KTM 990 Adventure AUS/UK 2009 Owner'S Manual Download

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100132-10

–

Check the rear sprocket/engine sprocket for wear.
» If the rear sprocket/engine sprocket are worn:

–

Change the rear sprocket/engine sprocket.

The engine sprocket, rear sprocket and chain should always be changed
together.
For safety reasons, the chain has no chain joint.

–

Check the chain guides for firm seating and wear.

ProCarManuals.com

Summary of Contents for 990 Adventure AUS/UK 2009

Page 1: ...ProCarManuals com...

Page 2: ...ProCarManuals com...

Page 3: ...tinuing devel opment and design of our motorcycles cannot however be completely excluded All specifications are non binding KTM Sportmotorcycle AG specifically reserves the right to modify or delete t...

Page 4: ...ess 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 pos...

Page 5: ...ay 26 Combination instrument speedometer 27 Setting kilometers or miles 27 Combination instrument time 28 Setting the clock 29 Combination instrument display ODO 29 Combination instrument setting rese...

Page 6: ...justing the low speed compression damping of the shock absorber 72 Adjusting the high speed compression damping of the shock absorber 74 Adjusting the rebound damping of the shock absorber 75 Adjustin...

Page 7: ...ctivating the ignition key 132 Removing the storage compartment and hanging it to one side x 135 Installing the storage compartment x 136 Removing the left fuel tank x 137 Installing the left fuel tan...

Page 8: ...oil 181 Capacity coolant 181 TECHNICAL DATA ENGINE TIGHTENING TORQUES 182 TECHNICAL DATA CHASSIS 185 Lighting equipment 187 Tires 188 Capacity fuel 188 TECHNICAL DATA FORK 189 990 Adventure 189 990 A...

Page 9: ...rstanding In the interest of your own safety have these jobs performed in an authorized KTM workshop There your motorcycle will be serviced opti mally by specially trained experts using the specialist...

Page 10: ...o 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 vice schedule...

Page 11: ...9019000 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 is used for screw connecti...

Page 12: ...sons 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 env...

Page 13: ...s are not taken Identifies a danger that will lead to environmental damage if the appropriate measures are not taken Be sure to read this owner s manual carefully and completely before taking your fir...

Page 14: ...100540 10 ProCarManuals com...

Page 15: ...1 Clutch lever 2 Seat 3 Seat lock 4 Luggage rack plate 5 Handrail 6 Front brake caliper 7 Underride guard 8 Side stand 9 Shift lever 10 Footrest 11 Center stand 12 Passenger footrest ProCarManuals com...

Page 16: ...100541 10 ProCarManuals com...

Page 17: ...headlight flasher switch 3 Hazard warning flasher switch 4 Accessories socket 5 Emergency OFF switch electric starter button 6 Hand brake lever 7 Filler cap 8 Rear brake caliper 9 Foot brake pedal 10...

Page 18: ...s number is stamped on the right side of the steering head The chassis number is also found on the type label 100543 10 The type label is located on the right frame tube in the vicinity of the oil tan...

Page 19: ...place Use the orange programming key to activate and deactivate the black ignition key Keep the orange programming key in a safe place it must only be used for learning and programming functions 10054...

Page 20: ...100545 10 The fork part number is stamped on the inner side of the fork stub 100546 10 The shock absorber part number is stamped on the upper part of the shock absorber ProCarManuals com...

Page 21: ...on the left side of the handlebar The clutch is hydraulically operated and self adjusting 100506 10 The hand brake lever is fitted on the right side of the handlebar The front brake is engaged using t...

Page 22: ...switched on High beam on The light switch is turned upwards In this position the high beam and tail light are switched on 100508 10 The headlight flasher switch is fitted on the left side of the handl...

Page 23: ...tion after use Turn signal right 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 th...

Page 24: ...ne can be started Steering locked In this position the ignition circuit is interrupted and the steering locked The black ignition key can be removed 100501 10 The electronic immobilizer secures the ve...

Page 25: ...emergency OFF switch is fitted on the right side of the handlebar Emergency OFF switch off In this position the ignition circuit is inter rupted a running engine stops and the engine cannot be starte...

Page 26: ...ometer Indicator lamps Display 100492 10 You can change the display mode with the button Possible display modes are the distance traveled trip master 1 trip mas ter 2 and the ambient temperature Press...

Page 27: ...ator lamp flashes green simultaneously with the turn signals The turn signal is switched on The idle speed indicator lamp lights up green The transmission is switched to idle The high beam indicator l...

Page 28: ...ator lamp lights up or flashes red Status or error message for immobilizer alarm system The battery warning lamp lights up red The voltage in vehicle system is too low The ABS warning lamp lights up f...

Page 29: ...umference of the 21 front wheel with a series production tire The display then changes to the last selected mode 100503 10 The speed is shown in kilometers per hour or in miles per hour If you change...

Page 30: ...o the position Press the button repeatedly until the mode is active Keep the button pressed until the display mode changes from to or from to 100502 10 The time is shown in area of the display The tim...

Page 31: ...utton pressed simultaneously The time display begins to flash Press the button to set the hour Press the button to set the minute Keep the button and the button pressed simultaneously The time is set...

Page 32: ...700121 01 Switch on the ignition by turning the black ignition key to the position Press the button repeatedly until the mode is active Keep the button pressed The display is set to The trip counter i...

Page 33: ...dly until the mode is active Keep the button pressed The display is set to 100499 10 If the fuel level drops to the reserve mark the display automatically changes to and starts to count from regardles...

Page 34: ...torcycle is standing 100500 11 Switch on the ignition by turning the black ignition key to the position Press the button repeatedly until the ambient temperature is active Keep the button pressed unti...

Page 35: ...y when the ambient temperature rises above the specified value again Temperature 4 C 39 F 400617 01 The temperature display consists of 12 bars The more bars that light up the hotter the coolant When...

Page 36: ...trument The hazard warning flasher is used to signal an emergency situation and to warn other road users Activate deactivate the hazard warning flasher with the ignition switched on or no more than 30...

Page 37: ...r necks The fuel tanks are connected to each other with a fuel line that equalizes the fuel level The two filler caps are equipped with a ventilation system 100515 10 Fuel is highly flammable poisonou...

Page 38: ...seat and locks and unlocks the storage compartment Storage compartment locked Storage compartment unlocked Seat unlocked The seat lock can be locked with the ignition key 100518 10 Insert the ignition...

Page 39: ...nition key to position Remove the ignition key 100520 10 Unlock the storage compartment p 36 Press button toward the seat and raise the cover at the same time The storage compartment can only be opene...

Page 40: ...mpartment can be opened again as long as it has not been locked using the seat lock Lock the storage compartment p 37 100522 10 The handrails are used for moving the motorcycle around When you have a...

Page 41: ...ded by the luggage manufacturer 100524 10 There is a fuel tap on every fuel tank The fuel taps must be open during operation The fuel taps are only closed when dismantling the fuel tank Fuel supply cl...

Page 42: ...525 10 Foot brake pedal is located in front of the right footrest The rear brake is activated using the foot brake pedal 100526 10 Shift lever is mounted on the left side of the engine ProCarManuals c...

Page 43: ...cond gears 100528 10 Side stand is coupled with the safety start system see the riding instructions Side stand folded out The vehicle can be leaned on the side stand The safety start system is active...

Page 44: ...nter stand in addition to a side stand 100530 10 The passenger footrests can be folded up and down Passenger footrests folded up For operation without a passenger Passenger footrests folded down For o...

Page 45: ...100531 10 The tool set is located in the storage compartment under the seat The extension can be mounted on several of the wrenches in the tool set ProCarManuals com...

Page 46: ...ead patterns to prevent loss of control over the vehicle Uncontrollable handling characteristics due to non approved and or non recommended tires wheels Only tires wheels approved by KTM and with the...

Page 47: ...of the handbrake lever p 88 Adjust the basic position of the footbrake lever x Get used to handling the motorcycle on a suitable piece of land before making a longer trip Try also to ride as slowly as...

Page 48: ...eed according to your payload Ride more slowly if your motorcycle is loaded with cases or other baggage Maximum speed with luggage 130 km h 80 8 mph Risk of breakage of suitcase system If you have fit...

Page 49: ...system If you are carrying baggage make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight distri bution between the front and rear wheels Do not exceed...

Page 50: ...an the chain p 80 Check the tire condition p 106 Check the tire air pressure p 107 Check the brake fluid level of the front brake p 89 Check the rear brake fluid level p 93 Check the front brake linin...

Page 51: ...engine in a closed space without an effective exhaust extraction system If the vehicle is operated with a discharged battery or without a battery electronic components and safety equipment may be dama...

Page 52: ...o not press the electric starter button until the function test of the combination instrument is finished When starting open the throttle If you open the throttle during the start ing procedure fuel i...

Page 53: ...lutch lever slowly and simultaneously open the throttle carefully Abrupt load alterations can cause the vehicle to get out of control Avoid abrupt load alterations and sudden braking actions and adapt...

Page 54: ...sible Reduced road grip with cold tires On every journey take the first miles carefully at moderate speed until the tires reach operating temperature and optimal road grip is ensured Reduced road grip...

Page 55: ...an air filter since dust and dirt can get into the engine and result in increased wear Overheating of engine If the coolant temperature warning lamp lights up stop and switch off the engine Allow the...

Page 56: ...itable for the road surface and weather conditions When traveling in bends do not shift and accelerate very carefully To shift down brake if necessary and close the throttle at the same time Pull the...

Page 57: ...e rear brake can fail due to overheating Take your foot off the foot brake pedal if you do not want to brake Longer stopping distance due to higher overall weight Take the longer stopping distance int...

Page 58: ...grip is reduced when braking with the motorcycle at an angle or on a laterally inclined surface Braking should be completed before you enter into a bend Braking should always be completed before you...

Page 59: ...touch hot components such as exhaust system radiator engine shock absorber and brakes Allow these components to cool down before starting work on them The parked vehicle can roll away or fall over Alw...

Page 60: ...itch 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...

Page 61: ...e 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 f...

Page 62: ...5 3 US gal Super unleaded ROZ 95 RON 95 PON 91 p 201 If the right fuel tank is filled to the filler neck fuel may flow out if the vehicle is resting on the side stand and the fuel heats up Close the f...

Page 63: ...ton for two seconds The fuel level warning lamp switches off is set to and appears in the previous display mode If you do not press the button the reset takes place automatically after about three min...

Page 64: ...y using the KTM diagnostics tool x Perform a status query with the KTM diagnostics tool for the neutral gear clutch 2nd 3rd gear and the side stand switch x Check the connection boots for cracks and l...

Page 65: ...ent is functioning properly Check the screws and nuts for tightness x Brakes Read out the ABS fault memory using the KTM diagnostics tool 990 Adventure x Check the front brake linings p 92 Check the r...

Page 66: ...p 106 Check the tire air pressure p 107 Check the chain wear p 85 Check the rear sprocket engine sprocket chain sliding guard to ensure that they are tight x Check the rear sprocket engine sprocket f...

Page 67: ...ing head bearing and sealing elements x Clean the battery poles and treat with contact grease x Change the coolant x after 15 000 km 9 320 mi every 15 000 km 9 320 mi after every sporting use every 30...

Page 68: ...e damaged and the motorcycle could fall over Pull the motorcycle up onto the center stand using the handrail and not the handwheel of the shock absorber adjustment The shock absorber could become leak...

Page 69: ...s on the handlebar As the vehicle moves off of the center stand activate the front brake to prevent the vehicle from rolling Check that the center stand is folded all the way up 100516 10 Insert the i...

Page 70: ...seat is correctly mounted 100532 10 The fork and the shock absorber offer many options of adapting the suspension to your rid ing style and the payload To help you adapt the vehicle we have summarize...

Page 71: ...ated at the bottom end of the fork legs Make the same adjustment on both fork legs Turn back counterclockwise by the number of clicks corresponding to the fork type Guideline Compression damping Comfo...

Page 72: ...vior 100534 10 Turn adjusting screws clockwise until they stop 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...

Page 73: ...turn counterclockwise to reduce damping 100535 10 Turn the adjusting screws counterclockwise until they stop Make the same adjustment on both fork legs Turn back clockwise by the number of turns corr...

Page 74: ...sorber can regulate compression damping separately in the low and high speed ranges Dual Compression Control The terms low speed and high speed refer to the movement of the shock absorber during compr...

Page 75: ...st perceptible click Do not loosen nut Turn back counterclockwise by the number of clicks corresponding to the shock absorber type Guideline Compression damping low speed Comfort 25 clicks Standard 20...

Page 76: ...ogen Adhere to the description provided Your authorized KTM workshop will be pleased to help The high speed setting can be seen during the fast compression of the shock absorber 100538 10 Turn adjusti...

Page 77: ...s Standard 1 5 turns Sport 1 turn Full payload 1 turn Turn clockwise to increase damping turn counterclockwise to reduce suspension damping Disassembly of pressurized parts can lead to injury The shoc...

Page 78: ...onding to the shock absorber type Guideline Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 cl...

Page 79: ...will be pleased to help 100549 10 Turn handweel counterclockwise as far as it will go Turn it clockwise by the number of turns corresponding to the shock absorber type and use Guideline Spring preload...

Page 80: ...to reduce the spring preload Jack up the vehicle on the center stand p 66 100536 10 Remove bleeder screws briefly Any excess pressure escapes from the interior of the fork Mount and tighten the bleed...

Page 81: ...iciency 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 necessary Clean and oil the dust boots and inner fork tube of...

Page 82: ...when necessary Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations The service life of the ch...

Page 83: ...engine sprocket or the rear sprocket causing the rear wheel to lock or damage the engine Check for correct chain tension and adjust if necessary 0 B B 0 A A 400620 10 Lean the motorcycle on the side s...

Page 84: ...are under additional load Apart from premature wear in extreme cases the chain may snap or the countershaft of the transmission can break On the other hand if the chain is loose it may jump off the e...

Page 85: ...ter are in the same position in relation to reference marks The rear wheel is then correctly aligned The upper chain section must be taut Chain wear is not always even so you should check the setting...

Page 86: ...r sprocket engine sprocket are worn Change the rear sprocket engine sprocket The engine sprocket rear sprocket and chain should always be changed together For safety reasons the chain has no chain joi...

Page 87: ...he upper chain section Chain wear is not always even so you should repeat this measurement at differ ent chain positions Maximum distance at the longest chain section 272 mm 10 71 in If distance is gr...

Page 88: ...aight ahead without the action of lateral forces ABS works with two mutually independent brake circuits front and rear brake Under nor mal conditions the brake system works like a conventional brake w...

Page 89: ...ll be pleased to help 400618 10 Check the thickness of the front and rear brake discs in several places to ensure that it conforms to measurement Wear reduces the thickness of the brake disc in area o...

Page 90: ...ke lever according to specifications 100555 10 Push the hand brake to the handlebar and check the free travel Free travel of hand brake lever 3 mm 0 12 in If the free travel does not meet specificatio...

Page 91: ...ly any force Do not make any adjustments while riding Failure of the brake system If the brake fluid level falls below the mark this indicates a leakage in the brake system or worn out brake linings C...

Page 92: ...brake system and do not continue riding Your authorized KTM workshop will be pleased to help Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and keep out of the reach...

Page 93: ...Avoid contact between brake fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container 100558 10 Move the brake fluid reservoir mounted on the handlebar to a...

Page 94: ...erviceable Check the brake linings regularly 100559 10 Check the brake linings for minimum thickness Minimum thickness 1 mm 0 04 in If the minimum thickness is less than specified Change the front bra...

Page 95: ...If the free travel does not meet specifications Adjust the basic position of the footbrake lever x Failure of the brake system If the brake fluid level falls below the mark this indicates a leakage i...

Page 96: ...nd do not continue riding Your authorized KTM workshop will be pleased to help Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and keep out of the reach of children W...

Page 97: ...5 brake fluid This is based on silicone oil and is colored purple Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attac...

Page 98: ...ency caused by worn brake linings Change worn brake linings immediately Your authorized KTM workshop will be pleased to help Reduced braking efficiency caused by damaged brake discs If the brake linin...

Page 99: ...brake linings for damage and cracking If there is wear or tearing Change the rear brake linings x x Jack up the vehicle on the center stand p 66 Load the vehicle down at the rear or jack it up on the...

Page 100: ...he wheel spindle out of the fork stub Reduced braking effect 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 withdra...

Page 101: ...on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary 100567 11 Clean and grease the shaft seal rings and bearing surface of the dista...

Page 102: ...spindle M25x1 5 45 Nm 33 2 lbf ft Raise the vehicle off of the center stand p 67 Pull the front wheel brake and push down hard on the fork several times to align the fork legs Fully tighten screws Gui...

Page 103: ...cle on the center stand p 66 100634 10 Press the brake caliper by hand on to the brake disc in order to press back the brake pistons 100635 10 Remove screw and pull wheel speed sensor out of the hole...

Page 104: ...the chain off of the rear sprocket and place it on chain sprocket guard Reduced braking due to damaged brake discs Always lay the wheel down in such a way that the brake disc is not damaged Holding t...

Page 105: ...the footbrake until the pressure point is reached Check the rear hub rubber dampers x p 105 100571 10 Clean and grease shaft seal ring and bearing surface of the distance bushing Long life grease p 20...

Page 106: ...and tighten nut Guideline In order for the rear wheel to be correctly aligned the markings on the left and right chain adjusters must be in the same position relative to the reference marks Nut rear w...

Page 107: ...r If the rubber dampers of the rear hub are damaged or worn Change all rubber dampers in the rear hub 100573 10 Lay the read wheel on a workbench with the rear sprocket facing upwards and insert the w...

Page 108: ...s Only tires wheels approved by KTM and with the corresponding speed index should be used Reduced road grip with new tires New tires have a smooth rolling surface and therefore cannot provide full roa...

Page 109: ...of the tires The tire s date of the manufacture is usually part of the tire markings and is indicated by the last four digits of the marking The first two digits refer to the week of manufacture and l...

Page 110: ...e does not meet specifications Correct the tire pressure Mount the dust cap Instable handling due to incorrect spoke tension Ensure that the spoke tension is correct Your authorized KTM workshop will...

Page 111: ...the same length and diameter vibrate with a different tone this is an indication that the spoke tensions differ You should hear a high note If the spoke tension differs Correct the spoke tension x x...

Page 112: ...of the reach of children Wear suitable protective clothing and goggles Avoid contact with battery acid and battery gases Keep the battery away from sparks or open flames Charge only in well ventilated...

Page 113: ...he positive plus cable of the battery Take the battery out of the battery compartment with battery tray Never operate the motorcycle with a discharged battery or without a battery In both cases electr...

Page 114: ...with the battery tray into the battery compartment Connect plus cable Connect minus cable 100579 11 Hook cover into the battery compartment at the bottom and swing up Mount and tighten screws Install...

Page 115: ...water If battery acid gets in the eyes rinse with water for at least 15 minutes and contact a physician Battery parts and acid are harmful to the environment Do not discard batteries with the househol...

Page 116: ...atedly the battery must be charged immediately If the battery is left in a discharged state for an extended period it will become over discharged and sulfate destroying the battery The battery is main...

Page 117: ...use the battery charger to test rest potential and start potential of the bat tery and to test the generator With this device you cannot overcharge the battery Switch off and disconnect the charger af...

Page 118: ...100581 10 Remove screws Remove the right underride guard 100581 11 Position right underride guard Mount and tighten screws Guideline Remaining chassis screws M6 10 Nm 7 4 lbf ft ProCarManuals com...

Page 119: ...ibed amperage Never by pass or repair fuses The main fuse is located in the starter relay under the right underride guard Switch off all power consumers and the engine Remove the right underride guard...

Page 120: ...be identified by the burned out fuse wire A reserve fuse is located in the starter relay The main fuse protects all power consumers of the vehicle Install a new main fuse Fuse 58011109130 p 187 Check...

Page 121: ...se which protects the ABS control unit is located in the fuse box Switch off all power consumers and the engine Remove the right underride guard p 116 100585 10 Remove protective cover and remove fuse...

Page 122: ...are fuse in the storage compartment so that it is available if needed Install the right underride guard p 116 The electrical system can be overloaded by the use of incorrect fuses Use only fuses with...

Page 123: ...parking light license plate lamp Fuse 10A horn brake light hazard warning flasher Fuse 10A radiator fan Fuse 10A ignition EFI control unit Fuse 10A combination instrument socket supplementary devices...

Page 124: ...use in the fuse box so that it is available if needed 100637 10 Use spare fuses with the correct rating only Fuse 58011109110 p 186 Fuse 58011109115 p 186 Spare fuses are located next to the fuse box...

Page 125: ...Remove screws Carefully swing out the side cover at the top and disconnect the plug in connectors of the turn signal cables Pull off the overflow hose of the fuel tank and take off the trim The opera...

Page 126: ...urn signal cables and swing the side cover up toward the vehicle Mount and tighten screws with the washers Guideline Remaining chassis nuts M6 15 Nm 11 1 lbf ft Check the function of turn signal Switc...

Page 127: ...ed 100591 10 Connect plug in connector Check the lighting function Position the headlight mask Install the front side cover p 123 Check the headlamp setting p 131 Reduced luminance Grease on the bulb...

Page 128: ...the headlight and attach the spring bar High beam H3 socket PK22s p 187 The bulb must be correctly seated at projections Connect the plug in connector and mount the rubber cap Install the headlight ma...

Page 129: ...light and attach the spring bar Low beam H7 socket PX26d p 187 The bulb must be positioned with projection in the recess Attach the connector to the bulb and mount the rubber cap Install the headlight...

Page 130: ...e Grease on the bulb will evaporate due to the heat and be deposited on the reflector Clean the bulb and keep it free of grease before mounting 100597 10 Remove the screw on the rear of the turn signa...

Page 131: ...nd first turn it counterclockwise until it engages in the thread Tighten the screw slightly Reduced luminance Grease on the bulb will evaporate due to the heat and be deposited on the reflector Clean...

Page 132: ...lighting function Position the tail light Mount and tighten the nuts with the washers Guideline Nut tail light M6 8 Nm 5 9 lbf ft Reduced luminance Grease on the bulb will evaporate due to the heat an...

Page 133: ...ashers Guideline Nut tail light M6 8 Nm 5 9 lbf ft 0 A A 0 B B 400609 10 On a light colored wall behind a horizontal area make a mark as high as the center of the low beam headlight Make another mark...

Page 134: ...u have a heavy payload you will need to correct the headlight range The orange programming key must only be used for activating and deactivating If a black ignition key is lost or replaced the black i...

Page 135: ...e position Warning lamp lights up switches off and then starts to flash Immobilizer indicator lamp lights up switches off briefly and lights up again Switch off the ignition by turning the black ignit...

Page 136: ...nd then starts to flash Immobilizer indicator lamp lights up switches off briefly and flashes the number of flashes equals the number of functional black ignition keys includ ing the orange programmin...

Page 137: ...e further ignition keys repeat the last 4 steps with the respective ignition key Insert the orange programming key in the ignition lock Switch on the ignition by turning the orange programming key to...

Page 138: ...ompartment and swing it to the right Place a cloth between the right fuel tank and the storage compartment to prevent damage x 100616 10 Remove the cloth and position the storage compartment Mount and...

Page 139: ...ing 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...

Page 140: ...or and fuel pump Pull off hose Disconnect fuel hose connection Remaining fuel may run out of the fuel hose Push the hose clamp back and pull fuel hose off of the fuel tap Take off the fuel tank x Fuel...

Page 141: ...d check the O ring for damage 100618 11 Position the fuel tank at about the same height as when mounted to connect the hoses and plug in connectors Attach fuel hose to the fuel tap and push the hose c...

Page 142: ...alfunctions 125 C 257 F 0 2 2 0 3 3 400619 10 Cooling takes place by means of the air stream and a radiator fan which is controlled by a thermoswitch The lower the speed the less the cooling effect Di...

Page 143: ...ling system when the engine is hot Allow the engine and radiator to cool down If you are scalded hold the affected part under cold water immediately Coolants are poisonous and a health hazard Avoid co...

Page 144: ...o coolant in the compensating tank Check the cooling system for leaks x Do not start up the motorcycle Fill bleed the cooling system x p 147 If the coolant level in the compensating tank does not meet...

Page 145: ...con tact 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 coolants...

Page 146: ...s x Do not start up the motorcycle Fill bleed the cooling system x p 147 Mount the radiator cap x During motorcycle operation the coolant gets very hot and is under pressure Do not open the radiator t...

Page 147: ...10 Remove radiator cap and the plug from the compensating tank Check the coolant antifreeze 25 45 C 13 49 F If the coolant antifreeze does not meet specifications Correct the coolant antifreeze Add c...

Page 148: ...olants out of the reach of children Jack up the vehicle on the center stand p 66 Remove the left fuel tank x p 137 100612 10 Place a suitable container under the radiator Remove screw Remove the radia...

Page 149: ...r 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 coolants out of the reach...

Page 150: ...vent hole and then mount and tighten the bleeder screw immediately Coolant p 198 Coolant mixed ready to use p 198 Fill the radiator completely with coolant Mount the radiator cap Lean the vehicle on...

Page 151: ...and allow it to cool down When the engine is cool check the coolant level in the radiator and if necessary add coolant Check the coolant level in the compensating tank and if necessary add coolant to...

Page 152: ...his ensures that all required parts are available when needed 0 5 5 0 1 1 0 1 1 0 2 2 0 3 3 0 4 4 100639 10 Place nuts onto tabs of the radiator Hook radiator guard into holes at the bottom and swing...

Page 153: ...Turn the adjusting screw by hand only and do not apply any force Do not make any adjustments while riding The fluid level rises with increasing wear of the clutch lining disc Do not use brake fluid 1...

Page 154: ...s Adjust the play in the gas Bowden cable x p 153 Exhaust gases are poisonous and can result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation an...

Page 155: ...le 3 5 mm 0 12 0 2 in Tighten counter nut Jack up the vehicle on the center stand p 66 Exhaust gases are poisonous and can result in unconsciousness and or death When running the engine always make su...

Page 156: ...x Drain engine oil clean oil screens x p 154 Install the oil filter x p 159 Install the left fuel tank x p 138 Fill up with engine oil x p 159 Install the underride guard x p 110 x Engine oil and gear...

Page 157: ...Place a suitable container under the engine Remove the oil drain plug with the magnet and seal ring Fully drain the engine oil out of the engine Remove screws and take off cover Pull the oil screen ou...

Page 158: ...0627 10 Pull oil sieve out of the oil tank Remove the oil filter x p 158 Clean all oil screens and oil drain plugs with a magnet Clean all sealing surfaces 100628 10 Check seal ring of the oil sieve f...

Page 159: ...o the engine case with the marking facing up Check the form ring in cover for damage and correct seating Position cover Mount and tighten the screws Guideline Screw clutch cover M6 10 Nm 7 4 lbf ft 10...

Page 160: ...ea under cold water immediately Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations The under...

Page 161: ...hly clean the parts and sealing surface x 100631 10 Insert oil filter Lubricate the O ring of the oil filter cover Install oil filter cover Mount and tighten the screws Guideline Remaining engine scre...

Page 162: ...temperature 0 C 32 F Engine oil SAE 5W 40 p 199 Replace the oil dipstick Jack up the vehicle on the center stand p 66 Exhaust gases are poisonous and can result in unconsciousness and or death When r...

Page 163: ...External temperature 0 C 32 F Engine oil SAE 5W 40 p 199 Replace the oil dipstick Too little engine oil or poor quality engine oil results in premature wear to the engine The engine oil level must be...

Page 164: ...ve a slightly lower power output this setting prevents engine damage by hindering spark knocking due to poor fuel quality Plug in connector disconnected Fuel with an octane rating of 80 to 94 RON can...

Page 165: ...r disconnected Fuel with an octane rating of 80 to 94 RON can be used for one tank full p 162 Connect plug in connector Figure 100554 10 p 162 Plug in connector connected Fuel with an octane rating of...

Page 166: ...ilizer control unit 14 Immobilizer indicator lamp flashes 1x short 1 second pause 4x short Malfunction in transponder of black ignition key 15 Immobilizer indicator lamp flashes 1x short 1 second paus...

Page 167: ...er indicator lamp flashes 3x short 1 second pause 1x short Malfunction encryption query from EFI control unit to immobilizer control unit 32 Immobilizer indicator lamp flashes 3x short 1 second pause...

Page 168: ...ylinder 2 sensor 1 interruption short circuit to ground Heating lambda sensor cylinder 2 sensor 1 input signal too high 09 Warning lamp flashes 9x short Manifold absolute pressure sensor cylinder 1 in...

Page 169: ...r circuit A input signal too low Throttle valve sensor circuit A input signal too high 17 Warning lamp flashes 1x long 7x short Lambda sensor cylinder 1 sensor 1 malfunction in circuit 18 Warning lamp...

Page 170: ...put signal too low Throttle position sensor circuit B input signal too high 02 Warning lamp flashes 2x short Circuit ignition pulse generator malfunction in circuit 37 Warning lamp flashes 3x long 7x...

Page 171: ...hes 4x long 9x short Idle control system malfunction in circuit 24 Warning lamp flashes 2x long 4x short Power supply malfunction in circuit 50 Warning lamp flashes 5x long Throttle position sensor ac...

Page 172: ...essure sensor input signal too high 41 Warning lamp flashes 4x long 1x short Fuel pump control interruption short circuit to ground Fuel pump control input signal too high 25 Warning lamp flashes 2x l...

Page 173: ...n circuit 11 Warning lamp flashes 1x long 1x short Manifold absolute pressure sensor cylinder 2 input signal too low Manifold absolute pressure sensor cylinder 2 input signal too high 91 Warning lamp...

Page 174: ...he CAN bus communication x Combination 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...

Page 175: ...oam formation in cooling system Drain the coolant x p 145 Fill bleed the cooling system x p 147 Buckled or damaged radiator hose Change the radiator hose x Fuse blown Change the fuses in the fuse box...

Page 176: ...ioning Fuse blown Change the fuses in the fuse box p 120 Turn signal hazard warning flasher brake light and horn are not functional Fuse blown Change the fuses in the fuse box p 120 Battery discharged...

Page 177: ...and appearance are maintained over a long period Avoid direct sunshine on the motorcycle during cleaning Before you clean the motorcycle close off the exhaust system to prevent penetration by water F...

Page 178: ...engine and on the brakes to evaporate After the motorcycle has cooled off lubricate all moving parts and bearings Clean the chain p 80 Treat bare metal parts except for brake discs and exhaust system...

Page 179: ...rrosive effects of salt Clean the motorcycle p 175 Treat the engine the swingarm and all other bare or galvanized parts except brake discs with a wax based anti corrosion substance To prevent serious...

Page 180: ...oil and filter clean the oil screens x p 154 Check the antifreeze x p 144 Check the tire air pressure p 107 Remove the battery x p 110 Recharge the battery x p 113 Guideline Storage temperature of bat...

Page 181: ...vehicle off of the center stand p 67 Recharge the battery x p 113 Install the battery x p 112 Set the clock p 29 Refuel p 59 Carry out checks before putting into operation p 48 Take a test ride ProCar...

Page 182: ...m 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 compressio...

Page 183: ...Spark plug NGK LKAR8BI9 Spark plug electrode gap 0 8 mm 0 031 in Cooling Water cooling permanent circulation of coolant by water pump Cold start device Electric starter Engine oil 3 0 l 3 2 qt Externa...

Page 184: ...Screw bearing bolt in generator cover M6 10 Nm 7 4 lbf ft 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 engin...

Page 185: ...M8 20 Nm 14 8 lbf ft 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 Stud exhaust flange M8 15 Nm 11 1 lbf ft Bearing bolt t...

Page 186: ...5 12 Nm 8 9 lbf ft Plug oil filter housing M14x1 5 15 Nm 11 1 lbf ft Bleeder flange generator cover M16x1 5 10 Nm 7 4 lbf ft Plug timing chain tensioner M16x1 5 20 Nm 14 8 lbf ft Rotor screw M16x1 5...

Page 187: ...Rear 265 mm 10 43 in Brake system Front Double disk brake with floating brake calipers and brake discs Rear Single disc brake with floating brake caliper and brake disc Brake system 990 Adventure Two...

Page 188: ...mm 36 22 in Ground clearance unloaded 990 Adventure 261 mm 10 28 in Ground clearance unloaded 990 Adventure R 316 mm 12 44 in Weight without fuel approx 990 Adventure 209 kg 461 lb Weight without fue...

Page 189: ...t PK22s 12 V 55 W Parking 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 WR5W socket W2 1x9 5d 12 V 5 W Brake light...

Page 190: ...ntal TKC 80 Alternative tires to max 160 km h 99 4 mph Additional information is available in the Service section under http www ktm com Total fuel tank capacity approx 20 l 5 3 US gal Super unleaded...

Page 191: ...damping Comfort 23 clicks Standard 18 clicks Sport 13 clicks Full payload 13 clicks Spring preload Comfort 5 turns Standard 5 turns Sport 8 turns Full payload 7 turns Spring length with preload space...

Page 192: ...on damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Rebound damping Comfort 23 clicks Standard 18 clicks Sport 13 clicks Full payload 13 clicks Spring preload Comfor...

Page 193: ...ium standard 4 8 N mm 27 4 lb in Hard 5 0 N mm 28 6 lb in Fork length 935 mm 36 81 in Air chamber length 100 30 20 mm 3 94 1 18 0 79 in Fork oil 655 ml 22 15 fl oz Fork oil SAE 5 p 200 ProCarManuals c...

Page 194: ...rt 15 clicks Full payload 15 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 15 clicks Sport 10 cli...

Page 195: ...k absorber oil p 200 SAE 2 5 Shock absorber part number 12 18 7E 09 Shock absorber PDS 5018 DCC PA Compression damping low speed Comfort 25 clicks Standard 20 clicks Sport 15 clicks Full payload 15 cl...

Page 196: ...t 8 turns Full payload 10 turns Spring rate Soft 130 N mm 742 lb in Medium standard 140 N mm 799 lb in Hard 150 N mm 857 lb in Spring length 265 mm 10 43 in Gas pressure 10 bar 145 psi Static sag 25 m...

Page 197: ...4 Nm 3 lbf ft Nut tail light M6 8 Nm 5 9 lbf ft Remaining chassis nuts M6 15 Nm 11 1 lbf ft Remaining chassis screws M6 10 Nm 7 4 lbf ft Screw connection wheel speed sensor front M6 6 Nm 4 4 lbf ft S...

Page 198: ...crew exhaust clamp M8 8 Nm 5 9 lbf ft Screw fork stub M8 15 Nm 11 1 lbf ft Screw front brake caliper M8 25 Nm 18 4 lbf ft Screw fuel tank M8 15 Nm 11 1 lbf ft Screw handlebar clamp M8 20 Nm 14 8 lbf f...

Page 199: ...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 greased Nut socket M18x1 4 Nm 3 lb...

Page 200: ...sponding properties KTM recommends and products Use only suitable coolant also in countries with high temperatures Use of low quality antifreeze can lead to corrosion and foaming KTM recommends produ...

Page 201: ...d that possess the corresponding properties KTM recommends products Fully synthetic engine oil JASO T903 MA p 204 SAE p 204 SAE 5W 40 Use only engine oils that comply with the specified standards see...

Page 202: ...products ISO VG 15 Use only hydraulic fluid that complies with the specified standards see specifications on the container and that possesses the corre sponding properties KTM recommends products SAE...

Page 203: ...DIN EN 228 ROZ 95 RON 95 PON 91 ProCarManuals com...

Page 204: ...KTM recommends products KTM recommends products KTM recommends products KTM recommends products ProCarManuals com...

Page 205: ...KTM recommends products KTM recommends products KTM recommends products ProCarManuals com...

Page 206: ...nded 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...

Page 207: ...ont brake checking 92 rear brake checking 96 55 55 42 checking for dirt 79 checking for wear 85 cleaning 80 adjusting 82 checking 81 16 175 176 fluid level checking rectifying 151 adjusting 151 coolan...

Page 208: ...diator checking 143 filling bleeding 147 26 23 23 running in 45 17 adding 161 changing 154 draining 154 refilling 159 checking 153 10 closing 35 opening 35 fuel 59 engine control 166 171 immobilizer 1...

Page 209: ...8 free travel checking 88 38 34 34 light range adjusting 132 checking 131 20 installing 125 removing 124 changing 125 21 adjusting to fuel quality 162 plug in connector 162 activating deactivating 132...

Page 210: ...rmation on first use 44 installing 150 removing 149 checking 105 checking for wear 84 installing 103 removing 101 starting up 51 mounting 68 removing 67 36 62 65 40 51 compression damping general 72 c...

Page 211: ...nging 129 chassis 185 188 chassis tightening torques 195 197 engine 180 181 engine tightening torques 182 184 fork 189 191 shock absorber 192 194 checking 107 checking 106 43 9 172 174 changing 128 21...

Page 212: ...front left side 12 rear right side vehicle differs slightly from photo 14 33 8 9 ProCarManuals com...

Page 213: ...5230 Mattighofen Austria 3 2009 Photo Mitterbauer 3211362en 3211362en ProCarManuals com...

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KTM 990 Adventure AUS/UK 2009, Owner'S Manual

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