KTM 990 SMT Page 96 Owner'S Manual Download

Page: 96 / 219

SERVICE WORK ON THE CHASSIS

10.17

Checking the chain, rear sprocket, engine sprocket and chain guide

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.

Info

The rear sprocket, engine sprocket and chain should always be changed
together.

Summary of Contents for 990 SMT

Page 1: ...OWNER S MANUAL 2011 990 Supermoto T USA Art no 3211663en...

Page 2: ......

Page 3: ...ompletely All specifications are non binding KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifications prices colors forms materials services designs equipmen...

Page 4: ...ccording 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 T V Management Service KTM S...

Page 5: ...tachometer 36 Combination instrument indicator lamps 37 Combination instrument display 38 Combination instrument speedometer 39 Setting kilometers or miles 39 Combination instrument time 40 Setting t...

Page 6: ...nd 81 Raising the motorcycle with the rear wheel stand 82 Taking the motorcycle off of the rear wheel stand 82 Bleeding the fork legs 83 Removing the seat 83 Mounting the seat 84 Mounting the helmet l...

Page 7: ...153 Cooling system 153 Checking the antifreeze and coolant level 153 Checking the coolant level in the compensating tank 155 Draining the coolant x 157 Filling bleeding the cooling system x 158 TUNIN...

Page 8: ...RQUES 191 TECHNICAL DATA CHASSIS 194 Lighting equipment 195 Tires 196 Capacity fuel 196 TECHNICAL DATA FORK 197 TECHNICAL DATA SHOCK ABSORBER 199 TECHNICAL DATA CHASSIS TIGHTENING TORQUES 201 SUBSTANC...

Page 9: ...anding 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 to...

Page 10: ...et 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 th...

Page 11: ...ses 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 Where thread lo...

Page 12: ...ful 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 motorcy...

Page 13: ...11...

Page 14: ...IMPORTANT INFORMATION 12 2 1 Overview of labels B00691 10...

Page 15: ...nformation on operating substances and tires 4 Information on noise emission 5 Information on preparing for use 6 Information on the fuel evaporation system 7 Information on chain tension 7 Informatio...

Page 16: ...IMPORTANT INFORMATION 14 B00693 01 Type label Canada B00694 01 Information on operating substances and tires...

Page 17: ...IMPORTANT INFORMATION 15 B00695 01 Information on noise emission 600961 01 Information on preparing for use...

Page 18: ...IMPORTANT INFORMATION 16 B00696 01 Information on the fuel evaporation system 600966 01 Information on chain tension...

Page 19: ...pe label USA Notes warnings Pay close attention to the notes warnings Info Various information and warning labels are affixed to the vehicle Do not remove information warning labels If they are missin...

Page 20: ...ns useful information and tips to help you operate and handle your motorcycle Only then will you find out how to best customize the motorcycle for your own use and how you can protect yourself from in...

Page 21: ...uno QC J3V 6B7 Phone 450 441 4451 x 4250 www ktmcanada com Tampering warning It is not permitted to make changes to the components of the noise damping system Federal law prohibits the following acts...

Page 22: ...o the applicable laws and regulations Consumer rights Warranty claims should be submitted to an authorized KTM workshop If you are not satisfied please contact KTM North America Inc Customer Support 1...

Page 23: ...21...

Page 24: ...VIEW OF VEHICLE 22 3 1 View of vehicle front left side vehicle differs slightly from photo B00690 10...

Page 25: ...ICLE 23 1 Combination instrument p 35 2 Rear mirror 3 Clutch lever p 30 4 Seat 5 Handrails p 48 6 Level viewer engine oil 7 Shift lever p 51 8 Engine number p 28 9 Compression damping of the shock abs...

Page 26: ...VIEW OF VEHICLE 24 3 2 View of vehicle rear right side vehicle differs slightly from photo B00689 10...

Page 27: ...Horn button p 33 3 Filler cap 4 Emergency OFF switch p 34 4 Electric starter button p 35 5 Hand brake lever p 30 6 Fork rebound setting and spring preload setting 7 Shock absorber rebound adjustment...

Page 28: ...UMBERS 26 4 1 Chassis number type label B00664 10 The chassis number is stamped on the frame behind the steering head on the right 601116 10 The type label for the USA is fitted on the frame tube on t...

Page 29: ...number 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 Use the orange programming key to activate and deactivate the...

Page 30: ...28 4 3 Engine number B00120 10 The engine number is stamped on the left side of the engine under the engine sprocket 4 4 Fork part number B00606 10 The fork part number is stamped on the inner side of...

Page 31: ...SERIAL NUMBERS 29 4 5 Shock absorber part number B00607 10 The shock absorber part number is stamped on the top of the shock absorber above the adjusting ring on the engine side...

Page 32: ...er is fitted on the left side of the handlebar The clutch is hydraulically operated and self adjusting 5 2 Hand brake lever B00609 10 The hand brake lever is fitted on the right side of the handlebar...

Page 33: ...switch B00684 10 The light switch is fitted on the left side of the handlebar Possible states Low beam on The light switch is turned downwards In this position the low beam and tail light are switched...

Page 34: ...gnal switch B00656 11 The turn signal switch is fitted on the left side of the handlebar Possible states Turn signal off Left turn signal on The turn signal switch is pressed to the left The turn sign...

Page 35: ...ay only be switched on using a black ignition key Use the orange programming key to activate and deactivate the black ignition key Possible states Ignition OFF In this position the ignition circuit is...

Page 36: ...lead to problems A lost black ignition key must be deactivated to prevent unauthorized persons from operat ing the vehicle The second black ignition key is activated when the vehicle is shipped Two a...

Page 37: ...Electric starter button in basic position Electric starter button pressed The electric starter is actuated in this position 5 12 Combination instrument 400885 10 The combination instrument is installe...

Page 38: ...ter 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 The ABS can be switched off usi...

Page 39: ...ights up red The coolant temperature has reached a critical value The low fuel warning lamp lights up orange The fuel level has reached the reserve mark The display switches to TRIP F The oil pressure...

Page 40: ...ents 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 circumferen...

Page 41: ...speed is shown in kilometers per hour km h or in miles per hour mph 5 18 Setting kilometers or miles Info If you change the unit the value ODO is retained and converted accordingly Making the setting...

Page 42: ...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 19 Combination instrument time 400893 11 The time is shown in area of the display Inf...

Page 43: ...tton pressed simultaneously The time is set 5 21 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 ret...

Page 44: ...ng 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...

Page 45: ...ark the display automatically changes to TRIP F and starts to count from 0 0 regardless of the previous display mode Info The low fuel warning lamp lights up in parallel to the TRIP F display 5 25 Com...

Page 46: ...ton pressed until the display mode changes from C to F or from F to C 5 27 Combination instrument warning of slippery roads 400894 10 The ice symbol lights up to indicate an increased danger of slippe...

Page 47: ...ch hazard warning flasher B00658 10 The hazard warning flasher switch is fitted next to the combination instrument on the left The hazard warning flasher is used to indicate emergency situations Info...

Page 48: ...that no fuel is spilt especially on hot vehicle components Clean up spilt fuel immediately Fuel in the fuel tank expands when warm and can escape if the tank is overfilled See the notes on refueling...

Page 49: ...ignition key 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 90 counterc...

Page 50: ...ip 5 34 Luggage rack plate B00659 10 The luggage rack plate is located behind the seat The base plate of a luggage system can be mounted on the luggage rack plate optional The luggage rack plate may n...

Page 51: ...9 5 35 Seat lock 600922 10 Seat lock is located at the rear under the tail light It can be locked with the ignition key 5 36 Tool set B00612 10 The tool set is located in the storage compartment under...

Page 52: ...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 5 38 Pa...

Page 53: ...51 5 39 Shift lever B00120 11 Shift lever is mounted on the left side of the engine B00121 10 The gear positions can be seen in the photograph The neutral or idle position is between the first and sec...

Page 54: ...t side of the vehicle The side stand is used to park the motorcycle Info The side stand must be folded up during motorcycle use Side stand is coupled with the safety start system see the riding instru...

Page 55: ...t 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 U...

Page 56: ...p Try also to ride 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 54 6 2...

Page 57: ...es 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 le...

Page 58: ...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...

Page 59: ...vel p 106 Check the front brake linings p 103 Check the rear brake linings p 109 Check that the brake system is functioning properly Check the coolant level in the compensating tank p 155 Check the ch...

Page 60: ...ate 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 of the engine Always warm up the engine...

Page 61: ...orcycle is equipped with a safety start system You can only start the engine if the transmission is in neutral or if the clutch is pulled when a gear is engaged If the side stand is folded out and you...

Page 62: ...up Warning Danger of accidents Malfunctions caused by incorrect ignition key position Do not change the ignition key position during a journey Warning Danger of accidents Distraction from traffic act...

Page 63: ...tires 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 an...

Page 64: ...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 s...

Page 65: ...nts 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...

Page 66: ...ing Danger of accidents Locking of the wheels due to braking action of the engine Pull the clutch during emergency braking full brake application and when braking on a slippery surface When braking fi...

Page 67: ...ch as exhaust system radiator engine shock absorber and brakes Allow these components to cool down before starting work on them Note Danger of damage The parked vehicle may roll away or fall over Alwa...

Page 68: ...to the position To make the steering lock engage more easily move the handlebar back and forth slightly Remove the ignition key 7 7 Refueling Danger Fire hazard Fuel is highly flammable Never refuel t...

Page 69: ...is motorcycle is equipped with a regulated catalytic converter Leaded fuel will destroy the catalytic converter You should there fore use unleaded fuel only 401182 10 Switch off the engine Open the fi...

Page 70: ...ality p 163 400885 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 butto...

Page 71: ...ear brake linings p 109 Check the rear brake disc p 106 Check that brake lines are undamaged and free of leaks Check the rear brake fluid level p 106 Check the free travel of the foot brake lever p 10...

Page 72: ...ss of the throttle valve body for damage and correct routing x Check the cables for damage and kink free routing x Check the control cables for damage kink free routing and adjustment Change the air f...

Page 73: ...dworthiness and take a test ride Read out the fault memory after a test ride using the KTM diagnostics tool x Make the service entries in the KTM DEALER NET and service record x K10N Once after 1 000...

Page 74: ...the adjusting screws against the stop and take the last perceptible click as the end position These adjustments should be understood as a guideline and should always be the basis of your own personal...

Page 75: ...the fork type Guideline Compression damping Comfort 25 clicks Standard 20 clicks Sport 15 clicks Full payload 15 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce damping...

Page 76: ...ine Rebound damping Comfort 25 clicks Standard 20 clicks Sport 15 clicks Full payload 15 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce damping 9 4 Adjusting the spring...

Page 77: ...according to the fork type Guideline Spring preload Preload Adjuster Comfort 5 turns Standard 5 turns Sport 3 turns Full payload 3 turns Info Turn clockwise to increase preload turn counterclockwise t...

Page 78: ...er long ground swells the rear wheel suspension compresses more slowly These two ranges can be adjusted separately although the transition between high speed and low speed is gradual Thus changes in t...

Page 79: ...ks Sport 15 clicks Full payload 15 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce damping 9 7 Adjusting the high speed compression damping of the shock absorber Caution...

Page 80: ...ng high speed Comfort 2 turns Standard 1 5 turns Sport 1 turn Full payload 1 turn Info Turn clockwise to increase damping turn counterclockwise to reduce damping 9 8 Adjusting the rebound damping of t...

Page 81: ...f accidents Modifications to the suspension settings can seriously alter the vehicle s ride behavior Following modifications ride slowly at first to get the feel of the new ride behavior Info The spri...

Page 82: ...n retaining ring Turn adjusting ring until the spring is no longer under tension Hook wrench T157S Measure the overall spring length without a load Tension the spring by turning adjusting ring to the...

Page 83: ...the handlebar to the straight ahead position Align the front wheel stand with the fork legs using the adapters Front wheel stand 61029055300 Info Always raise the rear of the motorcycle first Raise th...

Page 84: ...stand Adapter 61029055120 Rear wheel stand 61029055400 Stand the motorcycle upright align the wheel stand with the swingarm and the adapters and lift the motorcycle 10 4 Taking the motorcycle off of t...

Page 85: ...s pressure escapes from the interior of the fork Mount and tighten the bleeder screws Info Carry out this operation on both fork legs 10 6 Removing the seat 600922 10 Insert the ignition key in the se...

Page 86: ...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 for holding a helmet...

Page 87: ...ling the fuel tank Remove the seat p 83 Remove the mask spoiler p 87 B00669 10 Remove screws and the spoiler on both sides B00670 11 Remove screw on both sides Info The fuel hoses do not need to be di...

Page 88: ...B00670 10 Install and tighten screw with the bearing sleeve and rubber bushing on both sides Guideline Remaining chassis screws M8 25 Nm 18 4 lbf ft Check the routing of the fuel lines B00669 11 Posit...

Page 89: ...SERVICE WORK ON THE CHASSIS 87 10 11 Removing the mask spoiler B00625 10 Remove screws B00671 10 Remove screws Remove the mask spoiler...

Page 90: ...88 700633 01 Remove screws Remove the inside trim of the mask spoiler Repeat the operation on the opposite side 10 12 Installing the mask spoiler 700633 10 Position the inside trim of the mask spoile...

Page 91: ...SERVICE WORK ON THE CHASSIS 89 B00625 11 Position the mask spoiler Mount and tighten screws B00671 11 Mount and tighten screws Repeat the operation on the opposite side...

Page 92: ...es their grip Remove oil and grease with a suitable cleaning material Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of...

Page 93: ...ts Danger caused by incorrect chain tension If the chain tension is too high the components of the secondary power train chain engine sprocket rear sprocket bearings in transmission and rear wheel are...

Page 94: ...on p 92 10 16 Adjusting the chain tension Warning Danger of accidents Danger caused by incorrect chain tension If the chain tension is too high the components of the secondary power train chain engine...

Page 95: ...ce 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...

Page 96: ...ngine sprocket and chain guide 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 re...

Page 97: ...section Info 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 greater than...

Page 98: ...n the chain sliding guard Guideline Screw chain sliding guard M5 5 Nm 3 7 lbf ft Screw chain sliding guard M6 6 Nm 4 4 lbf ft Loctite 243 B00654 10 Check the chain sliding piece for wear If the drill...

Page 99: ...is limited Turn the adjusting screw by hand only and do not apply any force Do not make any adjustments while riding B00608 12 Adjust the basic setting of the clutch lever to your hand size by turnin...

Page 100: ...position Remove screws Remove cover with membrane Check the fluid level Fluid level below top edge of container 4 mm 0 16 in If the coolant level does not meet specifications Correct the fluid level o...

Page 101: ...ke and rear brake During normal operation the brake system operates like a conventional brake system without ABS If the ABS control unit detects a locking tendency in one of the wheels the ABS system...

Page 102: ...ver forward Adjust the basic setting of the hand brake lever to your hand size by turning adjusting wheel Info Do not make any adjustments while riding 11 3 Checking the front brake discs Warning Dang...

Page 103: ...cs exhibit damage cracking or deformation Change the brake discs x 11 4 Checking the front brake fluid level Warning Danger of accidents Failure of the brake system If the brake fluid level falls belo...

Page 104: ...e 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 wit...

Page 105: ...ill damage painted surfaces Use only clean brake fluid from a sealed container B00629 10 Move the brake fluid reservoir mounted on the handlebar to a horizontal position Remove screws Remove cover wit...

Page 106: ...have minimum thick ness Minimum thickness 1 mm 0 04 in If the minimum thickness is less than specified Change the front brake linings x Check all brake linings on both brake calipers for damage and c...

Page 107: ...basic position of the foot brake lever Warning Danger of accidents Brake system failure If there is no free travel on the foot brake lever pressure builds up on the rear brake circuit The rear brake...

Page 108: ...isc 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 c...

Page 109: ...brake fluid x 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 th...

Page 110: ...vironmental 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 co...

Page 111: ...ger 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 brakin...

Page 112: ...for minimum thickness Minimum thickness 1 mm 0 04 in If the minimum thickness is less than specified Change the rear brake linings x Check the brake linings for damage and cracking If damage or wear i...

Page 113: ...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 B00633 10 Lo...

Page 114: ...10 Check the wheel bearing for damage and wear If the wheel bearing is broken or worn Replace the wheel bearing x Clean grease and mount the left and right spacers and the shaft seal rings Long life...

Page 115: ...unt 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 Fix the hand bra...

Page 116: ...the front brake and compress the fork powerfully a few times The fork legs straighten Tighten screws Guideline Screw fork stub M8 15 Nm 11 1 lbf ft 12 3 Removing the rear wheel x Raise the motorcycle...

Page 117: ...spindle to the point where the chain adjuster is no longer in contact with the adjusting screw B00135 01 Push the rear wheel forward as far as possible and take the chain off the rear sprocket Withdra...

Page 118: ...the foot brake when the rear wheel is removed 12 4 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 dis...

Page 119: ...Replace the wheel bearing x Remove bushing Clean and grease the mating surfaces of the bushing and the shaft seal ring Long life grease p 210 Install the bushing Clean and grease the thread of the whe...

Page 120: ...the adjust ing screws and tighten the 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 ref...

Page 121: ...hock absorber x Position the rear sprocket carrier Info A set of bolts and shock absorbers should have as little free travel as possible to increase the service life of the shock absorbers Install the...

Page 122: ...alternating angles The full grip levels are not achieved until the tires have been run in Info The type condition and air pressure of the tires all have a major impact on the handling of the motorcyc...

Page 123: ...If a tire is more than five years old Change the tires 12 7 Checking the tire air pressure Info Low tire air pressure leads to abnormal wear and overheating of the tire Correct tire air pressure ensu...

Page 124: ...WHEELS TIRES 122 Mount the dust cap Info The rubber seal in the dust cap prevents air from leaking out of the tire if the valve is faulty...

Page 125: ...ell ventilated areas 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 physician Caution Danger of...

Page 126: ...ach rubber band Pull the battery up and out of the battery rack 13 2 Installing the battery x B00638 11 Position the battery in the battery rack Info The terminals of the battery must face in the dire...

Page 127: ...tery gases Keep the battery away from sparks or open flames Charge only in well ventilated areas In the event of skin contact rinse with large amounts of water If battery acid gets in the eyes rinse w...

Page 128: ...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 th...

Page 129: ...r remove lid Charge the battery at no more than 10 of the capacity specified on battery housing Switch off the charger after charging Disconnect the battery Guideline The charge current charge voltage...

Page 130: ...the seat p 83 B00640 10 Remove protection covers 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...

Page 131: ...under the seat These fuses protect the return pump and the hydraulic unit of the ABS The third fuse which protects the ABS control unit is located in the fuse box Switch off all power consumers and s...

Page 132: ...ction cap Mount the seat p 84 13 6 Changing the fuses of individual power consumers Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used Use only fuses with the pres...

Page 133: ...plate lamp Fuse 3 10 A horn brake light turn signal Fuse 4 10 A radiator fan Fuse 5 10 A ignition EFI control unit immobilizer Fuse 6 10 A combination instrument auxiliary equipment permanent positive...

Page 134: ...e seat p 84 13 7 Changing the headlight 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 f...

Page 135: ...retaining clamps Remove headlight bulb Position the new headlight bulb in the headlight housing Low beam high beam H4 socket P43t p 195 Info Insert the headlight bulb so that the bayonet lugs latch in...

Page 136: ...Changing the parking light 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...

Page 137: ...t carefully out of the housing Remove the bulb Position a new light bulb in the socket Parking light W5W socket W2 1x9 5d p 195 Carefully position the socket with the bulb in the housing Mount the cab...

Page 138: ...y 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 195 Check the turn signal to make sure it i...

Page 139: ...ELECTRICAL SYSTEM 137 B00641 10 Remove screws Remove the grab handles B00642 10 Remove screws on the left and right heat protectors Remove the heat protectors...

Page 140: ...ELECTRICAL SYSTEM 138 B00643 10 Remove screws on the left and right rear side parts Remove screws Remove the rear side parts B00644 10 Remove screws Remove the rear top part...

Page 141: ...new bulb carefully into the socket and turn it clockwise until it stops Brake light P21W socket BA15s p 196 Insert the bulb socket into the tail light and turn clockwise until it stops Check that the...

Page 142: ...screw con nection 3 3 Nm 2 43 lbf ft Subsequent screw connection 2 Nm 1 5 lbf ft Mount and tighten screws Guideline Remaining chassis screws M5 5 Nm 3 7 lbf ft Remaining frame bolts EJOT PT K50x12 T20...

Page 143: ...8 lbf ft Mount the seat p 84 13 11 Changing the tail light bulbs Note Damage to reflector Reduced luminance Grease on the lamp will evaporate due to the heat and be deposited on the reflector Clean t...

Page 144: ...CAL SYSTEM 142 B00642 10 Remove screws on the left and right heat protectors Remove the heat protectors B00643 10 Remove screws on the left and right rear side parts Remove screws Remove the rear side...

Page 145: ...ulb in the socket Tail light W5W socket W2 1x9 5d p 196 Carefully position the sockets with the bulbs into the bracket in the tail light Check that the tail light bulbs are functioning properly B00644...

Page 146: ...screw con nection 3 3 Nm 2 43 lbf ft Subsequent screw connection 2 Nm 1 5 lbf ft Mount and tighten screws Guideline Remaining chassis screws M5 5 Nm 3 7 lbf ft Remaining frame bolts EJOT PT K50x12 T20...

Page 147: ...00641 10 Position the grab handles Mount and tighten screws Guideline Screw handrail M8 20 Nm 14 8 lbf ft Mount the seat p 84 13 12 Changing the license plate lamp 700602 01 Remove screws Remove the l...

Page 148: ...emove the bulb Position a new light bulb in the holder License plate lamp W5W socket W2 1x9 5d p 196 Carefully position the holder with the bulb into the bracket 700602 01 Position the cover Mount and...

Page 149: ...tically 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...

Page 150: ...the ignition key Info The orange programming key must only be used for activating and deactivating If a black ignition key is lost or replaced the black ignition keys must be activated deactivated us...

Page 151: ...lights up Switch off the ignition by turning the orange programming key to the OFF position Pull out the programming key Insert the black ignition key in the ignition lock Switch on the ignition by t...

Page 152: ...Press the emergency OFF switch into the position B00652 10 Insert the orange programming key in the ignition lock Switch on the ignition by turning the orange programming key to the ON position FI Wa...

Page 153: ...s up Switch off the ignition by turning the orange programming key to the OFF position Pull out the programming key Insert the black ignition key in the ignition lock Switch on the ignition by turning...

Page 154: ...mber of flashes equals the number of functional black ignition keys includ ing the orange programming key Switch off the ignition by turning the orange programming key to the OFF position Pull out the...

Page 155: ...r the speed the less the cooling effect Dirty cooling fins also reduce the cooling effect The heat expansion causes the surplus coolant to flow into the compensating tank When the temperature falls th...

Page 156: ...ondition The engine is cold Stand the motorcycle upright on a horizontal surface Reset the fuel tank p 85 B00677 10 Remove radiator cap and plug from the compensating tank Check the coolant antifreeze...

Page 157: ...n for the coolant loss Alternative 1 Coolant p 205 Alternative 2 Coolant mixed ready to use p 205 If more coolant needed to be added than the specified value 0 50 l 0 53 qt Fill bleed the cooling syst...

Page 158: ...dition The engine is cold The radiator is completely full Stand the motorcycle on a horizontal surface B00679 10 Check the coolant level in the compensating tank The coolant level must be between the...

Page 159: ...oolant 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 im...

Page 160: ...ous 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 s...

Page 161: ...vent hole and then immediately mount and tighten the bleeder screw Alternative 1 Coolant p 205 Alternative 2 Coolant mixed ready to use p 205 Fill the radiator completely with coolant Mount the radia...

Page 162: ...ature display 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 compensati...

Page 163: ...lay in the throttle cable x p 162 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...

Page 164: ...ease of movement 15 3 Ignition curve plug in connector B00667 01 The plug in connection is located under the seat in front of the tail light By disconnecting the plug in connector the ignition curve...

Page 165: ...disconnected Fuel with an octane rating of 80 to 94 RON can be used for one tank full p 162 Activate the ignition curve for fuel with an octane rating of 95 or higher ROZ 95 RON 95 PON 91 Connect the...

Page 166: ...f the shift lever and shift shaft Mount the shift lever on the shift shaft in the required position and engage the gearing Info The range of adjustment is limited The shift lever must not come into co...

Page 167: ...exhaust extraction system Start the engine and run it until it reaches operating temperature Six bars of the temperature display light up B00683 11 Switch off the engine Park the motorcycle on a horiz...

Page 168: ...screens x Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden Wear appropriate protective clothing and safety gloves In case of burns rinse immediately with...

Page 169: ...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 700610 10 Remove screws and cover 700612 10 Pull oil s...

Page 170: ...ine to one side 700615 10 Pull oil sieve out of the oil tank 700617 10 Remove screw connections and move the oil line to one side Remove screws Take off oil filter cover with the O ring Pull oil filte...

Page 171: ...ll oil filter cover Mount and tighten the screws Guideline Remaining engine screws M5 6 Nm 4 4 lbf ft Position the oil line Mount and tighten screw cap Guideline Nut oil line M16x1 5 25 Nm 18 4 lbf ft...

Page 172: ...plug with magnet M12x1 5 25 Nm 18 4 lbf ft 700611 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 700616 10 Slide...

Page 173: ...the top marking Mount the plug 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 suf...

Page 174: ...The engine oil level must be corrected when the engine is warm B00683 10 Remove plug and add engine oil to the top marking Condition External temperature 0 C 32 F Engine oil SAE 10W 50 p 206 Conditio...

Page 175: ...id etc should be disposed of as stipulated in applicable regulations Info If you clean the motorcycle regularly its value and appearance will be maintained over a long period Avoid direct sunshine on...

Page 176: ...pplying the brakes occasionally Info The heat produced causes water at inaccessible positions in the engine and on the brakes to evaporate After the motorcycle has cooled off lubricate all moving part...

Page 177: ...water Warm water would enhance the corrosive effects of salt 401060 01 Clean the motorcycle p 173 Treat the engine the swingarm and all other bare or galvanized parts except brake discs with a wax ba...

Page 178: ...ible so that you can fill up with fresh fuel when you put the motorcycle back into operation Clean the motorcycle p 173 Change the engine oil and filter clean the oil screens x p 166 Check the antifre...

Page 179: ...nnot warm up properly the water vapor produced during combustion condenses and causes valves and exhaust system to rust 18 2 Preparing for use after storage 401059 01 Take the motorcycle off of the fr...

Page 180: ...lfunction in CAN bus communica tion Check the CAN bus communication x Combination instrument defective Check the combination instrument x Control unit for electric start lock defective Check the contr...

Page 181: ...fins Foam formation in cooling system Drain the coolant x p 157 Fill bleed the cooling system x p 158 Buckled or damaged radiator hose Change the radiator hose x Fuse 4 blown Change the fuses of indiv...

Page 182: ...the engine oil and filter clean the oil screens x p 166 The headlight and tail light are not functioning Fuse 2 blown Change the fuses of individual power consumers p 130 Turn signal hazard warning f...

Page 183: ...trol unit Blink code of immobilizer indica tor lamp 14 Immobilizer indicator lamp flashes 1x short 1 second pause 4x short Error level condition Malfunction in transponder of black ignition key Blink...

Page 184: ...indicator lamp flashes 3x short 1 second pause 1x short Error level condition Malfunction encryption query from EFI control unit to immobilizer control unit Blink code of immobilizer indica tor lamp 3...

Page 185: ...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 War...

Page 186: ...r 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 Ambi...

Page 187: ...r 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 co...

Page 188: ...r 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 Warning lamp FI MIL flashes 4x long 5x short Error...

Page 189: ...ing lamp FI MIL flashes 5x long 3x short Error level condition Fuel evaporation system short circuit to ground or open circuit Fuel evaporation system input signal too high Blink code FI of warning la...

Page 190: ...ld absolute pressure sensor cylinder 2 connection leaks Blink code FI of warning lamp MIL 81 Warning lamp FI MIL flashes 8x long 1x short Error level condition Immobilizer control unit circuit fault B...

Page 191: ...t 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 ri...

Page 192: ...R8BI9 Spark plug electrode gap 0 8 mm 0 031 in Cooling Water cooling permanent circulation of coolant by water pump Idle speed 1 400 1 600 rpm Cold start device Electric starter 22 1 Capacity engine o...

Page 193: ...M6 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 clutc...

Page 194: ...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...

Page 195: ...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...

Page 196: ...le 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 305 m...

Page 197: ...ible front axle load 160 kg 353 lb Maximum permissible rear axle load 250 kg 551 lb Maximum permissible total weight 400 kg 882 lb Battery YTZ14S Battery voltage 12 V Nominal capacity 11 2 Ah maintena...

Page 198: ...4 2 Tires Front tire Rear tire 120 70 ZR 17 M C 58W TL Continental ContiSportAttack 180 55 ZR 17 M C 73W TL Continental ContiSportAttack Additional information is available in the Service section unde...

Page 199: ...damping Comfort 25 clicks Standard 20 clicks Sport 15 clicks Full payload 15 clicks Spring preload Preload Adjuster Comfort 5 turns Standard 5 turns Sport 3 turns Full payload 3 turns Spring length wi...

Page 200: ...TECHNICAL DATA FORK 198 Fork oil per fork leg 737 ml 24 92 fl oz Fork oil SAE 5 p 207...

Page 201: ...cks 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 clicks Full...

Page 202: ...TECHNICAL DATA SHOCK ABSORBER 200 Spring length 200 mm 7 87 in Gas pressure 10 bar 145 psi Fitted length 372 mm 14 65 in Shock absorber fluid Shock absorber oil SAE 2 5 50180342S1 p 207...

Page 203: ...ft Subsequent screw connec tion 2 Nm 1 5 lbf ft Screw side stand switch M4 2 Nm 1 5 lbf ft Loctite 243 Remaining chassis nuts M5 5 Nm 3 7 lbf ft Remaining chassis screws M5 5 Nm 3 7 lbf ft Screw brak...

Page 204: ...w wheel speed sensor M6 6 Nm 4 4 lbf ft Loctite 243 Remaining chassis nuts M8 30 Nm 22 1 lbf ft Remaining chassis screws M8 25 Nm 18 4 lbf ft Screw bag carrier M8 15 Nm 11 1 lbf ft Loctite 243 Screw b...

Page 205: ...Nm 33 2 lbf ft Loctite 243 Banjo bolt brake line M10x1 15 Nm 11 1 lbf ft Brake light switch M10x1 15 Nm 11 1 lbf ft Screw connection rear hub shock absorber rear sprocket M10x1 25 50 Nm 36 9 lbf ft L...

Page 206: ...TECHNICAL DATA CHASSIS TIGHTENING TORQUES 204 Screw steering head M20x1 5 12 Nm 8 9 lbf ft Bolt front axle M25x1 5 45 Nm 33 2 lbf ft Nut rear wheel spindle M25x1 5 90 Nm 66 4 lbf ft Thread greased...

Page 207: ...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 antifree...

Page 208: ...responding 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 211 SAE p 211 SAE 5W 40 Guideline Use o...

Page 209: ...ic 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 r...

Page 210: ...SUBSTANCES 208 Super unleaded ROZ 95 RON 95 PON 91 According to DIN EN 228 ROZ 95 RON 95 PON 91...

Page 211: ...or road use Guideline KTM recommends Motorex products Supplier Motorex Chainlube Road Cleaning and preserving materials for metal rubber and plastic Guideline KTM recommends Motorex products Supplier...

Page 212: ...recommends Motorex products Supplier Motorex Bike Grease 2000 Motorcycle cleaner Guideline KTM recommends Motorex products Supplier Motorex Moto Clean 900 Universal oil spray Guideline KTM recommends...

Page 213: ...e 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...

Page 214: ...ar brake adding 107 Brake fluid level front brake checking 101 rear brake checking 106 Brake light bulb changing 136 Brake linings front brake checking 103 rear brake checking 109 Brakes 63 Braking 63...

Page 215: ...ting tank checking 155 Cooling system 153 filling bleeding 158 D Display 38 E Electric starter button 35 Emergency OFF switch 34 Engine running in 54 Engine number 28 Engine oil adding 172 changing 16...

Page 216: ...147 checking 147 Headlight bulb changing 132 Headlight flasher switch 32 Helmet lock 50 mounting on vehicle 84 Horn button 33 I Ignition curve adjusting to fuel quality 163 plug in connector 162 Igni...

Page 217: ...after storage 177 checks and maintenance measures when preparing for use 57 information on first use 53 Protective treatment for winter operation 175 R Rear hub shock absorber checking 119 Rear sproc...

Page 218: ...hanging 141 Technical data chassis 194 196 chassis tightening torques 201 204 engine 189 190 engine tightening torques 191 193 fork 197 198 shock absorber 199 200 Throttle grip 31 Tire air pressure ch...

Page 219: ...KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com 01 2011 Photo Mitterbauer 3211663en 3211663en...

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KTM 990 SMT, Owner'S Manual

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