KTM 990 Super Duke 2005 Owner'S Manual Download

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KTM-Sportmotorcycle AG

A–5230 Mattighofen

www.ktm.at

KTM Group Partner

OWNER’S MANUAL
MANUALE D’USO
MANUEL D’UTILISATION
MANUAL DE INSTRUCCIONES

ART. NR. 3.211.57

990 SUPER DUKE

BEDIENUNGSANLEITUNG

2005

Summary of Contents for 990 Super Duke 2005

Page 1: ...KTM Sportmotorcycle AG A 5230 Mattighofen www ktm at KTM Group Partner OWNER S MANUAL MANUALE D USO MANUEL D UTILISATION MANUAL DE INSTRUCCIONES ART NR 3 211 57 990 SUPER DUKE BEDIENUNGSANLEITUNG2005 ...

Page 2: ...o in extracts with written allowance of KTM SPORTMOTORCYCLE AG Mattighofen only COMSUMER INFORMATION 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 maintenance repair or replacement of any device or element of design incorporated into any new vehicle for th...

Page 3: ...ith an asterisk in the chapter Maintenance work on the chas sis and engine must be performed If maintenance work should become necessary during a competition it should be performed by a trained mechanic KTM strongly recommends that all service work to your KTM should be performed by a qualified KTM dealer For your own safety use KTM approved parts and accessories only KTM is not liable for damage ...

Page 4: ...r warranty will become void The fuels and lubricants specified in the owner s manual or those of an equal quality must be used in accordance with the maintenance schedule The warranty or guarantee shall become void for damage and consequential damage caused by manipu lations or conversions to the motorcycle The use of the motorcycle under extreme conditions e g on the race course can cause above a...

Page 5: ...bsorber 24 Page Checking the chain tension 24 Correcting the chain tension 24 Chain maintenance 25 Checking the chain for wear 25 General information on KTM disk brakes 26 Adjusting the basic position of the hand brake lever 27 Checking the front brake fluid level 27 Refilling front brake fluid 27 Checking the front brake pads 27 Changing the basic position of the foot brake lever 28 Checking the ...

Page 6: ...nter this number on page 1 Clutch lever The clutch lever 1 is fitted on the left hand side of the handle bar The adjusting screw A is used to change the original position of the clutch lever see maintenance work on chassis and engine The clutch is hydraulically actuated and adjusts itself automatically Hand brake lever The hand brake lever 2 is mounted on the handlebar on the right and actu ates t...

Page 7: ...will recognize the CLOCK display by the blinking dots between the hours and minutes It displays the speed temperature of the cooling liquid and the clock To switch to the next display mode press the MODE button ODO The speed temperature of the cooling liquid and the total kilometers or miles traveled are shown in the ODO mode To switch to the next display mode press the MODE button TRIP 1 The TRIP...

Page 8: ... 1 The trip meter 1 runs continuously and counts up to 999 9 It can be used to measure the length of a certain route on a trip or the distance between two refueling stops To return the trip meter 1 to zero switch on the ignition change to the TRIP 1 mode and press the SET button RESETTING TRIP 2 The trip meter 2 runs continuously and counts up to 999 9 It can be used similarly to TRIP 1 or togethe...

Page 9: ...ion The blue indicator lamp will light up when the high beams are switched on The red warning light will light up when the cooling liquid has reached a temperature of approx 120 C 248 F The orange warning light will start to blink when the fuel level has reached the reserve mark At the same time the display will auto matically change to TRIP F see TRIP F The red warning lamp lights up when the ign...

Page 10: ... The light signal high beam is actuated with button 2 The indicator switch 3 returns to central position after actuation Press flasher switch towards switch housing to switch off the flasher The horn is sounded with button 4 Emergency OFF tip switch light switch starter tip switch The emergency off switch 5 is provided for emergency situations and should not be used to switch off the engine The en...

Page 11: ...ding strap and pull off towards the back To mount the seat place it on the motorcycle and position the hooks 3 on the bottom of the seat behind the dollies 4 on the subframe Press down on the seat near the holding strap while sliding it forwards The two tabs 5 must hook onto the tank Turn the ignition key in the seat lock 90 in a counter clockwise direction and pull off Check whether the seat is m...

Page 12: ... shift lever is mounted on the left side of the engine The position of the gears is shown in the illustration Neutral or the idle speed is located between first and second gear The basic position of the shift lever can be adjusted according to your seat ing position see Maintenance work Side stand Fold the side stand 4 forward to the stop with your foot and put the weight of the motorcycle on the ...

Page 13: ... chapter 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 match your driv ing style and the payload The adjusting screws 3 are located on the upper end of the fork legs More information is provided in the chapter Adjusting the fork and shock absorber Spri...

Page 14: ...h a screwdriver The adjusting screw 2 for the high speed range can be adjusted with a 17 mm socket wrench More information is provided in the chapter Adjusting the fork and shock absorber Rebound damping of shock absorber The shock absorber s damping action during rebound travel rebound damp ing can also be adjusted This allows you adjust the damping behavior to match your driving style and the pa...

Page 15: ...first ride Enter the chassis engine and key numbers on page 1 Familiarize yourself with the operating elements Adjust the clutch lever the hand brake lever the foot brake lever and the shift lever in the position that is most convenient for you This motorcycle is equipped with a three way catalytic conver ter Leaded fuel will destroy the converter Always use unlea ded fuel Get used to handling the...

Page 16: ... are worn If the level of brake fluid falls below the minimum value this indicates a leak in the braking system or completely worn out brake pads Arrange for the braking system to be checked by a KTM specialist as com plete failure of the braking system can be avoided Also check the state of the brake hose and the thickness of the brake linings Check free travel at hand brake lever and foot brake ...

Page 17: ...ECONDS BEFORE TRYING AGAIN DON T RIDE YOUR MOTORCYCLE WITH FULL LOAD AND DON T REV ENGINE WHEN COLD BECAUSE THE PISTON IS WARMING UP FASTER THAN THE WATER COOLED CYLINDER IT CAN CAUSE ENGINE DAMAGE ALWAYS LET THE ENGINE WARM UP BEFORE AND REFRAIN FROM DRIVING WITH FULL LOAD UNTIL THE ENGINE IS WARM IF THE ENGINE IS DOES NOT CRANK WHEN YOU ACTUATE THE STARTER TIP SWITCH the transmission is switched...

Page 18: ...E ENGINE IN A MODERATE RPM RANGE FOR A FEW MILES GIV ING IT A CHANCE TO WARM UP AFTER THAT NO FURTHER PRE CAUTIONS IN THIS RESPECT NEED BE TAKEN THE ENGINE HAS REACHED OPERATING TEMPERATURE AS SOON AS THE SECOND BAR ON THE TEMPERATURE INDICATOR LIGHTS UP IF THE RED OIL PRESSURE WARNING LAMP LIGHTS UP WHILE DRIV ING THE OIL PRESSURE IS TOO LOW TO ADEQUATELY LUBRICATE THE ENGINE STOP IMMEDIATELY AND...

Page 19: ...ATERIALS ALWAYS TAKE OUT THE IGNITION KEY WHEN PARKING YOUR MOTORCYCLE SO THAT IT CANNOT BE USED BY UNAUTHORIZED PERSONS THE SIDE STAND IS DIMENSIONED FOR THE WEIGHT OF THE MOTORCYCLE ONLY SITTING ON THE MOTORCYCLE WILL INCREASE THE WEIGHT ON THE SIDE STAND THE SIDE STAND OR ENGINE CASE CAN BE DAMAGED AND THE MOTORCYCLE CAN TIP OVER Fuel In the condition at delivery the LC8 engine requires unleade...

Page 20: ...ENGLISH 19 ...

Page 21: ...S Check cooling system for leaks and antifreeze protection z z z Check radiator fan for proper operation z z z Check the exhaust system for leaks and correct suspension and the clamps for a tight fit z z z Replace the graphite gasket in the rear exhaust manifold slide z Check actuating cables for damage smooth operation and kink less arran gement adjust and lubricate z z z Check the oil level in t...

Page 22: ...and jerk damper for play z z IF MOTORCYCLE IS USED FOR COMPETITION 7500 KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE Service intervalls should never be exceeded by more than 500 km Maintenance work performed by an authorized KTM workshop is not a substitute for care and maintenance by the driver VITAL CHECKS AND CARE PROCEDURES TO CONDUCTED BY THE OWNER OR THE MECHANIC before each start after...

Page 23: ...etting Driving Sport Maximum Payload Compression adjuster clicks 20 15 10 15 Rebound adjuster clicks 20 15 10 15 Spring preload turns 5 5 5 6 1 2 2 Adjusting the fork and shock absorber There are a number of ways to adjust the fork and shock absorber to match the chassis to your driving style and the payload We have provided a table with pragmatical values to help you tune up your motorcycle These...

Page 24: ...mpression adjuster High Speed turns 2 5 2 2 1 5 Rebound adjuster clicks 22 17 10 5 Spring preload turns 6 6 6 6 3 Adjusting the spring preload on the fork The fork spring preload can be adjusted by turning the adjusting screws 1 wrench size 24 mm 5 mm 0 2 in Turning in a clockwise direction will increase the preload turning in a coun terclockwise direction will decrease the preload 1 turn will cha...

Page 25: ...e counternuts 3 To make sure the rear wheel is aligned the marks on the chain tensioners must be in the same position on the left and right in relation to the reference marks A Before tightening the wheel spindle make sure the chain tensioner 5 rests against the adjustment screws and the rear wheel is aligned with the front wheel Tighten the collar nut 2 to 90 Nm IF YOU DON T HAPPEN TO HAVE A TORQ...

Page 26: ...AN AUTHORIZED KTM WORKSHOP WHERE THE SERVICE 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 for wear proceed as follows Switch the transmission to idle and put a load of approx 15 kilograms 33 lbs on the lower part of the chain see illustration Now mea...

Page 27: ... MOTORCYCLE WILL NOT LONGER COMPLY WITH THE REGULATIONS AUTHORIZING THE USE OF VEHICLES FOR ROAD TRAFFIC AND THE WARRANTY WILL BE VOID BRAKE FLUID RESERVOIRS The brake fluid reservoirs on the front and rear wheel brakes have been designed in such a way that even if the brake pads are worn it is not neces sary to top up the brake fluid There is no reason to remove the reservoir cap under normal con...

Page 28: ... on KTM disk brakes However brake fluid must be refilled as soon as the brake fluid level reaches the MIN mark Remove the screws 2 and cover 3 with the rubber boot 4 Move the hand brake cylinder in a horizontal position and add DOT 5 1 Motorex Brake Fluid DOT 5 1 Press the rubber boot together and remount the cover Wash off any overflowing or spilled brake fluid with water Actuate the front brake ...

Page 29: ...d as soon as the brake fluid level reaches the MIN mark Remove the cover 3 and rubber boot 4 Add DOT 5 1 Motorex Brake Fluid DOT 5 1 Press the rubber boot together and remount the cover Wash off any overflowing or spilled brake fluid with water Actuate the rear brake until you feel the pressure point ACTUATE THE REAR BRAKE UNTIL YOU FEEL THE POINT OF PRESSURE NEVER USE DOT5 BRAKE FLUID IT IS BASED...

Page 30: ...istance bushing in the left shaft seal ring When mounting the distance bushing be careful not to press the sealing lips towards the inside position the front wheel according to the running direction shown by the arrows B on the rim To remount the front wheel lift the wheel on the fork and mount the wheel spindle Mount the collar screw 2 and tighten slightly tighten the clamping screws 3 on the rig...

Page 31: ...LONG THERM 2000 TO PREVENT THE THREAD FROM JAMMING Before remounting the rear wheel clean and grease the bearing surface of the bushings 5 and the shaft seal ring 6 The rear wheel is remounted in the reverse order Make sure the chain ten sioners 4 are mounted in the same way on the left and right The marks on the chain tensioners must be in the same position on the left and right in relation to th...

Page 32: ... the air pressure to the motorcycle s total weight Proper pressure ensures opti mum driving comfort and extends the life of your tires DO NOT MOUNT TIRES WHICH HAVE NOT BEEN APPROVED BY KTM OTHER TIRES COULD HAVE ADVERSE EFFECTS ON THE WAY YOUR MOTORCYCLE RIDES USE TIRES OF THE SAME BRAND AND TYPE FOR THE FRONT AND REAR WHEELS FOR YOUR OWN SAFETY REPLACE DAMAGED TIRES IMMEDIATELY WORN TIRES CAN HA...

Page 33: ...g the battery Note a battery charger item no 58429074000 is available from your KTM dealer You can also use the battery charger to test the off load voltage starta bility of the battery and the generator capacity Remove the front spoiler and fold the battery cover down then determine the battery s charge condition To determine the charge condition use a voltmeter to measure the voltage between the...

Page 34: ...A fuse box is mounted under the seat containing additional fuses that pro tect the individual electric power consumers The power consumers and the corresponding capacities are listed on the cover of the fuse box 5 Spare fuses 6 of 10 and 15 amperes are located next to the fuse box Replace a blown fuse only with an equivalent one If a new fuse that has just been set in gets blown again you are stro...

Page 35: ...ulb make sure the tab fits in the corresponding recess in the socket Attach the retaining clip connect the connector to the bulb and mount the rubber cap BULB FOR THE PARKING LIGHT Since a number of parts need to be removed to replace the parking light bulb we recommend that you have the lamp replaced at an authorized KTM workshop Adjusting the headlight range The payload can make it necessary to ...

Page 36: ...rder to mount a new bulb BULBS FOR THE TAILLIGHT Remove the bulb socket 2 from the housing and pull the bulb out of the socket Insert a new bulb and press the bulb socket all the way into the tail light housing Mount the seat Replacing the flasher bulbs Remove the screw on the back of the turn signal carefully fold the lens 3 towards the motorcycle and remove Turn the cap 4 approx 15 in a coun ter...

Page 37: ...LING LIQUID IN THE SYSTEM CHECK WHETHER ANY COOLING LIQUID IS LEAKING OUT ALSO ON THE BOT TOM OF THE MOTORCYCLE LET THE ENGINE COOL DOWN AND CHECK THE COOLING LIQUID LEVEL IN THE RADIATOR SEE CHAPTER CHECKING THE COOLING LIQUID LEVEL IN THE RADIATOR ONLY CONTINUE TO DRIVE IF THERE IS ENOUGH COOLING LIQ UID IN THE SYSTEM CONTACT AN AUTHORIZED KTM WORKSHOP TO HAVE THE ERROR ELIMINATED YOU WILL DAMAG...

Page 38: ...SCAPE DANGER OF SCALDING IF MORE THAN 1 LITER OF COOLING LIQUID NEEDS TO BE ADDED YOU WILL NEED TO BLEED THE COOLING SYSTEM Bleeding the cooling system Take off the left and right spoilers To take off the spoilers remove the screws 2 and 3 on each side Remove the bleeder screw 4 on the left side of the radiator To completely bleed the cooling system the motorcycle must be raised approx 50 cm in th...

Page 39: ...TCH DO NOT MIX THIS OIL WITH ANY OTHER HYDRAULIC OIL ALWAYS USE ORIGINAL KTM HYDRAULIC OIL AVAILABLE FROM YOUR AUTHORIZED KTM WORK SHOP TO MAKE SURE YOUR CLUTCH OPERATES SMOOTHLY NEVER REFILL WITH BRAKE FLUID Adjusting the handlebar tilt Loosen the screws 2 Adjust the handlebar and tighten the screws to 20 Nm Make sure the handlebar instruments do not touch the fuel tank when the handlebar is comp...

Page 40: ...engine oil level Check the engine oil level when the engine is warm at least 4 bars on the temperature indicator light up Allow the warm engine to run idle for approx 1 minute and place the motorcycle on a level surface not on the side stand Wait 20 seconds to allow the oil level in the inspection glass to adjust to the oil level in the oil tank The oil level should be between the MIN and MAX mark...

Page 41: ...E HAVING BEEN RUN WARM AND THE ENGINE OIL IN IT IS VERY HOT DO NOT BURN YOURSELF Park the motorcycle on an even surface in an upright position Place a ves sel under the engine to catch the used oil and remove the oil drain plug 1 Remove the oil drain plug 1 take off the cap 2 and pull the oil sieve out of the engine case with a pair of pliers Remove the oil filter cover 3 and pull the oil filter o...

Page 42: ...ug on the oil tank with a new seal ring and tighten to 20 Nm Grease the seal ring 4 and carefully slide the oil screen into the oil tank Position the oil return valve 5 mount the screws and tighten to 10 Nm Add 2 5 liters 0 7 USgal of fully synthetic engine oil meeting the JASO MA standard e g Motorex Power Synt 4T and mount the oil dipstick 6 Start the engine allow to run warm for 4 minutes and s...

Page 43: ...starting system Contact an authorized KTM workshop Engine cranks but doesn t start Operating error Blown fuse for the fuel pump Clutch not attached to the fuel line The plug and socket connector on the wiring harness is oxidized Error in the injection system A gear is engaged and the side stand is folded down Pay attention to starting off information see driving instruc tions Replace the fuel pump...

Page 44: ...l Blown fuse Replace fuse HORN BRAKELIGHT SPEEDO Time is not displayed or not correctly displayed Blown fuse thus no continuous power supply Replace fuse CLOCK and set the clock The battery is discharged The ignition power consumer has n t been switched off The battery isn t charged by the generator Recharge the battery according to the relevant instructions Voltage regulator and generator should ...

Page 45: ... stand switch Short circuit to ground Continues to run 33 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 Malfunction Stalls 41 Fuel pump relay Short circuit to ground positive Stalls 45 Lambda probe heater for rear cylinder Short circuit to ground posit...

Page 46: ...raying you will have to take precautions against the aggressive road salt clean motorcycle thoroughly and let it dry treat engine swing arm and all other bare parts except for brake discs with a wax based anti corrosion agent KEEP ANTI CORROSION AGENT FROM GETTING INTO CONTACT WITH THE BRAKE DISCS FOR OTHERWISE THIS WILL SIGNIFICANTLY REDUCE THE BRAKING POWER AFTER RIDES ON SALTED ROADS CLEAN MOTO...

Page 47: ...s LED position light rear 12V 5W Sockel W2 1x9 5d stoplight 12V 21W Sockel BA15s licens plate illumination 12V 5W Sockel W2 1x9 5d Battery maintenance free battery 12V 11 2 Ah Steering head angle 66 5 Wheel base 1438 10 mm Seat height unloaded 855 mm Ground clearance unloaded 165 mm Dry weight 184 kg 406 lbs Max axle load front 200 kg 441 5 lbs Max axle load rear 220 kg 485 6 lbs Max total weight ...

Page 48: ... shift shaft on connecting support M8 Loctite 243 25 Nm Relay for shift shaft on shift shaft M6 Loctite 243 18 Nm Gearshift rod attachment M6 Loctite 243 10 Nm HH bolts on foot brake pedal surface M5 Loctite 243 6 Nm AH bolts for side stand bracket engine M10 Loctite 243 45 Nm HH bolts for side stand fixture side stand bracket M10 Loctite 243 25 Nm HH bolts for side stand mounting M10 Loctite 243 ...

Page 49: ...l type expander Engine lubrication Dry sump with 2 trochoidal pumps pressure pump and suction pump Engine oil SAE 5W 40 10W 50 Motorex Power Synt 4T Quantity of engine oil approx 3 1 liters during oil filter change Primary drive Straight toothed spur wheels 35 67 Clutch Multi disc clutch in oil bath Transmission 6 speed claw shifted Gear ratio 1st gear 14 36 2nd gear 16 30 3rd gear 20 30 4th gear ...

Page 50: ...ring compression of shock absorber 13 Dismounting and remounting the front wheel 29 Dismounting and remounting the rear wheel 30 Display 6 Driving instructions 15 Emergency OFF tip switch light switch starter tip switch 9 Engine number engine type 5 Engine oil 39 Filler cap 10 Foot brake pedal 11 Page Footrests 12 Fuel 18 Fuses for individual power consumers 33 General information on KTM disk brak...

Page 51: ...ENGLISH 50 ...

Page 52: ...KTM Sportmotorcycle AG A 5230 Mattighofen www ktm at KTM Group Partner OWNER S MANUAL MANUALE D USO MANUEL D UTILISATION MANUAL DE INSTRUCCIONES ART NR 3 211 57 990 SUPER DUKE BEDIENUNGSANLEITUNG2005 ...

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