990 SUPER DUKE
990 SUPER DUKE R
ART. NR. 3.211.249 EN
OWNER’S MANUAL
2008
Page 1: ...990 SUPER DUKE 990 SUPER DUKE R ART NR 3 211 249 EN OWNER S MANUAL 2008...
Page 2: ...TION F FOR A AUSTRALIA O ONLY T Tampering w with n noise c control s system p prohibited Owners are warned that the law may prohibit a The removal or rendering inoperative by any person other than for...
Page 3: ...that the motor cycle is not road safe anymore The Owner s Manual corresponded to the latest information available for this model series at the time it was printed Minor devia tions resulting from enh...
Page 4: ...equivalent 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 assum...
Page 5: ...k absorber 20 Rebound damping of shock absorber 21 GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE 22 Instructions for initial operation 22 Running in the LC8 engine 22 Accessories and payload 2...
Page 6: ...he cooling liquid level in the compensating tank 61 Checking the cooling liquid level in the radiator 62 Bleeding the cooling system 62 Changing the basic position of the clutch lever 64 Checking the...
Page 7: ...Enter this num ber in the field on page no 1 The type label is located on the right frame tube under the seat Engine number engine type The engine number and the engine type are stamped into the left...
Page 8: ...ce work on chas sis 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 actuates the f...
Page 9: ...t MODE 1 Briefly press the MODE button to go to the next display mode The available display modes are ambient temperature distance traveled ODO trip master 1 TRIP 1 and trip master 2 TRIP 2 The speed...
Page 10: ...lown SETTING THE CLOCK Switch on the ignition and select the ODO mode Press and hold the MODE button while you press the SET button more than 1 second The time will start to blink Use the MODE button...
Page 11: ...ARNING 1 The frost symbol will start to blink regardless of the mode if the ambient temperature drops below 3 C 37 5 F ODO 2 Displays the total kilometers or miles traveled This figure will not be cle...
Page 12: ...reset the trip meter 2 to zero switch on the ignition select the TRIP 2 display mode and press the SET button more than 2 seconds Press the MODE button to go to the next display mode TRIP F 3 When the...
Page 13: ...to blink and the red warning lamp 2 will light up Possible causes for an increase in temperature causing the red warning light for the cool ing liquid temperature to light up Driving too slowly and d...
Page 14: ...atically change to TRIP F see TRIP F The red warning lamp lights up when the ignition is switched on but the engine is not running When the engine is started the warning lamp will go out as soon as th...
Page 15: ...ebar to the left then turn the ignition key to the left The ignition key can be withdrawn in position and Combination switch The rocker switch LIGHTS 1 actuates the high beam or low beam High beam lig...
Page 16: ...gine cannot be started in position ignition circuit and starter circuit are inter rupted Use the starter tip switch 3 to operate the electric starter Filler cap The filler cap 4 can be locked It is eq...
Page 17: ...he seat behind the dollies 3 on the subframe Press down on the seat near the holding strap while sliding it forwards The two tabs 4 must hook onto the tank Turn the ignition key in the seat lock 90 in...
Page 18: ...hrough the helmet attach both ends to the hook 3 and mount the seat The helmet lock is provided to secure the helmet to the motorcycle when parked Do not attach the helmet or other objects to the stee...
Page 19: ...ng position see Maintenance work Side stand Fold the side stand 1 forward to the stop with your foot and put the weight of the motor cycle on the stand Make sure it is standing securely on a firm surf...
Page 20: ...the fork leg axle passage More information is provided in the chapter Adjusting the fork and shock absorber Rebound damping of fork The fork s damping action during rebound travel rebound damping can...
Page 21: ...orber s damping behavior to match your driving style and the payload The damping rate can be adjusted in the low and high speed range Dual Compression Control The designation low and high speed refers...
Page 22: ...nd damping can also be adjusted This allows you adjust the damping behavior to match your driving style and the payload The adjusting screw 1 is located on the bottom of the shock absorber More inform...
Page 23: ...th new tires tilting the vehicle at different angles so that all sections are properly roughened Tires will not display their full grip char acteristics until they are properly run in Motorcycles are...
Page 24: ...uch purposes Never leave your motorcycle without super vision if the engine is running Accessories and payload Accessory parts and baggage can signifi cantly decrease a motorcycle s driving stabil ity...
Page 25: ...ced 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 correct function...
Page 26: ...e maximum total weight 387 kg 853 lbs and the motorcycle s wheel loads The maximum total weight is comprised of the motorcycle in a running condition and refueled 199 kg 439 lbs the baggage and access...
Page 27: ...iousness and death Always provide adequate ventila tion while the engine is running Never operate the motorcycle with a run down battery or without the battery This can damage the electronic component...
Page 28: ...trol of the motorcycle 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 you can shift to a higher gear Close thro...
Page 29: ...ever use your motorcycle without an air filter Otherwise dust and dirt may enter the engine and cause increased wear Stop immediately if a perceptible power loss occurs while driving due to a defec ti...
Page 30: ...he stop with your foot put the weight of the motor cycle on the stand and park the bike on a firm surface Lock the motorcycle always park your motorbike on a solid and horizontal surface Never leave y...
Page 31: ...d with a catalytic converter that will be destroyed if you use leaded fuel Always use unleaded fuel Fuel expands when its temperature rises Therefore do not fill the tank to the top see fig Gasoline i...
Page 32: ...31...
Page 33: ...inings 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 diagnosis too...
Page 34: ...or function low high beams stop light turn indica tors headlamp flasher tell tale lamps speedometer illumination horn side stand switch clutch switch emergency off switch z z z Make sure all bolts and...
Page 35: ...z z Check tire condition and inflation pressure z z z Check chain sprockets and chain guides for wear force fit and tension z z z Check bolts on pinion and chain sprocket for locking devices and a tig...
Page 36: ...er 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 coolant level z Check fuel lines...
Page 37: ...available apply Loctite 243 to the thread of the old nuts If the thread is damaged replace the screws and nuts Do not use toothed disks or split washers for the engine fastening bolts since they will...
Page 38: ...ping dur ing rebounding Make the same damping rate adjustment to both fork legs STANDARD ADJUSTMENT Turn adjusting screw clockwise as far as it will go Super Duke Turn 15 clicks in a counterclockwise...
Page 39: ...g of shock absorber The shock absorber can synchronize the compression damping in the low and high speed range separately Dual Compression Control Low and high speed refers to the movement of the shoc...
Page 40: ...rself Severe injuries could be the result Never unscrew the black screw connection 24mm Rebound damping of shock absorber By using the adjusting screw 2 the degree of damping of the rebound can be adj...
Page 41: ...E WORK ON CHASSIS AND ENGINE 40 Correcting the chain tension Loosen the collar nut 2 loosen the counternuts 3 and turn the left and right adjustment screws 4 the same distance Tighten the counternuts...
Page 42: ...ervice 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 chai...
Page 43: ...imum braking performance Front brake pads HAWK 7342 49 Rear brake pads TOSHIBA TTH 38 GF Brake pads available in the accessory trade are often not authorized for operation of your KTM motorcycle in ro...
Page 44: ...designed 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 presc...
Page 45: ...ver If this free travel is not provided pressure will build up in the braking system and the front wheel brake may fail due to overheating Checking the front brake fluid level The brake fluid reservoi...
Page 46: ...mm otherwise they could lead to brake failure For your own safety don t put off having your brake pads changed If the brake pads are replaced too late when the lining is partly or completely worn off...
Page 47: ...l rub against the brake disc imparing the braking effect and destroying the brake disc MAINTENANCE WORK ON CHASSIS AND ENGINE 46 Checking the rear brake fluid level The brake fluid reservoir for the r...
Page 48: ...or 0 6 in The parts required are supplied with the bike Remove the seat and the screws B Fit 4 spacers A at the same height front and back between the seat 1 and the seat carrier 2 and insert screws w...
Page 49: ...on solid ground and are correctly mounted The front wheel should not touch the ground NOTE FOR SUPER DUKE R First remove the crash pads Remove the screws 1 on the left and right brake caliper and care...
Page 50: ...ated Apply Loctite 243 to the screws 1 mount the screws and tighten to 45 Nm Take the motorcycle off the front stand actuate the front wheel brake and vigorously com press the fork several times to al...
Page 51: ...mounted Always place the wheel on the ground with the brake disc pointing upwards Otherwise the brake disc may be damaged If the axle is dismounted clean the thread of the wheel spindle and collar nut...
Page 52: ...ng effect would be strongly reduced MAINTENANCE WORK ON CHASSIS AND ENGINE 51 5 6 Tires air pressure Tire type tire condition and how much air pressure the tires have in them affect the way your motor...
Page 53: ...ecked regularly on a cold tire Adapt the air pressure to the motorcycle s total weight Proper pressure ensures optimum driving comfort and extends the life of your tires MAINTENANCE WORK ON CHASSIS AN...
Page 54: ...nt the front spoiler Apply Loctite 243 to the screws 1 and tighten to 10 Nm If electrolyte sulphuric acid leaks from the battery proceed with great care The elec trolyte can cause severe burns In the...
Page 55: ...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 sulfa tize destroying the battery Recharge the battery every 3 months...
Page 56: ...t remove the cap 2 and check the main fuse 3 A spare fuse 4 30 amperes is also plugged into the bracket Always replace blown fuses with an equivalent fuse Visit an authorized KTM workshop if a new fus...
Page 57: ...tachments positive supply 10 9 ACC1 for attachments switched with the ignition 10 10 SPARE Spare fuses 10 15 Replace a blown fuse only with an equivalent one If a new fuse that has just been set in ge...
Page 58: ...t a new bulb attach the retaining clip connect the connector and mount the rubber cap BULB FOR LOW BEAM B Remove the rubber cap 4 and pull off the connector 5 Detach the retaining clip and remove the...
Page 59: ...adlight Position your motorcycle 5 meters 16 4 ft from the wall in a fully loaded condition baggage driver passenger and switch on the low beam The light dark cut off should be 5 cm 2 in under the mar...
Page 60: ...B FOR BRAKE LIGHT Turn the bulb socket 1 approx 30 in a counterclockwise direction and pull it out of the taillight housing Slightly press in the bulb turn approx 30 in a counterclockwise direc tion a...
Page 61: ...ible 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 af...
Page 62: ...ve 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 tan...
Page 63: ...n the engine is cold If you need to remove the radiator cap when the engine is hot hold the cap with a cloth and open slowly allow ing any excess pressure to escape danger of scalding Accumulated soil...
Page 64: ...om entering the radiator Completely fill the radiator with cooling liquid Mount the radiator cap and move the motor cycle into a horizontal position again Now fill the compensating tank 6 with cooling...
Page 65: ...wise direction will move the clutch lever away from the driver Turning the adjusting screw in a counterclockwise direction will move the clutch lever towards the driver Adjustment of the clutch lever...
Page 66: ...ng damper Super Duke R The steering damper stabilizes the steering whenever the front wheel is relieved or off the ground The damping degree can be adjusted to harder or softer damping by turning the...
Page 67: ...n on the can KTM recommends Motorex Power Synt 4T in the 10W 50 viscosity for temperatures over 0 C 32 F or 5W 40 for temperatures under 0 C 32 F Checking the engine oil level Check the engine oil lev...
Page 68: ...Wait 20 seconds and check the oil level again The quantity of oil between the MIN and MAX marks is 0 3 liter Mount the plug and check the engine for leaks Finally mount the spoilers Insufficient amou...
Page 69: ...iod 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 out when the engine is still warm An engine having be...
Page 70: ...he screws 7 and tilt the oil return valve 8 to the side Carefully pull the oil screen 9 out of the oil tank Thoroughly clean the drain plugs the cover and both oil screens Clean all rubber seal rings...
Page 71: ...the engine case grease the O ring and mount the oil filter cover together with the O ring Tighten the screws to 6 Nm Only use original ktm oil filters The engine can be damaged if other filters are u...
Page 72: ...to run warm in neutral until 4 bars on the temperature indicator light up Switch off the engine and check the oil level see Checking the engine oil level Check the engine and the oil tank for oil leak...
Page 73: ...on the ignition switch the gear to neutral and switch the emergency OFF switch on do not accelerate while starting the engine Recharge the battery and investigate the causes for discharg ing contact a...
Page 74: ...kshop Engine will not reach full power Air filter fuel filter heavily soiled Error in the injection system Have the air filter fuel filter replaced at an authorized KTM workshop Visit an authorized KT...
Page 75: ...iving No fuel Fuse for fuel pump has blown Refuel Replace fuse 4 High oil consumption Engine oil level too high Engine oil too thin viscosity Check engine oil level when the engine is warm correct if...
Page 76: ...ts on the cable connector have oxidized Check the pickup cable for damage visit an authorized KTM workshop The blink code indicates which component is affected by an error This allows the error to be...
Page 77: ...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...
Page 78: ...motorcycle has cooled down oil or lubricate all of the friction bearings and bearing positions and treat the chain with chain spray Treat all bare areas except brake disks with a corrosion inhibitor...
Page 79: ...l since it will not allow and moisture to escape and will cause corrosion Do not briefly run the engine of an immobilized motorcycle since the engine will not become warm enough and any vapor produced...
Page 80: ...rear tires DUNLOP Sportmax D208 RR 180 55 ZR17 M C 73W Air pressure rear Road driver only 2 4 bar Road with passenger maximum payload 2 6 bar Fuel tank capacity 18 5 liters 4 9 USgal 3 5 0 9 USgal li...
Page 81: ...Comfort Basic Setting Driving Sport Maximum Payload Basic Setting Driving Sport Race course Maximum Payload Compression adjuster clicks 20 15 10 10 18 18 14 18 Rebound adjuster clicks 20 15 10 10 16 1...
Page 82: ...Nm AH bolt for handlebar mount Super Duke M10 20 Nm AH bolt for handlebar mount Super Duke R M10 45 Nm HH clamp bolts for steering stem M8 20 Nm Collar bolt front rear brake disk M8x1 25 Loctite 243...
Page 83: ...t M8 35 Nm AH bolts on tank cover M5 5 Nm HH bolts on tank mounting M6 6 Nm Collar screws for in tank pump M6 6 Nm AH screw on arm for tank support M10 15 Nm Collar screw for gas pressure shock absorb...
Page 84: ...TECHNICAL SPECIFICATIONS CHASSIS 83 TIGHTENING TORQUES CHASSIS 2008 Other bolts on chassis M6 M8 M10 10 Nm 25 Nm 45 Nm Other collar nuts on chassis M6 M8 M10 15 Nm 30 Nm 50 Nm...
Page 85: ...0 15 mm Exhaust 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 Pis...
Page 86: ...ough water pump Cooling liquid 2 1 liters 0 55 USgal 50 antifreeze 50 distilled water at least 25 C Starting aid electric starter 10W 50 5W 40 JASO T903 MA TEMPERATUR 0 C 32 F PON CLC RON ROZ MON 87 9...
Page 87: ...2 Checking the engine oil level 66 Checking the front brake fluid level 44 Checking the front brake pads 45 Checking the oil level of the hydraulic clutch 64 Checking the rear brake fluid level 46 Che...
Page 88: ...oil 67 Removing and remounting the battery 53 Replacing the brake light and taillight bulbs 59 Replacing the flasher bulbs 59 Replacing the headlight lamp 57 Running in the LC8 engine 22 Seat lock rem...
Page 89: ...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 90: ...INFORMATION FOR USA ONLY 89 under seat on fuel tank R S on fuel tank L S on steering head tube on fuel tank Sticker positions 3 4 5 on frame tube R S under seat on frame tube R S 7 on frame tube L S 6...
Page 91: ...A ONLY 3 Suspension setting Super Duke 5 Technical information 8 Before you go for the first ride 7 Vehicle emission 2 Type label CAN 6 Noise emission 1 EAVP 4 Chain tension 9 Type label USA 90 3 Susp...
Page 92: ...KTM Sportmotorcycle AG A 5230 Mattighofen www ktm at 11 2007 FOTO MITTERBAUER KTM Group Partner 3211249en 3211249en...
