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KTM 990 ADVENTURE, Owner'S Manual, Page: 62 / 102

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KTM 990 ADVENTURE Owner'S Manual Download Page 62

MAINTENANCE WORK ON CHASSIS AND ENGINE 

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61

Battery

The battery is located in the underride protection in front of the engine and is maintenance-

free. It is not necessary to check the electrolyte level or to refill water. Simply keep the bat-

tery poles clean and slightly grease them with an acid-free grease if necessary. The charge

condition and type of charge are very important for the battery's service life.

Never operate the motorcycle with a run-down battery or without the battery. This can dam-

age the electronic components or safety equipment in either caseand the motorcycle will no

longer be roadworthy. 

Do not remove the locking strip [1] otherwise the battery will be damaged. 

1

Summary of Contents for 990 ADVENTURE

Page 1: ...990 ADVENTURE 990 ADVENTURE S KTM Sportmotorcycle AG A 5230 Mattighofen www ktm at 10 2006 FOTO MITTERBAUER KTM Group Partner ART NR 3 211 149 EN OWNER S MANUAL 2007...

Page 2: ...N FOR AUSTRALIA ONLY Tampering with noise control system prohibited Owners are warned that the law may prohibit a The removal or rendering inoperative by any person other than for purposes of maintena...

Page 3: ...st information available for this model series at the time it was printed Minor devia tions resulting from enhancements to the motorcycle design cannot be entirely precluded The Owner s Manual is an i...

Page 4: ...quivalent specifications must be used in accordance with the maintenance schedule SPARE PARTS ACCESSORIES For your own safety only use spare parts and accessories approved by KTM KTM shall not assume...

Page 5: ...fork 20 Spring preload of the fork 20 Damping action during compression of shock absorber 21 Rebound damping of shock absorber 22 Shock absorber s preload adjuster 22 Baggage carrier plate 22 Grips 2...

Page 6: ...mounting the battery 62 Charging the battery 63 Jump start 63 Main fuse 64 ABS fuses models with ABS antilock brake system 64 Fuses for individual current consumers 65 Replacing the headlight lamps 66...

Page 7: ...ng head tube and on the type label Write this number into the relevant area on page 1 Engine number engine type The engine number and engine type are embossed in the engine case near the shift lever W...

Page 8: ...maintenance work on chassis and engine The clutch is hydraulically actuated and adjusts itself automatically Hand brake lever The hand brake lever 2 is mounted on the handlebars on the right and actu...

Page 9: ...the MODE button The indicator lamps 3 provide additional information on the motorcycle s running condition Display TEST When you switch on the ignition all of the display elements will light up for 1...

Page 10: ...1 The TRIP 1 mode shows the speed the temperature of the cooling liquid and the trip odo meter 1 To switch to the next display mode press the MODE button TRIP 2 The TRIP 2 mode shows the speed the te...

Page 11: ...o the CLOCK mode Simultaneously press MODE 1 and SET 2 The numbers on the clock will start to blink Use the MODE button to set the hours and the SET button to set the minutes The press the MODE and SE...

Page 12: ...o a roadbook you can easily correct the display to correspond to the roadbook again It can also be used to change the display modes The switch is mounted on the handlebars so that you can keep your ha...

Page 13: ...s reached a temperature of approx 40 C 104 F When the upper bar lights up 120 C 248 F all of the bars will start to blink and the red warning lamp 2 will light up Possible causes for an increase in te...

Page 14: ...range warning light will light up when the fuel level has reached the reserve mark At the same time the display will automatically change to TRIP F see TRIP F The red warning lamp lights up when the i...

Page 15: ...riving situations e g during a wheelie or if the rear wheel slips when accelerating on loose ground The ABS will no longer be active and the wheels can lock when braking To activate the ABS again stop...

Page 16: ...ff engine can t be started Ignition on engine can be started Ignition off handlebar blocked To switch the ignition to position turn the ignition key to position and firmly press it into the lock Turn...

Page 17: ...owards switch housing to switch off the flasher The horn is sounded with button 4 Emergency OFF tip switch starter tip switch The emergency off switch 5 is provided for emergency situations and should...

Page 18: ...rection Filler caps The 990 Adventure has 2 separate fuel tanks Both filler caps 2 can be locked and are equipped with a tank vent system To open insert the ignition key turn 45 in a clockwise directi...

Page 19: ...he level in the fuel tanks is equalized by means of a connecting hose Only close the fuel taps to remove the tanks Shift lever The shift lever is mounted on the left side of the engine The position of...

Page 20: ...ront of the right footrest Its basic position can be adjusted to your seat position see maintenance work Side stand Fold the side stand 1 forward to the stop with your foot and put the weight of the m...

Page 21: ...r Adjusting the fork and shock absorber Rebound damping of fork The fork s damping action during rebound travel rebound damping can also be adjusted This allows you adjust the damping behavior to matc...

Page 22: ...e payload The damping rate can be adjusted in the low and high speed range Dual Compression Control The designation low and high speed refers to the movement of the shock absorber and not to the motor...

Page 23: ...ovided in the chapter Adjusting the fork and shock absorber Shock absorber s preload adjuster The shock absorber s preload adjuster is infinitely variable by means of the hand wheel 2 This allows the...

Page 24: ...INSTRUMENTS 23 1 1 2 Grips The passenger can hold on to both grab handles 1 Footrests The passenger footrests 2 fold up Alarm system An alarm system can be retrofitted Ask your authorized KTM shop fo...

Page 25: ...s will not display their full grip char acteristics until they are properly run in Motorcycles are sensitive to changes in the weight distribution Read the section on Accessories and payload when car...

Page 26: ...our motorcy cle can easily go out of control at high speeds Choose your driving speed according to the conditions and your driving skills Drive carefully on unknown roads or on unfamiliar trials Renew...

Page 27: ...ust be replaced The tread depth must comply with the legal regulations Also check the air pressure Insufficient tread and incorrect air pressure deteriorate the driving performance 4 BRAKES Check corr...

Page 28: ...l weight is comprised of the motorcycle in a running condition and refueled 232 kg 512 lbs the baggage and accessories the driver and passenger with protective gear and helmet Adjust the tire inflatio...

Page 29: ...in a closed room Exhaust fumes are poison ous and can cause loss of consciousness and death Always provide adequate ventila tion while the engine is running Never operate the motorcycle with a run dow...

Page 30: ...tand drags on the ground the motorcycle can go out of control Shifting Riding You are now in first gear refered to as the drive or uphill gear Depending on the con ditions traffic road gradient etc yo...

Page 31: ...immediately if a perceptible power loss occurs while driving due to a defec tive ignition caused by a cylinder misfir ing or breaking down If the unburned fuel air mixture reaches the catalytic con v...

Page 32: ...d off when driving off road with a special driving technique when you want the wheels to lock up To switch off the ABS stop the motorcycle and press the ABS button for at least 3 sec onds with the eng...

Page 33: ...likely to touch it and get burned Never park your motorcycle in places where there exist fire hazards due to dry grass or other easily flammable materials Always take out the ignition key when parkin...

Page 34: ...und is solid and that your motorcycle is standing securely The center stand is designed to hold the weight of the motorcycle only By sitting on the motorcycle you will put additional weight on the cen...

Page 35: ...l only The 990 Adventure has 2 tanks with 1 filler cap each Both filler caps can be locked and are equipped with a tank vent system To open insert the ignition key turn 45 in a clock wise direction an...

Page 36: ...35...

Page 37: ...k clutch linings z Check clutch pressure booster system z Clean the oil jet for the clutch lubrication z z FUEL INJECTION Check rubber boots for cracks or leaks z z Check fault memory with the KTM dia...

Page 38: ...r tell tale lamps ABS warning lamp speedometer illumination horn side stand switch clutch switch emergency off switch z z z Make sure all bolts and nuts are tight z z z BRAKES Check brake fluid level...

Page 39: ...d be carried out after every race Service intervalls should never be exceeded by more than 500 km Maintenance work done by KTM autorized workshops is not a substitute of care and checks done by the ri...

Page 40: ...operation z Check horn for proper operation z Lubricate actuating cables and nipples z Bleed fork legs z Clean chain z Lubricate chain z z Check chain tension z Check tire pressure and wear z Check c...

Page 41: ...ced if the thread is damaged All screws and nuts must be tightened to the specified torque figures using a torque wrench If screws or nuts are not adequately tight ened they can become loose and cause...

Page 42: ...lts 3 in the lock hous ing and push the seat down in the back until you hear the catch bolts snap into place Check whether the seat is correctly mounted If not correctly mounted the seat can slip whil...

Page 43: ...tment to both fork legs STANDARD ADJUSTMENT Turn adjusting screw clockwise as far as it will go Turn 18 clicks in a counterclockwise direction MAINTENANCE WORK ON CHASSIS AND ENGINE 42 Adjusting the f...

Page 44: ...n will change the preload by 1 mm Changing the preload will not affect the rebound damping adjustment although adjusting screw 3 will turn at the same time Make the same spring preload adjustments to...

Page 45: ...the adjusting screw 1 to the limit in a clockwise direction using a screwdriver unscrew the respective number of clicks for the specific type of shock absorber in a coun terclockwise direction 990 Adv...

Page 46: ...hock absorber By using the adjusting screw 4 the degree of damping of the rebound can be adjusted Turn the knob in a clockwise direction to increase damping turn it in a counterclockwise direction to...

Page 47: ...ettings for the shock absorber to help you to make the necessary adjustments STANDARD ADJUSTMENT Turn the hand wheel in a counterclockwise direction up to the stop Turn the hand wheel 6 turns in a clo...

Page 48: ...e disks since this would considerably reduce the tire s road grip and the braking effect of the front brake Checking the chain tension Place the motorcycle on the side stand and switch the transmissio...

Page 49: ...ers 4 are sitting close to the adjusting screws and that the rear wheel has been aligned with the front wheel Tighten collar nut 1 with 90 Nm If you don t happen to have a torque wrench at hand make s...

Page 50: ...ice technicans have the required riveting tool Never mount a normal chain joint Also check sprockets and chain guides for wear and replace if necessary Checking the chain for wear To check the chain f...

Page 51: ...d therefore the braking power can deviate significantly from original KTM brake pads If you use dif ferent brake pads than those provided with the original equipment it cannot be war ranted that they...

Page 52: ...esigned for DOT 5 brake fluid Brake fluid is exposed to a high thermal load and absorbs moisture from the air which low ers the boiling point The brake fluid should therefore be changed at the prescri...

Page 53: ...e brake circuit and prevents the wheel from locking You can feel the control function as a slight pulsing in the brake lever The ABS warning lamp 3 must light up when the ignition is switched on and g...

Page 54: ...rovided with an inspection glass With the reservoir in a horizontal position the brake fluid level should not go below middle of the glass If the brake fluid level drops below the minimum either the b...

Page 55: ...ke fluid changed at an authorized KTM workshop every 2 years MAINTENANCE WORK ON CHASSIS AND ENGINE 54 Checking the rear brake pads The brake pads can be inspected from the rear The thickness of the l...

Page 56: ...55...

Page 57: ...of the shaft seal rings MAINTENANCE WORK ON CHASSIS AND ENGINE 56 2 1 2 4 3 A Before remounting the front wheel clean and grease the shaft seal rings 4 and the bear ing surface A of the distance bushi...

Page 58: ...sage take the motorcycle off the stand actuate the front wheel brake and vigorously compress the fork several times to align the fork legs Now you can tighten the clamp screws on both fork leg axle pa...

Page 59: ...mounted clean the thread of the wheel spindle and collar nut thoroughly and apply a new coat of grease Motorex Long Term 2000 to prevent the thread from jamming Models with ABS when you dismount and m...

Page 60: ...cked every time you want to ride your motorcycle Before leaving check for punctures and nails or other sharp objects that might have become embedded in the tire Refer to the specific regulations in yo...

Page 61: ...ng performance Torn spokes can damage the air hose The loss of air can easily cause the motorcycle to go out of control Excessively tensioned spokes may rupture due to local overloading The spokes mus...

Page 62: ...y poles clean and slightly grease them with an acid free grease if necessary The charge condition and type of charge are very important for the battery s service life Never operate the motorcycle with...

Page 63: ...t the screws and tighten to 25 Nm 19 ft lbs If electrolyte sulphuric acid leaks from the battery proceed with great care The elec trolyte can cause severe burns In the case of skin contact rinse thoro...

Page 64: ...ry with this device Charge the battery immediately if it is empty when you start the motorcycle If left to stand in an uncharged condition for a longer period of time the battery will run down and sul...

Page 65: ...stronger fuse allowed to be set in or a fuse allowed to be repaired An inexpert treatment could damage the whole electrical installation MAINTENANCE WORK ON CHASSIS AND ENGINE 64 2 1 1 1 3 4 6 5 ABS...

Page 66: ...Visit an authorized KTM workshop if the new fuse blows again Under no circumstances is a stronger fuse allowed to be set in or a fuse allowed to be repaired An inexpert treatment could damage the whol...

Page 67: ...te and settle down on the reflector HIGH BEAM BULB A Remove the rubber cap 3 and pull off the connector 4 Detach the retaining clip and remove the bulb Insert a new bulb see Technical specifications C...

Page 68: ...he upper part of the headlight in the USA design Bulb F see Technical specifications Chassis Lighting with high and low beams is mounted in the lower part of the headlight Connect the connectors to th...

Page 69: ...r the trip baggage driver passenger 10 meters away from the wall and switch on the low beam The light dark cut off line should be at the mark Replacing the brake and tail light bulbs Remove the hexago...

Page 70: ...turn signal carefully fold the lens 5 towards the motorcycle and remove Slightly depress the bulb turn it approx 30 counterclockwise and pull it out of the socket To mount the lamp reverse the workst...

Page 71: ...ble causes Slow riding with large loads at a higher air temperature If possible increase your running speed so that more air can blow through the radiators Should the warning light still be on off aft...

Page 72: ...lve in the radiator cap 4 a water temperature rising up to 125 C 257 F is admissi ble without fear of problems Any excess cooling liquid caused by thermal expansion is conducted to the compensating ta...

Page 73: ...cap and open slowly to release pres sure Carefully remove the radiator cap 2 with a rag turning in a counterclockwise direction The radiator should be completely filled with cooling liquid No air shou...

Page 74: ...m raise the motorcycle approx 50 cm in the front Add cooling liquid until it runs out of the discharge opening without bubbles and immedi ately mount the screw to prevent more air from getting into th...

Page 75: ...pply excessive force Checking the oil level of the hydraulic clutch To check the oil level in the master cylinder of the clutch remove the cover For this pur pose remove screws 2 and cover 3 together...

Page 76: ...r 0 C 32 F or 5W 40 for temperatures under 0 C 32 F Checking the engine oil level Check the engine oil level when the engine is warm at least 4 bars on the temperature indi cator light up Allow the wa...

Page 77: ...by an authorized KTM workshop During the guaranty period the oil change must be performed by an authorized KTM mechanic Otherwise the guarantee will become void The engine oil change is to be carried...

Page 78: ...ANCE WORK ON CHASSIS AND ENGINE Remove the 6 screws and the cover 4 Remove the 5 screws take off the left panel 5 and disconnect the turn signal cable Close both fuel taps 6 on the connecting line 4 6...

Page 79: ...the pickup cable fuel level and set down the tank Remove the lower screw 2 on the right tank Remove the HH screws and take off the bat tery cover 3 Remove the drain plug 4 on the oil tank and allow t...

Page 80: ...oil screens Clean all rubber seal rings and check for damage Replace if necessary Mount the oil drain plug on the engine with a new seal ring and tighten to 20 Nm Slide the oil screen 8 into the guid...

Page 81: ...ring and tighten to 20 Nm Grease the seal ring 2 and carefully slide the oil screen into the oil tank Position the oil return valve 3 mount the screws and tighten to 10 Nm Mount the battery cover and...

Page 82: ...oil dipstick and add engine oil up to the MAX mark approx 0 5 liters 0 13 USgal Check the engine and the oil tank for oil leakage Apply Loctite 243 to the thread of the 4 screws mount the underride p...

Page 83: ...are connected to each other the ignition curve for fuel having at least 95 octane RON is activated If you disconnect the plug and socket connection the ignition curve for fuel having 80 94 octane RON...

Page 84: ...he emergency OFF switch on do not accelerate while starting the engine Recharge the battery and investigate the causes for discharg ing contact an authorized KTM workshop Replace fuse IGNITION Remove...

Page 85: ...ch full power Air filter fuel filter heavily soiled Error in the injection system The ignition curve for 80 octane is activated Have the air filter fuel filter replaced at an authorized KTM workshop V...

Page 86: ...ose or the cable damaged ABS sensor wheel is bent Error in the ABS Stop switch off the ignition start again Replace the ABS fuses under the right engine cover Replace the ABS OPTIONAL fuse Check the A...

Page 87: ...nctional digital speedometer is not working Pickup cable is damaged or con tacts on the cable connector have oxidized Check the pickup cable for damage visit an authorized KTM workshop The blink code...

Page 88: ...Injection nozzle for rear cylinder Malfunction Stalls 34 Injection nozzle for front cylinder Malfunction Stalls 37 Ignition coil for rear cylinder Malfunction Stalls 38 Injection coil for front Malfu...

Page 89: ...this parts of the motorcycle is allowed to evaporate After the motorcycle has cooled down oil or lubricate all of the friction bearings and bearing positions and treat the chain with chain spray Treat...

Page 90: ...midity might not be able to escape and could cause corrosion It would be very bad to let the engine run for a short time during the storage period The engine would not get warmed up enough and the thu...

Page 91: ...ake circuits ADVENTURE S Authorized front tires Pirelli MT90 90 90 21 M C 54V Up to a max of 160 kph 100 mph Continental TKC80 90 90 21 M C 54S TT M S Air pressure front road driver only 2 4 bar 34 ps...

Page 92: ...949 lbs BASIC SETTING FORK 990 ADVENTURE 990 ADVENTURE S Driving Comfort Basic Setting Driving Sport Maximum Payload Compression adjuster clicks 20 15 10 10 Rebound adjuster clicks 23 18 13 13 Spring...

Page 93: ...ber top M14x1 5 80 Nm AH bolt shock absorber bottom M14x1 5 80 Nm AH bolt for top of brake hose guide M6 Loctite 243 8 Nm HH bolts on front brake caliper M8 Loctite 243 25 Nm HH bolts on footbrake cyl...

Page 94: ...et engine M10 Loctite 243 45 Nm HH bolts side stand bracket side stand console M10 Loctite 243 25 Nm HH bolts side stand mounting M10 Loctite 243 35 Nm HH bolt spring retainer side stand M8 Loctite 24...

Page 95: ...st 0 25 0 30 mm Crankcase bearing Friction bearings 2 main bearings 1 supporting bearing Conrod bearing Friction bearing Piston pin bearing Dual fuel bearing Piston Light alloy forged Piston rings 1 c...

Page 96: ...water pump Cooling liquid 2 1 liters 50 antifreeze 50 distilled water at least 25 C Starting aid 0 9 kW electric starter 10W 50 5W 40 JASO T903 MA TEMPERATURE 0 C 32 F Engine oil Only use fully synthe...

Page 97: ...Chassis number 6 Check the following before each start 26 Checking of brake fluid level front brake 53 Checking rear brake fluid level 54 Checking spoke tension 60 Checking the chain for wear 49 Chec...

Page 98: ...e 36 Rebound damping of fork 20 Rebound damping of shock absorber 45 Rebound damping of shock absorber 22 Removing and remounting the seat 41 Replacing the brake and tail light bulbs 68 Replacing the...

Page 99: ...CONSUMER INFORMATION FOR USA ONLY 98 on frame tube R S on frame tube R S on frame tube R S on frame tube R S under seat Sticker positions 2 4 5 6 7 8 9 3 1...

Page 100: ...9 2 Type label USA 5 Before you go for the first ride 8 Technical information 7 Noise emission 2 Type label CAN 6 Vehicle emission 1 EAVP CONSUMER INFORMATION FOR USA ONLY 4 Fuel level 9 Exhaust syste...

Page 101: ...1 Telephone 440 9853553 TAMPERING WARNING TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED FEDERAL LAW PROHIBITS THE FOLLOWING ACTS OR CAUSING THEREOF 1 The removal or rendering inoperative by any perso...

Page 102: ...990 ADVENTURE 990 ADVENTURE S KTM Sportmotorcycle AG A 5230 Mattighofen www ktm at 10 2006 FOTO MITTERBAUER KTM Group Partner ART NR 3 211 149 DE BEDIENUNGSANLEITUNG 2007...

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