in revolutions per minute The red marking shows the excess speed range of the engine ...

Page 27: ...on is shifted to idle The high beam indicator lamp lights up blue The high beam is switched on The temperature warning lamp lights up red The coolant has reached a critical value The fuel level warning lamp lights up orange The fuel level has reached the reserve mark The display switches to TRIP F The oil indicator lamp lights up red The oil pressure is too low Warning lamp FI MIL lights up flashe...

Page 28: ...ments light up for one second as a function test 400881 01 LEnGth Following the display function test the LEnGth wheel circumference is shown for one sec ond Info 1870 mm corresponds to the circumference of the 17 front wheel with a series pro duction tire The display then changes to the last selected mode ...

Page 29: ...e speed is shown in kilometers per hour km h or in miles per hour mph 5 16 Setting kilometers or miles Info If you change the unit the value ODO is retained and converted accordingly Making the setting according to the country Condition The motorcycle is stationary ...

Page 30: ...O mode is active Keep the MODE button pressed until the display mode changes from km h to mph or from mph to km h 5 17 Combination instrument time 400893 11 The time is shown in area of the display Info After reconnecting the battery or changing the fuse the time must be reset 5 18 Setting the clock Condition The motorcycle is stationary ...

Page 31: ...utton pressed simultaneously The time is set 5 19 Combination instrument ODO display 400839 01 In the ODO display mode the total distance traveled is shown in kilometers or miles Info This value is retained even if the battery is disconnected and or the fuse blows 5 20 Combination instrument setting resetting TRIP 1 Info The TRIP 1 trip counter is always running and counts up to 999 9 The trip cou...

Page 32: ...ing TRIP 2 Info The TRIP 2 trip counter is always running and counts up to 999 9 The trip counter can be used to measure the distance covered during trips or between two refueling stops After the value 999 9 is reached the trip counter starts at 0 0 again 400841 01 Switch on the ignition by turning the ignition key to the ON position Press the MODE button repeatedly until the TRIP 2 mode is active...

Page 33: ...e 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 5 23 Combination instrument ambient temperature display 400893 13 The ambient temperature is displayed in C or F ...

Page 34: ...tton pressed until the display mode changes from C to F or from F to C 5 25 Combination instrument warning of slippery roads 400894 10 The ice symbol lights up to indicate an increased danger of slippery roads The ice symbol appears in the display when the ambient temperature drops below the specified value Temperature 3 C 37 F The ice symbol goes out in the display when the ambient temperature ri...

Page 35: ...sts 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 Possible states Engine cold Up to five bars light up The engine is warm Six to eleven bars light up Engine hot All twelve bars flash ...

Page 36: ...r 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 Turn the ignition key clockwise Open the filler cap ...

Page 37: ... 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 Close the filler cap Push down the filler cap until the lock engages Remove the ignition key and close the cover ...

Page 38: ...t lock Super Duke B00165 10 Seat lock is located at the rear of the seat It can be locked with the ignition key 5 30 Seat lock Super Duke R B00187 10 The seat lock is behind the seat It can be locked with the ignition key ...

Page 39: ...senger to hold on to 5 32 Baggage lugs Super Duke B00239 10 Baggage lugs are located on the underside of the seat Info When the seat is mounted the lugs are accessible if they are turned outward No more than one small piece of luggage with the specified weight may be attached to the turned out baggage lugs Maximum luggage weight 5 kg 11 lb ...

Page 40: ...dents Impairment of ride behavior and vehicle operation if a helmet or helmet lock is attached to the vehicle Do not use the helmet lock for holding a helmet or other objects during the jour ney Always remove the helmet lock before starting out The steel cable in the tool set can be used to lock a helmet to the vehicle to prevent it from being stolen ...

Page 41: ...senger 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 5 36 Shift lever B00169 10 Shift lever is mounted on the left side of the engine ...

Page 42: ... can be seen in the photograph The neutral or idle position is between the first and second gear 5 37 Foot brake lever B00170 10 Foot brake lever is located in front of the right footrest The rear brake is activated using the foot brake lever ...

Page 43: ... 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 This position is mandatory for all trips The safety start system is inactive ...

Page 44: ...different tire tread patterns on front and rear wheels 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 Da...

Page 45: ...as slowly as possible to get a better feeling for the motorcycle Hold the handlebar firmly with both hands and keep your feet on the footrests when riding Run the engine in p 43 6 2 Running in the engine Do not exceed the specified engine speed and load during the running in period Guideline Maximum engine speed During the first 1 000 km 621 4 mi 6 500 rpm After the first 1 000 km 621 4 mi 9 500 r...

Page 46: ...gage cases note the manufacturer s specifications concerning the maximum payload Warning Danger of accidents Poor visibility for other road users due to slipped baggage If the tail light is covered you are less visible to traffic behind you especially in the dark Check that your baggage is fixed properly at regular intervals Warning Danger of accidents Changed handling characteristics and longer s...

Page 47: ... 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 Guideline Maximum permissible total weight 387 kg 853 lb Maximum permissible front axle load 180 kg 397 lb Maximum permissible rear axle load 250 kg 551 lb ...

Page 48: ...an the chain p 76 Check the tire condition p 98 Check the tire air pressure p 100 Check the front brake fluid level p 84 Check the rear brake fluid level p 88 Check the front brake linings p 87 Check the rear brake linings p 90 Check that the brake system is functioning properly Check the coolant level in the compensating tank p 133 Check that all controls are correctly adjusted and free to move C...

Page 49: ... in an enclosed space without an effective exhaust extraction system Caution Danger of accidents If the vehicle is operated with a discharged battery or without a battery electronic components and safety equipment may be damaged Never operate the vehicle with a discharged battery or without a battery Note Engine failure High engine speeds in cold engines have a negative effect on the service life ...

Page 50: ...tarting DO NOT open the throttle If you open the throttle during the start ing procedure fuel is not injected by the engine management system and the engine cannot start Press the starter for a maximum of 5 seconds Wait for a least 5 seconds before trying again This motorcycle is equipped with a safety start system You can only start the engine if the transmission is in neutral or if the clutch is...

Page 51: ...gnition key position Do not change the ignition key position during a journey Warning Danger of accidents Distraction from traffic activity by adjustments to the vehicle Make all adjustments when the vehicle is at a standstill Warning Risk of injury The passenger must be able to sit securely on the passenger seat The passenger must hold on to the rider or supporting strap firmly and place his her ...

Page 52: ...res have been run in Warning Danger of accidents Unstable handling characteristics Do not exceed the maximum permitted weight and axle loads The overall weight consists of motorcycle operational and with a full tank driver and passenger with protective clothing and helmet baggage Warning Danger of accidents Unstable handling characteristics due to slipped baggage Check the way your baggage is fixe...

Page 53: ...ch and open the throttle Info You can see the positions of the six forward gears in the figure The neutral or idle position is between the first and second gears First gear is used for starting off or for steep inclines After reaching maximum speed by fully opening the throttle grip turn the throttle back so it is open This will barely reduce the speed but fuel consumption will be consid erably lo...

Page 54: ...Danger of accidents If you brake too hard the wheels can lock Adapt your braking to the traffic situation and the road conditions 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 Warning Danger of accidents Reduced braking efficiency caused by spongy pressure point of front or rear brake Check the brake ...

Page 55: ...bend Shift down to a lower gear that is appropriate to your speed On long downhill stretches use the braking effect of the engine Do this by changing down two gears but do not race the engine You will require less braking force and the brakes will not overheat 7 6 Stopping parking Warning Risk of misappropriation Usage by unauthorized persons Never leave the vehicle while the engine is running Sec...

Page 56: ...y the brakes Shift the transmission to neutral Switch off the ignition by turning the ignition key to the OFF position Info If you switch off the engine with the emergency OFF switch but the ignition remains switched on at the ignition lock power continues to flow to most power consumers and the battery is soon discharged Therefore always switch off the engine with the ignition key the emergency O...

Page 57: ...hazard Avoid contact of the fuel with skin eyes and clothing Do not inhale fuel vapors If fuel gets into your eyes rinse immediately with water and contact a doctor Wash affected skin areas immediately with soap and water If fuel is swallowed contact a doc tor immediately Change clothing that has come into contact with fuel Warning Environmental hazard Improper handling of fuel is a danger to the ...

Page 58: ...el tank capacity approx 18 5 l 4 89 US gal Super unleaded ROZ 95 RON 95 PON 91 p 187 Close the filler cap p 35 400970 12 Press the SET button for two seconds The fuel level warning lamp switches off TRIP F is set to 0 0 and appears in the previous display mode Info If you do not press the SET button the reset takes place automatically after about three minutes ...

Page 59: ... brake disc p 83 Check that brake lines are undamaged and free of leaks Check the rear brake fluid level p 88 Check the shock absorber and fork for leaks Perform a fork and shock absorber service if needed and depending on vehicle use Check the swingarm bearings x Check the wheel bearing for play x Check the tire condition p 98 Check the tire air pressure p 100 Check the chain rear sprocket and en...

Page 60: ...uting x Check cables for damage and kink free routing x Check the control cables for damage kink free routing and adjustment Change the air filter Clean the air filter box x Check rectify the fluid level of the hydraulic clutch p 139 Check the fasteners for tightness x Change the coolant x Change the front brake fluid x Change the rear brake fluid x Check the clutch x Check the headlight setting p...

Page 61: ...SCHEDULE 59 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: ...dlebar to the straight ahead position Align the work stand at the front with the adapters to the fork legs Front work stand 61029055300 Info Always jack up the rear of the motorcycle first Jack up the motorcycle at the front 9 2 Taking the front from the work stand Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface Secure the mot...

Page 63: ... work stand Work stand adapter 61029055120 Work stand rear 61029055100 Stand the motorcycle upright align the work stand to the link fork and the adapters and jack up the motorcycle 9 4 Taking the rear from the workstand Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface Secure the motorcycle against falling over Remove the work ...

Page 64: ...screw up against the stop with force set the last discernible click as the last position These adjustments should be understood as a guideline and should always be the basis of your own personal suspension adaptation Do not change the adjustments at random or by more than 40 since otherwise the riding characteristics could deteriorate particularly at high speeds 9 6 Adjusting the compression dampi...

Page 65: ...tment on both fork legs Turn back counterclockwise by the number of clicks corresponding to the fork type Guideline Super Duke Compression damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Super Duke R Compression damping Comfort 23 clicks Standard 18 clicks Sport 13 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce damping ...

Page 66: ...the fork to the zero position B00176 10 Turn adjusting screws clockwise all the way Info The adjusting screws are located at the top 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 Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Super Du...

Page 67: ...ght of the rider and that of any baggage and a passenger thus ensuring an ideal compromise between maneuverability and stability B00176 11 Turn adjusting screws clockwise all the way Info The adjusting screws are located at the top end of the fork legs Make the same adjustment on both fork legs Turn back counterclockwise by the number of turns according to the fork type Guideline Super Duke Spring...

Page 68: ...reload has no influence on the rebound damping although the adjusting screws turn during the adjustment work However you should also adjust the rebound damping when you alter the spring preload 9 9 Bleeding the fork legs Lean the motorcycle on the side stand B00177 10 Remove bleeder screws briefly Any excess pressure escapes from the interior of the fork Mount and tighten the bleeder screws Info C...

Page 69: ...nd not the riding speed of the motorcycle Changes in the low speed range settings have an impact on the high speed range and vice versa 9 11 Adjusting the low 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 wor...

Page 70: ...lockwise by the number of clicks corresponding to the shock absorber type Guideline Super Duke Compression damping low speed Comfort 25 clicks Standard 20 clicks Sport 10 clicks Full payload 10 clicks Super Duke R Compression damping low speed Comfort 25 clicks Standard 20 clicks Sport 15 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce damping ...

Page 71: ...scription 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 B00178 11 Turn adjusting screw clockwise all the way using a socket wrench Info Do not loosen nut Turn back counterclockwise the number of turns corresponding to the shock absorber type Guideline Super Duke Compression damping high speed Com...

Page 72: ... 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 B00179 10 Turn adjusting screw clockwise up to the last perceptible click Turn back counterclockwise by the number of clicks corresponding to the shock absorber type Guideline Super Duke Reboun...

Page 73: ...st to get the feel of the new ride behavior Info The spring preload defines the initial situation of the spring process on the shock absorber 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 Before changing the spring preload make a note of the prese...

Page 74: ... Measure the overall spring length without a load Tension the spring by turning adjusting ring to the prescribed value Guideline Super Duke Spring preload Comfort 6 mm 0 24 in Standard 6 mm 0 24 in Sport 6 mm 0 24 in Full payload 6 mm 0 24 in Super Duke R Spring preload Comfort 6 mm 0 24 in Standard 6 mm 0 24 in Sport 6 mm 0 24 in Tighten locking ring ...

Page 75: ...n negatively affect han dling and steering precision so the damping should be set to low 9 16 Adjusting the steering damper Super Duke R Info The hydraulic steering damper stabilizes the steering if the front wheel is raised off the ground or carries no load In contrast to other damping elements the steering damper is adjusted with the damping element open B00234 10 Turn the adjusting screw counte...

Page 76: ...stance of apart Hole distance 15 mm 0 59 in The handlebar can be mounted in two different positions In this way the handlebar can be installed in the position most comfortable for the rider 9 18 Adjusting the handlebar position x Super Duke R 1 1 2 2 B00236 10 Remove the four screws Remove the handlebar clamp Take off the handlebar and set it aside Info Protect the motorcycle and attachments again...

Page 77: ...right Position the handlebar Info Ensure that the cables and lines are routed correctly Position the handlebar clamp Mount and tighten the four screws and tighten evenly Guideline Screw handlebar clamp M8 20 Nm 14 8 lbf ft 9 19 Checking the chain for dirt 400678 01 Check the chain for coarse dirt accumulation If the chain is very dirty Clean the chain p 76 ...

Page 78: ...il and grease and clean them with brake cleaner when necessary 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 The service life of the chain depends largely on its maintenance 400725 01 Clean the chain regularly Rinse off loose dirt with a soft jet of wat...

Page 79: ...k On the other hand if the chain is loose it can fall off the engine sprocket or the rear sprocket and block the rear wheel or damage the engine Check the chain tension and correct if necessary 700570 01 Lean the motorcycle on the side stand Shift the transmission to neutral In the area after the chain sliding guard press the chain upward toward the link fork and measure chain tension Info The upp...

Page 80: ...gine sprocket rear sprocket bearings in transmission and rear wheel are under additional load Apart from premature wear in extreme cases the chain can rupture or the countershaft of the transmission can break On the other hand if the chain is loose it can fall off the engine sprocket or the rear sprocket and block the rear wheel or damage the engine Check the chain tension and correct if necessary...

Page 81: ...eference marks The rear wheel is then correctly aligned Info The upper chain section must be taut Chain wear is not always even so you should check the setting at different chain positions Tighten nuts Make sure that chain adjusters are resting against adjusting screws Tighten nut Guideline Nut rear wheel spindle M25x1 5 90 Nm 66 4 lbf ft Thread greased Info The wide adjustment range of the chain ...

Page 82: ... sprocket and engine sprocket 100132 10 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 x Info The rear sprocket engine sprocket and chain should always be changed together ...

Page 83: ...ximum distance at the longest chain section 272 mm 10 71 in If distance is greater than the specified measurement Replace the chain x Info When the chain is replaced the rear sprocket and engine sprocket should also be changed New chains wear out faster on old worn sprockets For safety reasons the chain has no chain joint B00241 01 Check the chain sliding guard for wear If the chain sliding guard ...

Page 84: ...rkshop will be glad to help 100135 10 Check the thickness of the brake disc in several places to see if it conforms to measure ment Info Wear reduces the thickness of the brake discs in area of the brake discs Brake discs wear limit Front 4 mm 0 16 in If the brake disc thickness is less than the specified value Change the brake discs x Check the brake discs for damage cracking and deformation If t...

Page 85: ...00480 10 Check the thickness of the brake disc in several places to see if it conforms to measure ment Info Wear reduces the thickness of the brake disc in area of the brake disc Brake disc wear limit Rear 4 5 mm 0 177 in If the brake disc thickness is less than the specified value Change the brake disc x Check the brake disc for damage cracking and deformation If damage cracks or deformation are ...

Page 86: ...ake fluid level Warning Danger of accidents Failure of the brake system If the brake fluid level falls below the MIN mark this indicates a leakage in the brake system or worn out brake linings Check the brake system and do not continue riding 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 ...

Page 87: ...ake system or worn out brake linings Check the brake system and do not continue riding Your authorized KTM workshop will be glad to help Warning Skin irritation Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and keep out of the reach of children Wear suitable protective clothing and goggles If brake fluid gets into your eyes rinse thoroughly with water and contac...

Page 88: ...corrosive and will damage painted surfaces Use only clean brake fluid from a sealed container B00182 10 Move the brake fluid reservoir mounted on the handlebar to a horizontal position Remove screws Remove cover with membrane Add brake fluid to the MAX level Brake fluid DOT 4 DOT 5 1 p 184 Position the cover with the membrane Mount and tighten the screws Info Clean up overflowed or spilt brake flu...

Page 89: ...cidents 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 reduced and the brake discs are ren...

Page 90: ...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 B00184 10 Stand the vehicle upright Check the brake fluid level of the brake fluid reservoir If the fluid level reaches the MIN mark Add rear brake fluid x p 88 9 32 Adding rear brake fluid x Warning Danger of accidents Failure of the brake system ...

Page 91: ...e 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 Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals a...

Page 92: ...33 Checking the rear brake linings 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 brakin...

Page 93: ...r is encountered Change the rear brake linings x 9 34 Removing the front wheel x Jack up the motorcycle at the rear p 61 Jack up the motorcycle at the front p 60 B00244 10 Remove the screws from both brake calipers Press back the brake linings with a light lateral tilting of the brake calipers on the brake disc Pull the brake calipers carefully back from the brake discs and hang them to one side I...

Page 94: ... efficiency caused by damaged brake discs Always lay the wheel down in such a way that the brake discs are not dam aged Holding the front wheel withdraw the wheel spindle Take the front wheel out of the fork 9 35 Installing the front wheel x Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean th...

Page 95: ...ork position it and insert the wheel spindle Mount and tighten screw Guideline Bolt front axle M25x1 5 45 Nm 33 2 lbf ft B00244 11 Position the brake calipers and check that the brake linings are seated correctly Mount screws on both brake calipers but do not tighten yet Operate the hand brake lever repeatedly until the brake lining presses up against the brake disc and there is a pressure point F...

Page 96: ...rom the work stand p 61 700640 11 Pull the front brake and compress the fork powerfully a few times The fork legs straighten Fully tighten screws Guideline Screw fork stub M8 15 Nm 11 1 lbf ft 9 36 Removing the rear wheel x Jack up the motorcycle at the rear p 61 B00134 10 Remove nut Remove chain adjuster Pull out wheel spindle to the point where the chain adjuster is no longer in contact with the...

Page 97: ...cs are not dam aged Take the rear wheel carefully out of the swingarm without damaging the rim and or brake disc Info Do not operate the foot brake when the rear wheel is removed 9 37 Installing the rear wheel x Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when nec...

Page 98: ...or worn Replace the wheel bearing x Remove bushing and bushing Clean and grease the roll surfaces of the bushing and the shaft seal rings Long life grease p 189 Fit the bushings Clean and grease the thread of the wheel spindle and nut Long life grease p 189 Clean the fixing locations on the brake caliper support and swingarm ...

Page 99: ...gs on the left and right chain adjusters must be in the same position relative to the reference marks Nut rear wheel spindle M25x1 5 90 Nm 66 4 lbf ft Thread greased Operate the foot brake lever repeatedly until the brake linings lie on the brake disc and there is a pressure point Take the rear from the work stand p 61 Check the chain tension p 77 9 38 Checking rear hub shock absorbers x Info The ...

Page 100: ...Checking the tire condition Warning Danger of accidents Uncontrollable handling characteristic caused by a flat tire For your own safety have damaged tires changed immediately Warning Danger of crashing Poor vehicle handling due to different tire tread patterns on front and rear wheels The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over t...

Page 101: ...fo The type condition and air pressure of the tires all have a major impact on the handling of the motorcycle Worn tires have a negative effect on vehicle handling especially on wet surfaces 400602 10 Check the front and rear tires for cuts run in objects and other damage If the tires exhibit cuts run in objects or other damage Change the tires Check the depth of the tread Info Note local national...

Page 102: ...state of wear If a tire is more than five years old Change the tires 9 40 Checking the tire air pressure Info Low tire air pressure leads to abnormal wear and overheating of the tire Correct tire air pressure ensures optimal riding comfort and maximum tire service life 400695 01 Remove the dust cap Check the tire air pressure when the tires are cold Tire air pressure solo Front 2 4 bar 35 psi Rear...

Page 103: ...y 9 41 Removing the front spoiler 0 0 0 1 1 1 1 2 2 B00245 10 Remove screws with the washer Loosen screws and remove the front spoiler from the front 9 42 Installing the front spoiler 0 0 0 1 1 1 1 2 2 B00245 10 Position the front spoiler Mount and tighten screws with the washer Guideline Screw front spoiler M6 10 Nm 7 4 lbf ft Loctite 243 Fully tighten screws ...

Page 104: ...t 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 B00187 10 Super Duke R 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 ...

Page 105: ... The two hooks must engage in the subframe Turn the ignition key counterclockwise in the seat lock and withdraw it Finally check that the seat is correctly mounted B00189 01 Super Duke R Position the seat on the motorcycle and push it forward Turn the ignition key counterclockwise in the seat lock and withdraw it Finally check that the seat is correctly mounted ...

Page 106: ...at 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 9 46 Adjusting the seat height Super Duke R Remove the seat p 102 ...

Page 107: ...sis screws M6 10 Nm 7 4 lbf ft Condition Without spacer Use an M6x16 screw Condition Spacer 7 mm 0 28 in Use an M6x20 screw Condition Spacer 15 mm 0 59 in Use an M6x30 screw Mount the seat p 103 9 47 Mounting the helmet lock on the vehicle Warning Danger of accidents Impairment of ride behavior and vehicle operation if a helmet or helmet lock is attached to the vehicle Do not use the helmet lock f...

Page 108: ...ith one loop on the lug Steel cable 60012015000 Guide the steel cable through the helmet opening Then position the free loop of the steel cable on the lug Position the helmet carefully on the side of the vehicle Mount the seat p 103 9 48 Removing the spoiler Info The operations are the same on the left and right sides ...

Page 109: ...MAINTENANCE WORK ON FRAME AND ENGINE 107 B00197 10 Remove screws and Take off the spoiler 9 49 Installing the spoiler Info The operations are the same on the left and right sides ...

Page 110: ...MAINTENANCE WORK ON FRAME AND ENGINE 108 B00197 10 Position the spoiler Mount and tighten screws and Guideline Screw spoiler M6 6 Nm 4 4 lbf ft ...

Page 111: ...ontact rinse with large amounts of water If battery acid gets in the eyes rinse with water for at least 15 minutes and contact a doctor Caution Danger of accidents If the vehicle is operated with a discharged battery or without a battery electronic components and safety equipment may be damaged Never operate the vehicle with a discharged battery or without a battery Switch off all power consumers ...

Page 112: ...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 The vehicle is then no longer safe to ride 9 51 Installing the battery x B00192 11 Position the battery in the battery compartment Connect positive cable Connect negative cable ...

Page 113: ...rotective clothing and goggles Avoid contact with battery acid and battery gases Keep the battery away from sparks or open fire Charge only in well ventilated rooms In the event of skin contact rinse with large amounts of water If battery acid gets in the eyes rinse with water for at least 15 minutes and contact a doctor Warning Environmental hazard Battery parts and acid are harmful to the enviro...

Page 114: ...th a high charging current shortens the battery s service life If the charging current charging voltage and charging time are exceeded electrolyte escapes through the safety valves This reduces the battery capacity If the battery is depleted from starting the vehicle repeatedly the battery must be charged immediately If the battery is left in a discharged state for an extended period it will becom...

Page 115: ...battery Info Never remove lid Charge the battery at no more than 10 of the capacity specified on battery housing Switch off the charger after charging Guideline The charge current charge voltage and charge time must not be exceeded Charge the battery regularly when the motorcycle is not in use 3 months Install the battery x p 110 9 53 Changing the main fuse Warning Fire hazard The electrical syste...

Page 116: ...ve the front spoiler p 101 B00194 10 Detach the connector and protection cap Remove the faulty main fuse Info A defective fuse can be identified by the burned out fuse wire A reserve fuse is located in the starter relay Install a new main fuse Fuse 58011109130 p 172 Tip Place the spare fuse in the starter relay so that it is available if needed Mount protection cap and the connector Install the fr...

Page 117: ...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 Switch off all power consumers and switch off the engine Remove the seat p 102 B00195 10 Open fuse box cover ...

Page 118: ...ignal Fuse 4 10A radiator fan Fuse 5 10A fuel pump Fuse 6 10A power relay combination instrument Fuse 7 10A clock Fuse 8 10A for supplementary equipment standard accessories Fuse 9 10A for auxiliary equipment accessories connected to the ignition switch Fuse 10 not used Fuse SPARE 10A 15A spare fuses Use spare fuses with the correct rating only Fuse 75011088010 p 172 Fuse 75011088015 p 172 Tip Ins...

Page 119: ...flector Clean the lamp and keep it free of grease before mounting Switch off all power consumers and switch off the engine B00206 10 Remove screw B00207 10 Push the headlight mask spoiler slightly to the side Pull out lamp socket Remove bulb Position a new light bulb in the holder Parking light W5W socket W2 1x9 5d p 173 Carefully position the holder with the bulb into the holder in the headlight ...

Page 120: ...ning properly 9 56 Changing the low beam bulb 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 Switch off all power consumers and switch off the engine B00198 10 Remove screws ...

Page 121: ...eadlight mask forward B00200 10 Remove rubber cap Disconnect plug in connector B00201 10 Detach spring bar Remove headlight bulb Position the new headlight bulb in the headlight housing Low beam H7 socket PX26d p 173 Info Insert the headlight bulb so that the bayonet lugs latch into the slots ...

Page 122: ... mask Mount and tighten screws Guideline Remaining chassis screws M6 10 Nm 7 4 lbf ft Check that the lighting is functioning properly 9 57 Changing the high beam bulb 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 123: ...MAINTENANCE WORK ON FRAME AND ENGINE 121 Switch off all power consumers and switch off the engine B00198 10 Remove screws B00199 01 Cover the fender with a cloth Swing the headlight mask forward ...

Page 124: ...tor B00204 10 Detach spring bar Remove headlight bulb Position the new headlight bulb in the headlight housing High beam H3 socket PX22s p 173 Info Insert the headlight bulb so that the bayonet lugs latch into the slots Position the spring bar B00203 10 Connect plug in connector Mount rubber cap ...

Page 125: ...r Clean the lamp and keep it free of grease before mounting B00208 10 Remove the screw on the rear of the turn signal housing Carefully remove diffuser Press bulb carefully into the socket turn it counterclockwise by about 30 and pull it out of the socket Press the new bulb carefully into the socket and turn it clockwise until it stops Turn signal RY10W socket BAU15s p 173 Check the turn signal to...

Page 126: ...the seat p 102 B00209 10 Turn bulb socket counterclockwise all the way and take it out of the tail light B00211 10 Push bulb carefully into the socket turn it counterclockwise and pull it out of the socket Press the new bulb carefully into the socket and turn it clockwise until it stops Brake light PR21W socket BAW15s p 173 Insert the bulb socket into the tail light and turn clockwise until it sto...

Page 127: ...reflector Clean the lamp and keep it free of grease before mounting Remove the seat p 102 B00209 11 Pull bulb holders carefully out of the bracket B00210 10 Remove bulb Position a new light bulb in the holder Tail light WR5W socket W2 1x9 5d p 173 Carefully position the holders with the bulbs into the holder in the tail light Mount the seat p 103 Check that the tail light bulbs are functioning pro...

Page 128: ...ense plate lamp B00212 10 Super Duke Remove screws B00213 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 173 Carefully position the holder with the bulb into the bracket ...

Page 129: ...NTENANCE WORK ON FRAME AND ENGINE 127 B00212 10 Position the license plate holder Mount and tighten screws B00214 10 Super Duke R Remove screw B00215 10 Carefully pull holder out of the license plate lamp ...

Page 130: ...ove 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 B00214 10 Mount and tighten screw Check that the license plate lamp is functioning properly ...

Page 131: ...nce of vertically in front of the wall and switch on the low beam headlight Guideline Distance 5 m 16 ft The rider with luggage and passenger if applicable now mounts the motorcycle Check the headlight setting The light dark boundary must lie exactly on the lower mark when the motorcycle is ready to operate with the rider mounted along with any luggage and a passenger if applicable If the boundary...

Page 132: ...lower mark applied in Checking headlight adjustment Info Turn clockwise to increase the light range turn counterclockwise to reduce the light range 9 64 Cooling system B00222 11 The water pump in the engine forces the coolant to flow The pressure in the cooling system resulting from heat is regulated by a valve in the radia tor cap This permits the specified coolant temperature without causing any...

Page 133: ...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 In case of scalding rinse immediately with lukewarm water Warning Danger of poisoning Coolant is poisonous and a health hazard Avoid contact between coolant and skin eyes and clothing If it gets into your eyes rinse immed...

Page 134: ...lant level in the compensating tank The coolant level must be between min and max If the coolant level in the compensating tank does not meet specifications but the tank is not empty Add coolant to the upper marking Alternative 1 Coolant p 184 Alternative 2 Coolant mixed ready to use p 184 If there is no coolant in the compensating tank Check the cooling system for leaks x Info Do not start up the...

Page 135: ...ting tank 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 In case of scalding rinse immediately with lukewarm water Warning Danger of poisoning Coolant is poisonous and a health hazard Avoid c...

Page 136: ... level in the compensating tank does not meet specifications but the tank is not empty Remove the spoiler p 106 Info Remove the right side only Remove the compensating tank cap Add coolant to the max marking Alternative 1 Coolant p 184 Alternative 2 Coolant mixed ready to use p 184 Mount the cap of the compensating tank Install the spoiler p 107 If there is no coolant in the compensating tank Chec...

Page 137: ... and cooling system to cool down In case of scalding rinse immediately with lukewarm water Warning Danger of poisoning Coolant is poisonous and a health hazard Avoid contact between coolant and skin eyes and clothing If it gets into your eyes rinse immediately with water and contact a doctor Wash affected skin areas immediately with soap and water If coolant is swallowed contact a doctor immediate...

Page 138: ...ing Danger of poisoning Coolant is poisonous and a health hazard Avoid contact between coolant and skin eyes and clothing If it gets into your eyes rinse immediately with water and contact a doctor Wash affected skin areas immediately with soap and water If coolant is swallowed contact a doctor immediately Change clothes that have come into contact with coolants Keep coolant out of the reach of ch...

Page 139: ...ooling system is less effective at cooling and the engine can overheat B00223 10 Remove the radiator cap and pour in coolant until it emerges without bubbles at the vent hole and then immediately mount and tighten the bleeder screw Guideline Remaining chassis screws M6 10 Nm 7 4 lbf ft Alternative 1 Coolant p 184 Alternative 2 Coolant mixed ready to use p 184 Fill the radiator completely with cool...

Page 140: ...light up Stop the engine and allow it to cool down When the engine is cool check the coolant level in the radiator and add coolant if nec essary Check the coolant level in the compensating tank p 133 Install the spoiler p 107 9 69 Adjusting the basic position of the clutch lever Info Turn the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar Turn the adj...

Page 141: ...ith increasing wear of the clutch lining disc Do not use brake fluid Move the clutch fluid reservoir mounted on the handlebar to a horizontal position 100194 10 Check the fluid level The fluid level must be between the MIN and MAX markings If the coolant level does not meet specifications Remove the screw cap with the membrane Correct the fluid level of the hydraulic clutch Hydraulic fluid 15 p 18...

Page 142: ...just the play in the throttle cable x p 141 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 Start the engine and let it run idle Move the handlebar to and f...

Page 143: ...ew Guideline Play in throttle cable 3 5 mm 0 12 0 2 in Tighten counter nut 9 73 Checking the engine oil level 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 syste...

Page 144: ...e wait one minute before checking the level Check the engine oil level at oil rising pipe The engine oil level must be between the min and max markings If the engine oil level is not at the specified level Add engine oil p 149 9 74 Changing the engine oil and filter cleaning the oil screens x B00119 01 Drain the engine oil and filter clean the oil screens x p 143 Fill up with engine oil x p 147 ...

Page 145: ...urns rinse immediately with lukewarm water 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 Drain the engine oil only when the engine is warm Remove the front spoiler p 101 B00225 10 Place a suitable container under the engine Remove the oil drain plug wit...

Page 146: ... cover Pull oil screen out of the engine case with pliers B00227 10 Place a suitable container under the engine Remove oil drain plug Fully drain the engine oil out of the oil tank Remove screws and move oil line to one side B00228 10 Pull oil sieve out of the oil tank ...

Page 147: ... drain the engine oil Clean all oil screens and oil drain plugs with a magnet Clean all sealing surfaces B00230 10 Insert the new oil filter Lubricate the O ring of the oil filter cover Mount oil filter cover Mount and tighten the screws Guideline Remaining engine screws M5 6 Nm 4 4 lbf ft B00231 10 Check seal ring of the oil sieve for damage and correct seating Insert oil sieve into the oil tank ...

Page 148: ... magnet M12x1 5 25 Nm 18 4 lbf ft B00225 10 Mount oil drain plug with the magnet and new seal ring and tighten Guideline Oil drain plug with magnet M22x1 5 35 Nm 25 8 lbf ft B00226 11 Slide oil sieve into the engine case with the TOP marking facing up Check the form ring in cover for damage and correct seating Position the cover Mount and tighten the screws Guideline Screw clutch cover M6 10 Nm 7 ...

Page 149: ...right side only B00232 10 The oil must be added in two steps Engine oil 3 0 l 3 2 qt External temperature 0 C 32 F Engine oil SAE 10W 50 p 185 External temperature 0 C 32 F Engine oil SAE 5W 40 p 185 Remove screw plug and add engine oil Engine oil 1st quantity approx 2 50 l 2 64 qt External temperature 0 C 32 F Engine oil SAE 10W 50 p 185 External temperature 0 C 32 F Engine oil SAE 5W 40 p 185 Mo...

Page 150: ...t the engine and run it until it reaches operating temperature Six bars of the temperature display light up Check the lubrication system for leaks Switch off the engine Park the motorcycle on a horizontal surface in a vertical position not on the side stand Remove the plug B00224 11 Add engine oil to the max marking of oil rising pipe Engine oil 2nd quantity approx 0 50 l 0 53 qt External temperat...

Page 151: ...iler p 106 Info Remove the right side only B00233 10 Remove screw plug Add engine oil to the max marking of oil rising pipe Condition External temperature 0 C 32 F Engine oil SAE 10W 50 p 185 Condition External temperature 0 C 32 F Engine oil SAE 5W 40 p 185 Info For optimal performance of the engine oil do not mix different types of engine oil We recommend changing the engine oil if necessary Mou...

Page 152: ...p FI MIL flashes 7x short Error level condition Throttle position sensor circuit B input signal too low Throttle position sensor circuit B input signal too high Blink code FI of warning lamp MIL 09 Warning lamp FI MIL flashes 9x short Error level condition Manifold absolute pressure sensor cylinder 1 input signal too low Manifold absolute pressure sensor cylinder 1 input signal too high Blink code...

Page 153: ...ir temperature sensor input signal too high Blink code FI of warning lamp MIL 14 Warning lamp FI MIL flashes 1x long 4x short Error level condition Ambient air pressure sensor input signal too low Ambient air pressure sensor input signal too high Blink code FI of warning lamp MIL 15 Warning lamp FI MIL flashes 1x long 5x short Error level condition Rollover sensor A D type input signal too low Rol...

Page 154: ...or level condition Power supply circuit fault Blink code FI of warning lamp MIL 25 Warning lamp FI MIL flashes 2x long 5x short Error level condition Side stand A D type malfunction in circuit Blink code FI of warning lamp MIL 33 Warning lamp FI MIL flashes 3x long 3x short Error level condition Injector cylinder 1 circuit fault Blink code FI of warning lamp MIL 34 Warning lamp FI MIL flashes 3x l...

Page 155: ... level condition Fuel pump control interruption short circuit to ground Fuel pump control input signal too high Blink code FI of warning lamp MIL 45 FI Warning lamp MIL flashes 4x long 5x short Error level condition Heating lambda sensor cylinder 1 sensor 1 interruption short circuit to ground Heating lambda sensor cylinder 1 sensor 1 input signal too high Blink code FI of warning lamp MIL 46 Warn...

Page 156: ... warning lamp MIL 54 Warning lamp FI MIL flashes 5x long 4x short Error level condition Secondary air valve interruption short circuit to ground Secondary air valve input signal too high Blink code FI of warning lamp MIL 68 Warning lamp FI MIL flashes 6x long 8x short Error level condition Manifold absolute pressure sensor cylinder 1 connection leaks Blink code FI of warning lamp MIL 69 Warning la...

Page 157: ...amp 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: ...bination instrument defective Check the combination instrument x Control unit for electric start lock defective Check the control unit of the electric start lock x Engine turns only if the clutch lever is drawn The vehicle is in gear Shift the transmission to neutral Defect in safety start system Check the safety start system x Engine turns although a gear is engaged Defect in safety start system ...

Page 159: ...vidual power consumers p 115 Thermostat defective Check the thermostat x Defect in radiator fan system Check the radiator fan system x Air in cooling system Fill bleed the cooling system x p 136 Warning lamp FI MIL lights up flashes Defect in fuel injection system Read out the fault memory using the KTM diag nostics tool x Engine dies during a trip Lack of fuel Fill up with fuel p 55 Fuse 1 5 blow...

Page 160: ...ff when vehicle was parked Recharge the battery x p 111 Battery is not charged by the alternator Check the charging voltage x Combination instrument shows nothing in the display Fuse 6 blown Change the fuses of individual power consumers p 115 Speedometer in combination instru ment not functioning Wiring harness of wheel revolution counter damaged or plug in connec tor oxidized Check the wheel spe...

Page 161: ...ulations Info If you clean the motorcycle regularly its value and appearance will be maintained over a long period Avoid direct sunshine on the motorcycle during cleaning Close off the exhaust system to keep water from entering Remove coarse dirt particles with a gentle spray of water Spray very dirty areas with a normal motorcycle cleaner and then clean with a paintbrush Motorcycle cleaner p 189 ...

Page 162: ...er at inaccessible positions in the engine and on the brakes to evaporate After the motorcycle has cooled off lubricate all moving parts and bearings Clean the chain p 76 Treat bare metal parts except for brake discs and exhaust system with anti corrosion materials Cleaning and preserving materials for metal rubber and plastic p 188 Treat all painted parts with a mild paint polish High luster poli...

Page 163: ...n it with cold water Warm water would enhance the corrosive effects of salt Clean the motorcycle p 159 Treat the engine the swingarm and all other bare or galvanized parts except brake discs with a wax based anti corrosion substance Info To prevent serious reduction of the braking efficiency make sure no anti corrosion substance gets on to the brake discs After use on salted roads clean the motorc...

Page 164: ...fill up with fresh fuel when you put the motorcycle back into opera tion Clean the motorcycle p 159 Change the engine oil and filter clean the oil screens x p 142 Check the antifreeze and coolant level p 131 Check the tire air pressure p 100 Remove the battery x p 109 Recharge the battery x p 111 Guideline Storage temperature of battery without direct sunshine 0 35 C 32 95 F The storage place shou...

Page 165: ...properly the water vapor produced during combustion condenses and causes valves and exhaust system to rust 14 2 Putting into operation after storage Take the front from the work stand p 60 Take the rear from the work stand p 61 Recharge the battery x p 111 Install the battery x p 110 Set the clock p 28 Fill up with fuel p 55 Carry out checks before putting into operation p 46 Take a test ride ...

Page 166: ... Valve diameter Super Duke R Exhaust 33 mm 1 3 in Intake 41 mm 1 61 in Valve clearance Exhaust at 20 C 68 F 0 25 0 30 mm 0 0098 0 0118 in Intake at 20 C 68 F 0 10 0 15 mm 0 0039 0 0059 in Crankshaft bearing Sleeve bearing Conrod bearing Sleeve bearing Piston Forged light alloy Piston ring 1 L ring 1 tapered compression piston ring 1 oil scraper ring Engine lubrication Dry sump lubrication system w...

Page 167: ...ition adjustment Alternator 12 V 450 W Spark plug Super Duke NGK KR8DI Spark plug Super Duke R NGK LKAR8AI 9 Spark plug electrode gap 0 8 mm 0 031 in Cooling Water cooling permanent circulation of coolant by water pump Idle speed 1 400 1 500 rpm Cold start device Electric starter 15 1 Capacity engine oil Engine oil 3 0 l 3 2 qt External temperature 0 C 32 F Engine oil SAE 10W 50 p 185 External tem...

Page 168: ...TECHNICAL DATA ENGINE 166 15 2 Capacity coolant Coolant 2 10 l 2 22 qt Coolant p 184 Coolant mixed ready to use p 184 ...

Page 169: ...6 10 Nm 7 4 lbf ft Screw in alternator cover M6 10 Nm 7 4 lbf ft Screw bearing bolt in alternator cover M6 10 Nm 7 4 lbf ft Loctite 243 Screw camshaft bearing support M6 10 Nm 7 4 lbf ft Screw clutch cover M6 10 Nm 7 4 lbf ft Screw clutch spring M6 10 Nm 7 4 lbf ft Screw engine case M6 10 Nm 7 4 lbf ft Screw freewheel holder M6 10 Nm 7 4 lbf ft Loctite 243 Screw freewheel ring M6 13 Nm 9 6 lbf ft ...

Page 170: ...ng chain guide rail M8 15 Nm 11 1 lbf ft Loctite 243 Bearing bolt timing chain tensioning rail M8 20 Nm 14 8 lbf ft Loctite 243 Screw camshaft bearing support M8 Step 1 10 Nm 7 4 lbf ft Step 2 18 Nm 13 3 lbf ft Screw clutch cover M8 15 Nm 11 1 lbf ft Screw cylinder head M8 Step 1 18 Nm 13 3 lbf ft Step 2 23 Nm 17 lbf ft Loctite 243 Stud exhaust flange M8 15 Nm 11 1 lbf ft Bearing bolt timing gears...

Page 171: ... 2nd cylinder M12x1 5 25 Nm 18 4 lbf ft Spark plug M12x1 5 12 Nm 8 9 lbf ft Plug oil filter housing M14x1 5 15 Nm 11 1 lbf ft Loctite 243 Bleeder flange alternator cover M16x1 5 10 Nm 7 4 lbf ft Loctite 243 Plug timing chain tensioner M16x1 5 20 Nm 14 8 lbf ft Rotor screw M16x1 5 150 Nm 110 6 lbf ft Loctite 243 Nut balancer shaft M20x1 5 120 Nm 88 5 lbf ft Loctite 243 Nut engine sprocket M20x1 5 1...

Page 172: ...TECHNICAL DATA ENGINE TIGHTENING TORQUES 170 Nut primary gear M33LHx1 5 130 Nm 95 9 lbf ft Loctite 243 ...

Page 173: ...ion travel Super Duke R Front 135 mm 5 31 in Rear 150 mm 5 91 in Brake system Front Double disc brake with radially screwed four piston brake calipers float mounted brake discs Rear Single disc brake with dual piston brake caliper rigid mounted brake disc Brake discs diameter Front 320 mm 12 6 in Rear 240 mm 9 45 in Brake discs wear limit Front 4 mm 0 16 in Brake disc wear limit Rear 4 5 mm 0 177 ...

Page 174: ...50 mm 33 46 in Seat height unloaded Super Duke R 860 875 mm 33 86 34 45 in Ground clearance unloaded Super Duke 140 mm 5 51 in Ground clearance unloaded Super Duke R 150 mm 5 91 in Weight without fuel approx 186 kg 410 lb Maximum permissible front axle load 180 kg 397 lb Maximum permissible rear axle load 250 kg 551 lb Maximum permissible total weight 387 kg 853 lb Battery YTZ14S Battery voltage 1...

Page 175: ...light W5W socket W2 1x9 5d 12 V 5 W Instrument lights and indicator lamps LED Turn signal RY10W socket BAU15s 12 V 10 W Tail light Super Duke WR5W socket W2 1x9 5d 12 V 5 W Tail light Super Duke R LED Brake light Super Duke PR21W socket BAW15s 12 V 21 W Brake light Super Duke R LED License plate lamp W5W socket W2 1x9 5d 12 V 5 W ...

Page 176: ...IABLO CORSA III Super Duke R 120 70 ZR 17 M C 58W TL Pirelli DRAGON SUPERCORSA PRO 180 55 ZR 17 M C 73W TL Pirelli DRAGON SUPERCORSA PRO Additional information is available in the Service section under http www ktm com 17 3 Capacity fuel Total fuel tank capacity approx 18 5 l 4 89 US gal Super unleaded ROZ 95 RON 95 PON 91 p 187 Fuel reserve approx 3 5 l 3 7 qt ...

Page 177: ...ks Full payload 10 clicks Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Spring preload Preload Adjuster Comfort 5 turns Standard 5 turns Sport 5 turns Full payload 5 turns Spring length with preload spacer s 353 mm 13 9 in Spring rate Soft 9 N mm 51 lb in Medium standard 9 5 N mm 54 2 lb in Hard 10 N mm 57 lb in Fork length 757 mm 29 8 in ...

Page 178: ...wn 4860 ROMA PA Compression damping Comfort 23 clicks Standard 18 clicks Sport 13 clicks Rebound damping Comfort 12 clicks Standard 10 clicks Sport 8 clicks Spring preload Preload Adjuster Comfort 5 turns Standard 5 turns Sport 5 turns Spring length with preload spacer s 352 mm 13 86 in Spring rate Soft 9 N mm 51 lb in Medium standard 9 5 N mm 54 2 lb in Hard 10 N mm 57 lb in Fork length 757 mm 29...

Page 179: ...TECHNICAL DATA FORK 177 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: ...25 clicks Standard 20 clicks Sport 10 clicks Full payload 10 clicks Compression damping high speed Comfort 2 turns Standard 1 5 turns Sport 1 turn Full payload 1 turn Rebound damping Comfort 20 clicks Standard 12 clicks Sport 8 clicks Full payload 8 clicks Spring preload Comfort 6 mm 0 24 in Standard 6 mm 0 24 in Sport 6 mm 0 24 in Full payload 6 mm 0 24 in Spring rate ...

Page 181: ...length 387 mm 15 24 in Shock absorber fluid Shock absorber oil SAE 2 5 50180342S1 p 186 19 2 Super Duke R Shock absorber part number 15 18 7J 05 Shock absorber WP Suspension 4618 BAVP DCC Compression damping low speed Comfort 25 clicks Standard 20 clicks Sport 15 clicks Compression damping high speed Comfort 2 turns Standard 1 5 turns Sport 1 turn Rebound damping Comfort 12 clicks Standard 10 clic...

Page 182: ... 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 10 bar 145 psi Static sag 17 mm 0 67 in Fitted length 392 mm 15 43 in Shock absorber fluid Shock absorber oil SAE 2 5 50180342S1 p 186 ...

Page 183: ...Screw chain sliding guard M6 6 Nm 4 4 lbf ft Loctite 243 Screw foot brake cylinder M6 10 Nm 7 4 lbf ft Loctite 243 Screw front spoiler M6 10 Nm 7 4 lbf ft Loctite 243 Screw fuel pump M6 6 Nm 4 4 lbf ft Screw fuel tank holder M6 6 Nm 4 4 lbf ft Screw heel protector M6 2 Nm 1 5 lbf ft Loctite 243 Screw push rod ball joint on foot brake cylinder M6 10 Nm 7 4 lbf ft Loctite 243 Screw shift rod M6 12 N...

Page 184: ...bar clamp M8 20 Nm 14 8 lbf ft Screw ignition lock ratchet screw M8 Loctite 243 Screw lower subframe M8 25 Nm 18 4 lbf ft Screw rear brake disc M8 30 Nm 22 1 lbf ft Loctite 243 Screw rear footrest bracket Super Duke M8 25 Nm 18 4 lbf ft Loctite 243 Screw shift lever M8 25 Nm 18 4 lbf ft Loctite 243 Screw shift shaft relay lever M8 25 Nm 18 4 lbf ft Loctite 243 Screw spring holder on side stand bra...

Page 185: ...bracket M10 45 Nm 33 2 lbf ft Loctite 243 Screw side stand holder M10 45 Nm 33 2 lbf ft Loctite 243 Rear sprocket bolt M10x1 25 50 Nm 36 9 lbf ft Loctite 243 Screw front brake caliper M10x1 25 45 Nm 33 2 lbf ft Loctite 243 Oil drain plug with magnet M12x1 5 25 Nm 18 4 lbf ft Screw bottom shock absorber M14x1 5 80 Nm 59 lbf ft Thread greased Screw top shock absorber M14x1 5 80 Nm 59 lbf ft Thread g...

Page 186: ...x products Supplier Castrol RESPONSE BRAKE FLUID SUPER DOT 4 Motorex Brake Fluid DOT 5 1 Coolant Guideline Use only suitable coolant also in countries with high temperatures Use of low quality antifreeze can lead to corrosion and foaming KTM recommends Motorex products Mixture ratio Antifreeze protection 25 45 C 13 49 F 50 corrosion inhibitor antifreeze 50 distilled water Coolant mixed ready to us...

Page 187: ...rresponding properties KTM recommends Motorex products Fully synthetic engine oil Supplier Motorex Power Synt 4T Engine oil SAE 5W 40 According to JASO T903 MA p 190 SAE p 190 SAE 5W 40 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 Synthetic engine oil Supplie...

Page 188: ...lic fluid 15 According to 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 Shock absorber oil SAE 2 5 50180342S1 According to SAE p 190 SAE 2 5 Guideline Use only oils that comply with the specified standards se...

Page 189: ...SUBSTANCES 187 Super unleaded ROZ 95 RON 95 PON 91 According to DIN EN 228 ROZ 95 RON 95 PON 91 ...

Page 190: ... road use Guideline KTM recommends Motorex products Supplier Motorex Chain Lube 622 Strong Cleaning and preserving materials for metal rubber and plastic Guideline KTM recommends Motorex products Supplier Motorex Protect Shine 645 High luster polish for paint Guideline KTM recommends Motorex products Supplier Motorex Moto Polish ...

Page 191: ...e 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 Supplier Motorex Joker 440 Universal ...

Page 192: ...ce intervals are demanded for automobile engines high performance at high engine speeds are in the foreground for motorcycle engines With most motorcycles the gearbox and the clutch are lubricated with the same oil as the engine The JASO MA Stan dard meets these special requirements SAE The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils ...

Page 193: ...brake checking 88 Brake light bulb changing 124 Brake linings 86 front brake checking 87 rear brake checking 90 Brakes 52 Braking 52 C Chain checking 80 cleaning 76 dirt checking 75 Chain tension adjusting 78 checking 77 Chassis number 16 Cleaning 159 160 Clutch fluid level checking correcting 139 Clutch lever 19 basic position adjusting 138 Combination instrument 23 clock setting 28 coolant tempe...

Page 194: ... Cooling system 130 filling bleeding 136 D Display 26 E Electric starter button 23 Emergency OFF switch 22 Engine running in 43 Engine number 17 Engine oil adding 149 changing 142 draining 143 refilling 147 Engine oil level checking 141 Engine sprocket checking 80 Environment 10 F Filler cap closing 35 opening 34 Filling up fuel 55 Foot brake lever 40 Fork 62 compression damping adjusting 62 fork ...

Page 195: ...8 mounting on vehicle 105 High beam bulb changing 120 Horn button 21 I Ignition lock 22 Indicator lamps 25 K Key number 17 L License plate lamp changing 126 Light switch 20 Loading the vehicle 43 Low beam bulb changing 118 M Main fuse changing 113 Maintenance 8 Motorcycle cleaning 159 jacking up front 60 jacking up rear 61 taking front from work stand 60 taking rear from work stand 61 O Oil filter...

Page 196: ...arting up 48 S Seat mounting 103 removing 102 Seat height 104 adjusting 104 Seat lock 36 Service schedule 57 59 Shift lever 39 Shifting 49 Shock absorber 62 compression damping general 67 compression damping high speed adjusting 69 compression damping low speed adjusting 67 rebound damping adjusting 70 spring preload adjusting 71 Shock absorber part number 18 Side stand 41 Spare parts 9 Spoiler in...

Page 197: ...ues 167 170 fork 175 177 shock absorber 178 180 Tire air pressure checking 100 Tire condition checking 98 Tool set 38 Transport 9 Troubleshooting 156 158 Turn signal bulb changing 123 Turn signal switch 21 Type label 16 U Use definition 8 V View of vehicle front left 12 rear right side 14 W Warning of slippery roads 32 Warranty 8 Work rules 9 ...

Page 198: ...KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com 12 2009 Photo Mitterbauer 3211522en 3211522en ...

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KTM 2010 990 Super Duke R, Owner'S Manual

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Summary of Contents for 2010 990 Super Duke R

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