KTM 990 SUPERMOTO 2008 Page 47 Owner'S Manual Download

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MAINTENANCE WORK ON CHASSIS AND ENGINE

Checking the front brake pads

The brake pads can be seen from the rear. The linings must be at least 1 mm (0.04 in) thick.

At their most worn point brake pad linings should not be thinner than 1 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, the

steel parts on the brake pads will grind against the brake disks. This significantly decreases

the braking effect and destroys the brake disks.

min.

1 mm

Summary of Contents for 990 SUPERMOTO 2008

Page 1: ...990 SUPERMOTO ART NR 3211247en OWNER S MANUAL 2008...

Page 2: ...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 maintenanc...

Page 3: ...atest 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 a...

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: ...pression damping of fork 21 Rebound damping of fork 21 Spring preload of the fork 21 Damping action during compression of shock absorber 22 Rebound damping of shock absorber 22 GENERAL TIPS AND WARNIN...

Page 6: ...light range 58 Replacing the flasher bulbs 58 Replacing the brake light and taillight bulbs 59 Cooling system 60 Checking the cooling liquid level in the compensating tank 62 Checking the cooling liqu...

Page 7: ...d tube Enter this num ber in the field on page no 1 The type label is located next to the chassis number Engine number engine type The engine number and the engine type are stamped into the left side...

Page 8: ...lutch lever see maintenance work on chassis and engine The clutch is hydraulically actuated and adjusts itself automatically Hand brake lever The hand brake lever 3 is mounted on the right side of the...

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: ...as blown 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 but...

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: ...g liquid temperature display The temperature display 1 is shown in 12 bars The more bars that light up the hotter the cooling liquid When the upper bar lights up 120 C 248 F all of the bars will start...

Page 14: ...uble shooting The red warning lamp will light up if the voltage in the on board electrics drops below 10 volts Immediately drive to the nearest authorized KTM workshop and have the electrical system c...

Page 15: ...rawn in position and NOTE Only the black ignition keys may be used primary key or reserve key The vehicle cannot be started with the orange master key it can only be used for programming the immobi li...

Page 16: ...ing the orange master key 2 The red indicator lamp 1 lights up Switch off the ignition Switch the ignition on and off again using the orange master key 2 All keys for this vehicle are now blocked Reor...

Page 17: ...beam light Low beam light 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...

Page 18: ...inter rupted Use the starter tip switch 2 to operate the electric starter Filler cap The filler cap 3 can be locked and is provided with a fuel evaporation control system To open the cap insert the i...

Page 19: ...he same time Both noses 5 should fit into the frame Insert the catch bolts 6 in the lock housing and push the seat down in the back until you hear the catch bolts snap into place Check whether the sea...

Page 20: ...nt 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 steel rope while driving You can easily lose con trol of the...

Page 21: ...securely on a firm surface The side stand is linked to the safety start system follow the driving instructions Foot brake pedal The foot brake pedal 2 is located in front of the right footrest Its bas...

Page 22: ...he 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 drivin...

Page 23: ...not to the motorcycle s driving speed The adjusting screw 1 for the low speed range can be adjusted with a screwdriver The adjusting screw 2 for the high speed range can be adjusted with a 17 mm sock...

Page 24: ...icle at different angles so that all sections are properly roughened Tires will not display their full grip characteristics until they are prop erly run in Motorcycles are sensitive to changes in the...

Page 25: ...linded A passenger may only ride on the motor cycle if passenger footrests are mounted Never leave your motorcycle without super vision if the engine is running Accessories and payload Accessory parts...

Page 26: ...eck for damaged tires Tires showing cuts or dents must be replaced The tread depth must comply with the legal regulations Also check the air pressure Insufficient tread and incorrect air pressure dete...

Page 27: ...consequently to engine damage 9 BAGGAGE PAYLOAD Never exceed the maximum total weight 400 kg 883 lbs and the motorcycle s wheel loads The maximum total weight is comprised of the motorcycle in a runni...

Page 28: ...on 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 down battery or without the battery This c...

Page 29: ...r objects to the helmet lock rope while driving You can easily lose control of the motorcycle Shifting Riding You are now in first gear refered to as the drive or uphill gear Depending on the con diti...

Page 30: ...ly get out of control Never 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 dr...

Page 31: ...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 32: ...mp This motorcycle is equipped 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...

Page 33: ...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 tool z z z P...

Page 34: ...r 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: ...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 tight...

Page 36: ...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 fo...

Page 37: ...mounting If no new self locking nuts are 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 th...

Page 38: ...he high speed range Make sure both fork legs are equally adjusted Adjusting compression damping of fork Hydraulic compression damping determines the reaction when the fork is compressed Turn the adjus...

Page 39: ...he preload is higher the rebound damping should also be set higher STANDARD ADJUSTMENT Turn adjusting screw counterclockwise as far as it will go Turn 5 turns in a clockwise direction 1 1 2 MAINTENANC...

Page 40: ...ing is effective at fast compression rates Turning in a clockwise direction will increase the damping turning counterclockwise will decrease the damping STANDARD ADJUSTMENT LOW SPEED Turn adjusting sc...

Page 41: ...rection The damping unit of the shock absorber is filled with high compression nitrogen Never try to take the shock absorber apart or to do any maintenance work yourself Severe injuries could be the r...

Page 42: ...ange of the chain adjusters 32mm allows you to use different second ary ratios in combination with the same chain length The chain adjusters 4 can be rotated by 180 7 mm Checking the chain tension Pla...

Page 43: ...ed sprockets Chain maintenance Maintenance of the X ring chain is reduced to a minimum Rinse off any heavy dirt with plenty of water Residual used grease must be removed prior to lubrication Motorex C...

Page 44: ...e contact to the brake disk For safety reasons always have maintenance work and repairs to the brake system performed by an authorized KTM workshop BRAKE PADS Your motorcycle is equipped with sintered...

Page 45: ...formance applications Brake fluid DOT 5 1 is a poly ethylene glycol based fluid amber colored and can be mixed with DOT 4 brake fluid Do not in any event use DOT 5 brake fluid It is based on silicone...

Page 46: ...luid level The brake fluid reservoir for the front brake is located on the right side of the handlebar and has a MIN and a MAX mark The brake fluid level may not fall below the MIN mark when the vehic...

Page 47: ...d linings should not be thinner than 1 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 l...

Page 48: ...worn away the steel components of the brake pad will rub against the brake disc imparing the braking effect and destroying the brake disc Checking rear brake fluid level The brake fluid reservoir for...

Page 49: ...correctly mounted The front wheel should not touch the ground MAINTENANCE WORK ON CHASSIS AND ENGINE 48 2 1 1 3 3 2 Remove the screws 1 from the left and right brake calipers and carefully pull the b...

Page 50: ...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 align the fork legs Before you tighten t...

Page 51: ...d the rear wheel while you pull out the wheel spindle 3 Push the rear wheel forward as far as possible and remove the chain from the rear sprocket Carefully take the rear wheel off the swing arm Do no...

Page 52: ...s the rear wheel towards the front to allow the chain tensioner to rest against the clamping screws If you don t happen to have a torque wrench at hand make sure you have the tighten ing torque correc...

Page 53: ...re to the motorcycle s total weight Proper pressure ensures optimum driving comfort and extends the life of your tires Do not mount tires which have not been approved by KTM Other tires could have adv...

Page 54: ...ront see illustration Connect the minus pole to the battery last If electrolyte sulphuric acid leaks from the battery proceed with great care The elec trolyte can cause severe burns In the case of ski...

Page 55: ...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 if it is being stored for a longer period of t...

Page 56: ...spare fuse is always at hand Replace a blown fuse only with an equivalent one If a new fuse that has just been set in gets blown again you are strongly advised to have it inspected by a KTM dealer The...

Page 57: ...ned for accessories with a maximum power con sumption of 10 amperes each Sockets to connect the accessories are located under the headlight mask For more infor mation contact an authorized KTM worksho...

Page 58: ...move the bulb Proceed in the reverse order to mount a new bulb Attach the headlight mask at the bottom mount the screw and tighten to 10 Nm MAINTENANCE WORK ON CHASSIS AND ENGINE 57 Replacing the head...

Page 59: ...e a mark on a light wall behind a level surface at a height corresponding to the center of the headlight Position your motorcycle loaded ready for the trip 5 meters 16 4 ft away from the wall and swit...

Page 60: ...o the taillight housing Mount the rear side parts and tighten the screws Mount the rear top part and tighten the screws Mount the handrails and tighten the screws to 25 Nm Mount the seat MAINTENANCE W...

Page 61: ...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 62: ...ents can cause corrosion and coolant foaming More antifreeze must be added if you plan to travel to a region where temperatures are expected to drop below 25 C 13 F MAINTENANCE WORK ON CHASSIS AND ENG...

Page 63: ...ly turn in a counterclockwise direction and remove The radiator should be completely filled with cooling liquid no air should be in the radiator If any cooling liquid is missing the cooling system is...

Page 64: ...cooling liquid Mount the radiator cap and move the motor cycle into a horizontal position again Fill the compensating tank with cooling liquid until it reaches a level between the MIN and MAX mark Clo...

Page 65: ...apply 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 and cover 2 together...

Page 66: ...65...

Page 67: ...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 level when the e...

Page 68: ...ne case to the oil tank The engine oil must also be drained from the oil tank during an oil change Since many parts must be demounted for an oil change we recommend having the engine oil changed by an...

Page 69: ...plugs the cover and both 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 oi...

Page 70: ...ully slide the oil screen in the oil tank Position the con nector 2 mount the screws and tighten to 10 Nm Unscrew the plug 3 Add 2 5 liters 0 7 USgal of fully synthetic engine oil according to the JAS...

Page 71: ...the ignition switch the gear to neutral and switch the emergency OFF switch on do not accelerate while start ing the engine Recharge the battery and investigate the causes for discharg ing contact an...

Page 72: ...filter fuel filter heavily soiled Error in the injection system Have the air filter fuel filter replaced at an authorized KTM workshop Contact an authorized KTM workshop Engine overheats Insufficient...

Page 73: ...s blink code and remove it or con tact an authorized KTM workshop Engine stalls while driving No fuel Fuse for fuel pump has blown Refuel Replace fuse IGNITION FUEL PUMP High oil consumption Engine oi...

Page 74: ...tor should be checked by an authorized KTM workshop No values are visible in the com bined instrument display Blown fuse Replace fuse HORN BRAKELIGHT SPEEDO The speed indication on the com bined instr...

Page 75: ...rol unit voltage supply Malfunction 25 Side stand switch Short circuit to ground 33 Injection nozzle for rear cylinder Malfunction 34 Injection nozzle for front cylinder Malfunction 37 Ignition coil f...

Page 76: ...blinks 1x short 1 second pause 5x short Other blink codes following a 3 second pause BLINKCODE ERROR DESCRIPTION 12 Key not programmed 13 Antenna not connected 14 No response from key 15 Communication...

Page 77: ...e and a cloth Then take a short drive until the engine has reached the working temperature and also use the brakes Due to the heat the water also evaporates at the unapproach able parts of the engine...

Page 78: ...ssive 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 g...

Page 79: ...s as a possible humidity 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...

Page 80: ...R17 M C 58W Air pressure front road driver only 2 2 bar 31 psi road with passenger maximum payload 2 4 bar 34 psi Authorized rear tires PIRELLI Scorpion Sync 180 55 ZR17 M C 73W Air pressure rear road...

Page 81: ...tal weight 400 kg 883 lbs FORK 990 SUPERMOTO 2008 Type 14187D20 WP Suspension Spring 6 2 450 Spring preload 5 mm 0 2 in Air chamber lenght 110 mm 4 3 in Fork oil SAE 5 WP 4860 0401 SHOCK ABSORBER 990...

Page 82: ...bolts on fork leg axle passages M8 15 Nm Collar bolts for handlebar clamps M8 20 Nm AH bolt for handlebar mount M10 20 Nm HH clamp bolts for steering stem M8 20 Nm Collar bolt front rear brake disk M...

Page 83: ...l Exhaust clamp M8 8 Nm Exhaust clamp for ball joint M8 35 Nm HH bolts on exhaust suspension M6 Loctite 243 12 Nm HH bolt on fuel level indicator M5 3 Nm HH bolts fuel taps M6 6 Nm Jerk damper bolt re...

Page 84: ...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 compression ring 1 taper face ring...

Page 85: ...e 0 8 mm Cooling system liquid cooled permanent circulation of cooling liquid through water pump Cooling liquid 2 1 liters 0 55 USgal 50 antifreeze 50 distilled water at least 25 C Starting aid electr...

Page 86: ...oil level 66 Checking the front brake fluid level 45 Checking the front brake pads 46 Checking the oil level of the hydraulic clutch 64 Checking the rear brake pads 47 Cleaning 76 Clutch lever 7 Combi...

Page 87: ...mping of shock absorber 22 Refilling engine oil 67 Reordering and programming keys 15 Replacing the brake light and taillight bulbs 59 Replacing the flasher bulbs 58 Replacing the headlight lamp 57 Ru...

Page 88: ...USE THIS SPACE FOR NOTES 87...

Page 89: ...USE THIS SPACE FOR NOTES 88...

Page 90: ...KTM Sportmotorcycle AG A 5230 Mattighofen www ktm com 12 2007 FOTO MITTERBAUER KTM Group Partner 3211247en 3211247en...

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