KTM 990 Supermoto R USA 2010 Owner'S Manual Download

Page: 167 / 220

MAINTENANCE WORK ON FRAME AND ENGINE

165

700610-10

–

Remove screws



and cover



700612-10

–

Pull oil screen



out of the engine case with pliers.

700613-10

–

Place a suitable container under the engine.

–

Remove oil drain plug



–

Fully drain the engine oil out of the oil tank.

–

Remove screws



and move oil line



to one side.

Summary of Contents for 990 Supermoto R USA 2010

Page 1: ...OWNER S MANUAL 2010 990 Supermoto R USA 990 Supermoto T USA Art no 3211562en...

Page 2: ......

Page 3: ...wever it is never possible to exclude small deviations arising from further development in design and construction All specifications are non binding KTM Sportmotorcycle AG specifically reserves the r...

Page 4: ...s is permitted only with the express written permission of the copyright owner ISO 9001 12 100 6061 According to the international quality management standard ISO 9001 KTM uses quality assurance proce...

Page 5: ...tion buttons 41 Combination instrument tachometer 42 Combination instrument indicator lamps 42 Combination instrument display 43 Combination instrument speedometer 44 Setting kilometers or miles 44 Co...

Page 6: ...absorber x 86 Checking the chain for dirt 88 Cleaning the chain 88 Checking the chain tension 90 Adjusting the chain tension 91 Checking the chain rear sprocket and engine sprocket 93 Checking the fro...

Page 7: ...le 161 Adjusting the play in the throttle cable x 162 Checking the engine oil level 162 Changing the engine oil and filter cleaning the oil screens x 163 Draining the engine oil and filter cleaning th...

Page 8: ...TABLE OF CONTENTS 6 STANDARDS 212 INDEX 213...

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: ...dy or wet 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 specifie...

Page 11: ...ve 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 If a thread lock e g Loct...

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: ...IMPORTANT INFORMATION 11...

Page 14: ...IMPORTANT INFORMATION 12 Overview of labels Supermoto T 601100 10...

Page 15: ...nformation on operating substances and tires 4 Information on noise emission 5 Information on the fuel evaporation system 6 Information on chain tension 6 Information on suspension setting 7 Type labe...

Page 16: ...IMPORTANT INFORMATION 14 600962 01 Type label Canada 600969 01 Information on operating substances and tires...

Page 17: ...IMPORTANT INFORMATION 15 601103 01 Information on noise emission 600968 01 Information on the fuel evaporation system...

Page 18: ...IMPORTANT INFORMATION 16 600966 01 Information on chain tension 601104 01 Information on suspension setting...

Page 19: ...IMPORTANT INFORMATION 17 600963 01 Type label USA 600961 01 Information on preparing for use...

Page 20: ...IMPORTANT INFORMATION 18 Overview of labels Supermoto R 601101 10...

Page 21: ...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 22: ...IMPORTANT INFORMATION 20 600962 01 Type label Canada 600969 01 Information on operating substances and tires...

Page 23: ...IMPORTANT INFORMATION 21 600965 01 Information on noise emission 600961 01 Information on preparing for use...

Page 24: ...IMPORTANT INFORMATION 22 600968 01 Information on the fuel evaporation system 600966 01 Information on chain tension 600967 01 Information on suspension setting...

Page 25: ...nings 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 missing you or others may no...

Page 26: ...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 27: ...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 28: ...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 29: ...27...

Page 30: ...VIEW OF VEHICLE 28 View of vehicle front left side vehicle differs slightly from photo B00143 10...

Page 31: ...CLE 29 1 Combination instrument 2 Filler cap 3 Rear mirror 4 Clutch lever 5 Seat 6 Handrails 7 Shock absorber compression damping 8 Shock absorber spring preload 9 Engine number 10 Shift lever 11 Oil...

Page 32: ...VIEW OF VEHICLE 30 View of vehicle rear right side vehicle differs slightly from photo B00142 10...

Page 33: ...indicator switch horn button 3 Emergency OFF switch electric starter button 4 Hand brake lever 5 Fork spring preload fork rebound damping 6 Chassis number 7 Fork compression damping 8 Type label 9 Foo...

Page 34: ...SERIAL NUMBERS 32 Chassis number type label 601117 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...

Page 35: ...Code 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...

Page 36: ...L NUMBERS 34 Engine number B00120 10 The engine number is stamped on the left side of the engine under the engine sprocket Fork part number 700546 01 The fork part number is stamped on the inner side...

Page 37: ...LOCATION OF SERIAL NUMBERS 35 Shock absorber part number 700547 01 The shock absorber part number is stamped on the top of the shock absorber above the adjusting ring on the engine side...

Page 38: ...er is fitted on the left side of the handlebar The clutch is hydraulically operated and self adjusting Hand brake lever 700549 01 The hand brake lever is fitted on the right side of the handlebar The...

Page 39: ...light are switched on High beam on The light switch is turned upwards In this position the high beam and tail light are switched on Headlight flasher switch 700551 01 The headlight flasher switch is f...

Page 40: ...to the central position after use Right turn signal on The turn signal switch is pressed to the right The turn signal switch automatically returns to the central position after use To switch off the...

Page 41: ...n circuit is closed and the engine can be started Steering locked In this position the ignition circuit is interrupted and the steering locked The ignition key can be removed Immobilizer 400887 01 The...

Page 42: ...0 The emergency OFF switch is fitted on the right side of the handlebar Possible states Emergency OFF switch on This position is necessary for operation as it closes the ignition circuit Emergency OFF...

Page 43: ...chometer Indicator lights Display Combination instrument function buttons 400921 10 You can change the display mode with the MODE button Possible display modes are the distance traveled ODO trip maste...

Page 44: ...f the motorcy cle Possible states The turn signal indicator lamp flashes green simultaneously with the turn signal The turn signal is switched on The idle speed indicator lamp lights up green The tran...

Page 45: ...or safety critical fault The immobilizer indicator lamp lights up or flashes red Status or error message for immobilizer alarm system The battery warning lamp lights up red The voltage in the vehicle...

Page 46: ...the 17 front wheel with a series pro duction tire The display then changes to the last selected mode Combination instrument speedometer 400838 10 The speed is shown in kilometers per hour km h or in m...

Page 47: ...sition Press the MODE button repeatedly until the ODO mode is active Keep the MODE button pressed until the display mode changes from km h to mph or from mph to km h Combination instrument time 400893...

Page 48: ...SET button pressed simultaneously The time display begins to flash Press the MODE button to set the hour Press the SET button to set the minute Keep the MODE button and the SET button pressed simulta...

Page 49: ...in 400840 01 Switch on the ignition by turning the ignition key to the ON position Press the MODE button repeatedly until the TRIP 1 mode is active Keep the SET button pressed The TRIP 1 display is se...

Page 50: ...is active Keep the SET button pressed The TRIP 2 display is set to 0 0 Combination instrument TRIP F display 400842 01 If the fuel level drops to the reserve mark the display automatically changes to...

Page 51: ...or F Setting the temperature units Condition The motorcycle is stationary 400893 14 Switch on the ignition by turning the ignition key to the ON position Press the MODE button repeatedly until the am...

Page 52: ...isplay when the ambient temperature rises above the specified value again Temperature 4 C 39 F Combination instrument coolant temperature indicator 700124 01 The temperature display consists of 12 bar...

Page 53: ...essure off of the ignition key push down on the filler cap Damaged igni tion keys must be replaced Turn the ignition key 90 counterclockwise and remove the filler cap Info The filler cap has a tank ai...

Page 54: ...ils are used for moving the motorcycle around If you carry a passenger the passenger can hold onto the handrails during the trip Seat lock 600922 10 Seat lock is located at the rear under the tail lig...

Page 55: ...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 or other objects during the jour ney Always remo...

Page 56: ...footrests can be folded up and down Possible states Passenger footrests folded up For operation without a passenger Passenger footrests folded down For operation with a passenger Shift lever B00120 1...

Page 57: ...s can be seen in the photograph The neutral or idle position is between the first and second gear Foot brake lever B00122 10 Foot brake lever is located in front of the right footrest The rear brake i...

Page 58: ...safety start system see the riding instructions Possible states Side stand folded out The vehicle can be leaned on the side stand The safety start system is active Side stand folded in This position...

Page 59: ...ferent 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 accide...

Page 60: ...de 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 58 Running in the engi...

Page 61: ...age cases 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...

Page 62: ...center 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 w...

Page 63: ...e chain p 88 Check the tire condition p 112 Check the tire air pressure p 114 Check the front brake fluid level p 98 Check the rear brake fluid level p 102 Check the front brake linings p 100 Check th...

Page 64: ...an enclosed space without an effective exhaust extraction system Caution Danger of accidents If the vehicle is operated with a discharged battery or without a battery electronic components and safety...

Page 65: ...starting DO NOT open the throttle If you open the throttle during the start ing procedure fuel is not injected by the engine management system and the engine cannot start Press the starter for a maxim...

Page 66: ...tion key position Do not change the ignition key position during a journey Warning Danger of accidents Distraction from traffic activity by adjustments to the vehicle Make all adjustments when the veh...

Page 67: ...es 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 and wi...

Page 68: ...h and 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...

Page 69: ...ger of accidents If you brake too hard the wheels can lock Adapt your braking to the traffic situation and the road conditions Warning Danger of accidents Reduced braking efficiency due to wet or dirt...

Page 70: ...bend Shift down to a lower gear that is appropriate to your speed On long downhill stretches use the braking effect of the engine Do this by changing down two gears but do not race the engine You wil...

Page 71: ...brakes Shift the transmission to neutral Switch off the ignition by turning the ignition key to the OFF position Info If you switch off the engine with the emergency OFF switch but the ignition remai...

Page 72: ...ard Avoid contact of the fuel with skin eyes and clothing Do not inhale fuel vapors If fuel gets into your eyes rinse immediately with water and contact a doctor Wash affected skin areas immediately w...

Page 73: ...filler cap p 51 Low octane fuel Note Engine damage Low quality fuel damages the engine Operate the vehicle with fuel with an octane rating below 95 ROZ 95 RON 95 PON 91 for no more than one tank full...

Page 74: ...sc p 96 Check that brake lines are undamaged and free of leaks Check the rear brake fluid level p 102 Check the free travel of the foot brake lever p 97 Check the shock absorber and fork for leaks Per...

Page 75: ...heck the cables for damage and kink free routing x Check the control cables for damage kink free routing and adjustment Change the air filter Clean the air filter box x Check rectify the fluid level o...

Page 76: ...SERVICE SCHEDULE 74 K10N Once after 1 000 km 621 4 mi K75A Every 7 500 km 4 660 mi or annually K150A Every 15 000 km 9 321 mi or every 2 years K300A Every 30 000 km 18 641 mi or every 4 years...

Page 77: ...lebar to the straight ahead position Align the work stand at the front with the adapters to the fork legs Front work stand 61029055300 Info Always jack up the rear of the motorcycle first Jack up the...

Page 78: ...work stand Work stand adapter 61029055120 Work stand rear 61029055100 Stand the motorcycle upright align the work stand to the link fork and the adapters and jack up the motorcycle Taking the rear fro...

Page 79: ...e to turn 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...

Page 80: ...rk legs Turn back counterclockwise by the number of clicks corresponding to the fork type Guideline Supermoto R Compression damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10...

Page 81: ...ero position B00124 10 Turn adjusting screws clockwise until they stop Info The adjusting screws are located at the top end of the fork legs Make the same adjustment on both fork legs Turn back counte...

Page 82: ...t for the weight of the rider and that of any baggage and a passenger and thus ensures a compromise between maneuverability and stability B00124 11 Turn adjusting screws clockwise until they stop Info...

Page 83: ...he spring preload has no influence on the rebound damping although the adjusting screws turn during the adjustment work However you should also adjust the rebound damping when you alter the spring pre...

Page 84: ...d not the riding speed of the motorcycle Changes in the low speed range settings have an impact on the high speed range and vice versa Adjusting the low speed compression damping of the shock absorber...

Page 85: ...number of clicks corresponding to the shock absorber type Guideline Supermoto R Compression damping low speed Comfort 25 clicks Standard 20 clicks Sport 15 clicks Full payload 15 clicks Supermoto T Co...

Page 86: ...ption provided Your authorized KTM workshop will be glad to help Info The high speed setting can be seen during the fast compression of the shock absorber 700567 10 Turn adjusting screw clockwise all...

Page 87: ...g Adjusting the rebound damping of the shock absorber Danger Danger of accidents Disassembly of pressurized parts can lead to injury The shock absorber is filled with high density nitrogen Adhere to t...

Page 88: ...andard 15 clicks Sport 10 clicks Full payload 10 clicks Info Turn clockwise to increase suspension damping turn counterclockwise to reduce damping Adjusting the spring preload of the shock absorber x...

Page 89: ...resent setting e g by measuring the length of the spring Take the weight off the rear wheel and swingarm Info The spring preload can be adjusted correctly only if the rear wheel and the swingarm are f...

Page 90: ...n Full payload 13 mm 0 51 in Tighten locking ring Checking the chain for dirt 400678 01 Check the chain for coarse dirt accumulation If the chain is very dirty Clean the chain p 88 Cleaning the chain...

Page 91: ...mental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info The service life of th...

Page 92: ...n the other hand if the chain is loose it can fall off the engine sprocket or the rear sprocket and block the rear wheel or damage the engine Check the chain tension and correct if necessary 700570 01...

Page 93: ...sprocket rear sprocket bearings in transmission and rear wheel are under additional load Apart from premature wear in extreme cases the chain can rupture or the countershaft of the transmission can b...

Page 94: ...ference 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...

Page 95: ...ocket and engine sprocket 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 rear sp...

Page 96: ...imum distance at the longest chain section 272 mm 10 71 in If distance is greater than the specified measurement Replace the chain x Info When the chain is replaced the rear sprocket and engine sprock...

Page 97: ...p will be glad to help 100135 10 Check the thickness of the brake disc in several places to see if it conforms to measure ment Info Wear reduces the thickness of the brake discs in area of the brake d...

Page 98: ...0 10 Check the thickness of the brake disc in several places to see if it conforms to measure ment Info Wear reduces the thickness of the brake disc in area of the brake disc Brake disc wear limit Rea...

Page 99: ...ning 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 can fail due to over heating Adjust free tr...

Page 100: ...ystem and do not continue riding Your authorized KTM workshop will be glad to help Warning Danger of accidents Reduced braking effect caused by old brake fluid Change the brake fluid of the front and...

Page 101: ...yes rinse thoroughly with water and contact a doctor immediately Warning Danger of accidents Reduced braking effect caused by old brake fluid Change the brake fluid of the front and rear brakes accord...

Page 102: ...entered in the homologation documents Info Brake linings available in accessories shops are often untested and unapproved for use on KTM vehicles The structure and friction coefficient of the brake li...

Page 103: ...ave 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 cra...

Page 104: ...ld brake fluid Change the brake fluid of the front and rear brakes according to the service schedule Your authorized KTM workshop will be glad to help B00131 10 Stand the vehicle upright Check the bra...

Page 105: ...brake fluid of the front and rear brakes according to the service schedule Your authorized KTM workshop will be glad to help Warning Environmental hazard Hazardous substances cause environmental dama...

Page 106: ...5 1 p 206 Position the cover with the membrane Mount and tighten the screws Info Clean up overflowed or spilt brake fluid immediately with water Checking the rear brake linings Warning Danger of accid...

Page 107: ...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 is encountered Change the rear brake linings...

Page 108: ...ng efficiency caused by damaged brake discs Always lay the wheel down in such a way that the brake discs are not dam aged Holding the front wheel withdraw the wheel spindle Take the front wheel out of...

Page 109: ...rk position it and insert the wheel spindle Mount and tighten screw Guideline Bolt front axle M25x1 5 45 Nm 33 2 lbf ft 700639 11 Position the brake calipers and check that the brake linings are seate...

Page 110: ...from the work stand p 76 700640 11 Pull the front brake and compress the fork powerfully a few times The fork legs straighten Fully tighten screws Guideline Screw fork stub M8 15 Nm 11 1 lbf ft Remov...

Page 111: ...iscs are not dam aged Take the rear wheel carefully out of the swingarm without damaging the rim and or brake disc Info Do not operate the foot brake when the rear wheel is removed Installing the rear...

Page 112: ...or worn Replace the wheel bearing x Remove bushing and bushing Clean and grease the roll surfaces of the bushing and the shaft seal rings Long life grease p 211 Fit the bushings Clean and grease the t...

Page 113: ...ings on the left and right chain adjusters must be in the same position relative to the reference marks Nut rear wheel spindle M25x1 5 90 Nm 66 4 lbf ft Thread greased Operate the foot brake lever rep...

Page 114: ...cking the tire condition Warning Danger of accidents Uncontrollable handling characteristic caused by a flat tire For your own safety have damaged tires changed immediately Warning Danger of crashing...

Page 115: ...fo The type condition and air pressure of the tires all have a major impact on the handling of the motorcycle Worn tires have a negative effect on vehicle handling especially on wet surfaces 400602 10...

Page 116: ...l state of wear If a tire is more than five years old Change the tires Checking the tire air pressure Info Low tire air pressure leads to abnormal wear and overheating of the tire Correct tire air pre...

Page 117: ...Raise the rear of the seat push it towards the rear and remove it upwards Remove the ignition key from the seat lock Mounting the seat B00136 01 Position front recesses of the seat on the oval head s...

Page 118: ...Guide the steel cable through the helmet opening Then position the free loop of the steel cable on the lug Position the helmet carefully on the side of the vehicle Mount the seat p 115 Removing the ba...

Page 119: ...uipment may be damaged Never operate the vehicle with a discharged battery or without a battery Switch off all power consumers and the engine Remove the seat p 115 700582 01 Disconnect negative minus...

Page 120: ...ry in the battery rack Info The terminals of the battery must face in the direction of travel Attach rubber band Reconnect the positive plus cable of the battery Position positive terminal cover 70058...

Page 121: ...e with large amounts of water If battery acid gets in the eyes rinse with water for at least 15 minutes and contact a doctor Warning Environmental hazard Battery parts and acid are harmful to the envi...

Page 122: ...electrolyte escapes through the safety valves This reduces the battery capacity If the battery is depleted from starting the vehicle repeatedly the battery must be charged immediately If the battery...

Page 123: ...o Never remove lid Charge the battery with a maximum of 10 of the capacity specified on the bat tery housing Switch off the charger after charging Disconnect the battery Guideline The charge current c...

Page 124: ...ne Remove the seat p 115 700589 01 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 rel...

Page 125: ...prescribed amperage Never by pass or repair fuses Info The fuse box containing the fuses of individual power consumers is located under the seat Switch off all power consumers and the engine Remove th...

Page 126: ...10A radiator fan Fuse POWER RELAY 10A ignition EFI control unit Fuse ACC1 CLOCK 10A combination instrument socket supplementary devices permanent positive alarm system optional Fuse ACC2 10A suppleme...

Page 127: ...e lamp will evaporate due to the heat and be deposited on the reflector Clean the lamp and keep it free of grease before mounting Switch off all power consumers and the engine B00137 10 Supermoto R Re...

Page 128: ...removed for this model Removal is not necessary 700592 10 Disconnect plug in connector Remove rubber cap 700593 01 Push off retaining clamp on both sides squeeze and fold down Remove headlight bulb P...

Page 129: ...MAINTENANCE WORK ON FRAME AND ENGINE 127 Position the retaining clamp 700592 11 Mount rubber cap Position plug in connection 700591 11 Supermoto R Position holes onto holding lugs...

Page 130: ...f ft 700604 01 Supermoto T Mount the cover Check that the lighting is functioning properly Changing the parking light bulb Note Damage to reflector Reduced luminance Grease on the lamp will evaporate...

Page 131: ...10 Cover the fender with a cloth Swing the headlight mask forward and pull it upward out of holding lugs 700604 01 Supermoto T Remove the cover Info For purposes of illustration only the following ste...

Page 132: ...ng light carefully out of the holder Remove the bulb Position a new light bulb in the holder Parking light W5W socket W2 1x9 5d p 196 Carefully position the holder with the bulb into the holder in the...

Page 133: ...s screws M6 10 Nm 7 4 lbf ft 700604 01 Supermoto T Mount the cover Check that the lighting is functioning properly Changing the turn signal bulb Note Damage to reflector Reduced luminance Grease on th...

Page 134: ...il it stops Turn signal RY10W socket BAU15s p 197 Check the turn signal to make sure it is functioning properly Position the diffuser Insert the screw and first turn it counterclockwise until it engag...

Page 135: ...MAINTENANCE WORK ON FRAME AND ENGINE 133 B00138 10 Remove screws Remove screws on the left and right rear side part Remove the rear side part 700599 10 Remove screws Remove the top part...

Page 136: ...turn it counterclockwise and pull it out of the socket Press the new bulb carefully into the socket and turn it clockwise until it stops Brake light PR21W socket BAW15s p 197 Insert the bulb socket i...

Page 137: ...ghten screws on the left and right rear side part Guideline Screw rear side part EJOT Initial screw con nection 3 3 Nm 2 43 lbf ft Subsequent screw connection 2 Nm 1 5 lbf ft 700597 11 Position the gr...

Page 138: ...e 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 the lamp and keep it free of grease before mount...

Page 139: ...MAINTENANCE WORK ON FRAME AND ENGINE 137 B00138 10 Remove screws Remove screws on the left and right rear side part Remove the rear side part 700599 10 Remove screws Remove the top part...

Page 140: ...et Remove the bulb Position a new light bulb in the holder Tail light WR5W socket W2 1x9 5d p 197 Carefully position the holders with the bulbs into the holder in the tail light 700599 11 Position the...

Page 141: ...ighten screws on the left and right rear side part Guideline Screw rear side part EJOT Initial screw con nection 3 3 Nm 2 43 lbf ft Subsequent screw connection 2 Nm 1 5 lbf ft 700597 11 Position the g...

Page 142: ...700602 01 Remove screws Remove the license plate lamp cover 700603 01 Pull holder carefully out of the bracket Remove the bulb Position a new light bulb in the holder License plate lamp W5W socket W2...

Page 143: ...nter of the headlight Make another mark at a distance of under the first mark Guideline Distance 5 cm 2 in Park the vehicle at a distance of vertically in front of the wall and switch on the low beam...

Page 144: ...dark boundary must be exactly on the lower mark applied in Checking headlight adjustment Info Turn clockwise to increase the light range turn counterclockwise to reduce the light range B00139 10 Supe...

Page 145: ...second black ignition key available The following procedure deactivates all activated black ignition keys that are not included in the procedure Press the emergency OFF switch into the position Inser...

Page 146: ...ortant to prevent misuse of the lost black ignition key Press the emergency OFF switch into the position Insert the orange programming key in the ignition lock Switch on the ignition by turning the or...

Page 147: ...tion key in the ignition lock Switch on the ignition by turning the ignition key to the ON position FI Warning lamp MIL lights up switches off and then starts to flash Immobilizer indicator lamp light...

Page 148: ...system resulting from heat is regulated by a valve in the radia tor cap This permits the specified coolant temperature without causing any malfunctions 125 C 257 F 700621 10 Cooling takes place by mea...

Page 149: ...tely with water and contact a doctor Wash affected skin areas immediately with soap and water If coolant is swallowed contact a doctor immediately Change clothes that have come into contact with coola...

Page 150: ...the cooling system x p 151 Mount cap of the compensating tank 700625 10 Check the coolant level in the radiator The radiator must be completely filled If the coolant level does not meet specification...

Page 151: ...into your eyes rinse immediately with water and contact a doctor Wash affected skin areas immediately with soap and water If coolant is swallowed contact a doctor immediately Change clothes that have...

Page 152: ...oses or other cooling system components when the engine is hot Allow the engine and cooling system to cool down In case of scalding rinse immediately with lukewarm water Warning Danger of poisoning Co...

Page 153: ...ant Mount screw with a new seal ring and tighten it Guideline Screw water pump cover M6 10 Nm 7 4 lbf ft Filling bleeding the cooling system x Warning Danger of poisoning Coolant is poisonous and a he...

Page 154: ...move bleeder screw 0 A A 400677 10 Position the vehicle as shown and secure it against rolling Height difference must be reached Guideline Height difference 50 cm 19 7 in Info To make sure that all of...

Page 155: ...149 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 sufficient ventilation and do...

Page 156: ...154 Reinstalling the fuel tank Remove the seat p 115 Supermoto T Remove the mask spoiler p 157 B00141 10 Remove screws and the spoiler on both sides B00147 10 Remove screw on both sides Info The fuel...

Page 157: ...ully push the fuel tank back Positioning the fuel tank Carefully push the fuel tank forward Supermoto T The fuel tank fixations must engage in the recesses 700652 10 Supermoto R Mount and tighten scre...

Page 158: ...on both sides Check the fuel tank for tightness Guideline Remaining chassis screws M8 25 Nm 18 4 lbf ft Check the routing of the fuel lines B00141 11 Position the spoilers on both sides Mount and tig...

Page 159: ...MAINTENANCE WORK ON FRAME AND ENGINE 157 Removing the mask spoiler Supermoto T 700632 01 Remove screws 700634 01 Remove screws Remove the mask spoiler...

Page 160: ...E 158 700633 01 Remove screws Remove the inside trim of the mask spoiler Repeat the operation on the opposite side Installing the mask spoiler Supermoto T 700633 10 Position the inside trim of the mas...

Page 161: ...basic position of the clutch lever Info Turn the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar Turn the adjusting screw counterclockwise to decrease the...

Page 162: ...ur hand size by turning adjusting screw When adjusting the clutch lever make sure that there is a minimum clearance to other parts of the vehicle Guideline Minimum clearance 5 mm 0 2 in Checking recti...

Page 163: ...Move the throttle grip backwards and forwards to ascertain the play in the throttle cable Play in throttle cable 3 5 mm 0 12 0 2 in If the throttle cable play does not meet specifications Adjust the p...

Page 164: ...ttle cable by turning adjusting screw Guideline Play in throttle cable 3 5 mm 0 12 0 2 in Tighten counter nut Checking the engine oil level Danger Danger of poisoning Exhaust gases are poisonous and i...

Page 165: ...e wait one minute before checking the level Check the engine oil level at oil level viewer The engine oil level must be between the upper and lower marking If the engine oil level is not at the specif...

Page 166: ...In case of burns rinse immediately with lukewarm water Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed...

Page 167: ...Remove screws and cover 700612 10 Pull oil screen out of the engine case with pliers 700613 10 Place a suitable container under the engine Remove oil drain plug Fully drain the engine oil out of the o...

Page 168: ...l filter out of the oil filter housing Circlip pliers reverse 51012011000 Completely drain the engine oil Clean all oil screens and oil drain plugs with a magnet Clean all sealing surfaces 700618 10 I...

Page 169: ...heck seal ring of the oil sieve for damage and correct seating Insert oil sieve into the oil tank 700613 10 Position oil line Mount and tighten screws Guideline Remaining engine screws M6 10 Nm 7 4 lb...

Page 170: ...25 8 lbf ft 700616 10 Slide oil sieve into the engine case with the TOP marking facing up Check the form ring in cover for damage and correct seating Position the cover Mount and tighten the screws Gu...

Page 171: ...haling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in an enclosed space without an effec...

Page 172: ...corrected when the engine is warm 700619 10 Remove plug and add engine oil to the top marking Condition External temperature 0 C 32 F Engine oil SAE 10W 50 p 207 Condition External temperature 0 C 32...

Page 173: ...rating of 95 or higher can be used Adjusting the ignition curve to the fuel quality Switch off the ignition by turning the ignition key to the OFF position Remove the seat p 115 To activate the ignit...

Page 174: ...MAINTENANCE WORK ON FRAME AND ENGINE 172 Mount the seat p 115...

Page 175: ...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 176: ...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 177: ...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 178: ...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 179: ...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 180: ...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 FI Warning lamp MIL flashes 4x long 5x short Error l...

Page 181: ...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 182: ...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 183: ...rol unit x Malfunction 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 Ch...

Page 184: ...n in cooling system Drain the coolant x p 150 Fill bleed the cooling system x p 151 Buckled or damaged radiator hose Change the radiator hose x Fuse FAN blown Change the fuses of individual power cons...

Page 185: ...functional Fuse HORN BRAKE LIGHT SPEEDO blown Change the fuses of individual power consumers p 123 Battery discharged Ignition not switched off when vehicle was parked Recharge the battery x p 119 Bat...

Page 186: ...tions Info If you clean the motorcycle regularly its value and appearance will be maintained over a long period Avoid direct sunshine on the motorcycle during cleaning Close off the exhaust system to...

Page 187: ...r at inaccessible positions in the engine and on the brakes to evaporate After the motorcycle has cooled off lubricate all moving parts and bearings Clean the chain p 88 Treat bare metal parts except...

Page 188: ...with cold water Warm water would enhance the corrosive effects of salt Clean the motorcycle p 184 Treat the engine the swingarm and all other bare or galvanized parts except brake discs with a wax ba...

Page 189: ...up with fresh fuel when you put the motorcycle back into opera tion Clean the motorcycle p 184 Change the engine oil and filter clean the oil screens x p 163 Check the antifreeze and coolant level p...

Page 190: ...arm up properly the water vapor produced during combustion condenses and causes valves and exhaust system to rust Putting into operation after storage Take the front from the work stand p 75 Take the...

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: ...GK KR8DI Spark plug electrode gap 0 8 mm 0 031 in Cooling Water cooling permanent circulation of coolant by water pump Idle speed 1 400 1 500 rpm Cold start device Electric starter Capacity engine oil...

Page 193: ...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 clutch c...

Page 194: ...g chain guide rail M8 15 Nm 11 1 lbf ft Loctite 243 Bearing bolt timing chain tensioning rail M8 20 Nm 14 8 lbf ft Loctite 243 Screw camshaft bearing support M8 Step 1 10 Nm 7 4 lbf ft Step 2 18 Nm 13...

Page 195: ...2nd cylinder M12x1 5 25 Nm 18 4 lbf ft Spark plug M12x1 5 12 Nm 8 9 lbf ft Plug oil filter housing M14x1 5 15 Nm 11 1 lbf ft Loctite 243 Bleeder flange alternator cover M16x1 5 10 Nm 7 4 lbf ft Loctit...

Page 196: ...TECHNICAL DATA ENGINE TIGHTENING TORQUES 194 Nut primary gear M33LHx1 5 130 Nm 95 9 lbf ft Loctite 243...

Page 197: ...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 198: ...to R 189 kg 417 lb Weight without fuel approx Supermoto T 196 kg 432 lb Maximum permissible front axle load 160 kg 353 lb Maximum permissible rear axle load 250 kg 551 lb Maximum permissible total wei...

Page 199: ...elli DRAGON SUPERCORSA PRO Supermoto T 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 sect...

Page 200: ...damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Spring preload Preload Adjuster Comfort 5 turns Standard 5 turns Sport 3 turns Full payload 3 turns Spring length wi...

Page 201: ...ing 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 with p...

Page 202: ...cks Standard 20 clicks Sport 15 clicks 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 Stand...

Page 203: ...absorber oil SAE 2 5 50180342S1 p 208 Supermoto T Shock absorber part number 15 18 7E 43 Shock absorber WP Suspension 4618 BAVP DCC Compression damping low speed Comfort 25 clicks Standard 20 clicks...

Page 204: ...Standard 11 mm 0 43 in Sport 11 mm 0 43 in Full payload 13 mm 0 51 in Spring rate Medium standard 140 N mm 799 lb in Spring length 200 mm 7 87 in Gas pressure 10 bar 145 psi Static sag 20 mm 0 79 in F...

Page 205: ...ft Screw windshield Supermoto T M5 3 3 Nm 2 43 lbf ft Nut tail light M6 8 Nm 5 9 lbf ft Remaining chassis nuts M6 15 Nm 11 1 lbf ft Remaining chassis screws M6 10 Nm 7 4 lbf ft Remaining screws on fue...

Page 206: ...ignition lock ratchet screw M8 Loctite 243 Screw mask holder Supermoto T M8 15 Nm 11 1 lbf ft Loctite 243 Screw rear brake disc M8 30 Nm 22 1 lbf ft Loctite 243 Screw rear footrest bracket M8 25 Nm 1...

Page 207: ...ine M14x1 5 45 Nm 33 2 lbf ft Loctite 577 Screw bottom shock absorber M14x1 5 80 Nm 59 lbf ft Thread greased Screw top shock absorber M14x1 5 80 Nm 59 lbf ft Thread greased Nut swingarm pivot M19x1 5...

Page 208: ...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 209: ...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 212 SAE p 212 SAE 5W 40 Guideline Use o...

Page 210: ...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 211: ...SUBSTANCES 209 Super unleaded ROZ 95 RON 95 PON 91 According to DIN EN 228 ROZ 95 RON 95 PON 91...

Page 212: ...road use Guideline KTM recommends Motorex products Supplier Motorex Chain Lube 622 Strong Cleaning and preserving materials for metal rubber and plastic Guideline KTM recommends Motorex products Suppl...

Page 213: ...KTM recommends Motorex products Supplier Motorex Fett 2000 Motorcycle cleaner Guideline KTM recommends Motorex products Supplier Motorex Moto Clean 900 Universal oil spray Guideline KTM recommends Mo...

Page 214: ...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 215: ...ke checking 102 Brake light bulb changing 132 Brake linings 100 front brake checking 100 rear brake checking 104 Brakes 67 Braking 67 C Chain checking 93 cleaning 88 dirt checking 88 Chain tension adj...

Page 216: ...ooling system 146 filling bleeding 151 D Display 43 E Electric starter button 40 Emergency OFF switch 40 Engine running in 58 Engine number 34 Engine oil adding 170 changing 163 draining 164 refilling...

Page 217: ...mounting on vehicle 116 Horn button 38 I Ignition curve adjusting to fuel quality 171 plug in connector 171 Ignition key activating deactivating 143 Ignition lock 39 Immobilizer 39 Indicator lamps 42...

Page 218: ...s before putting into operation 61 R Rear hub shock absorber checking 111 Rear sprocket checking 93 Rear wheel installing 109 removing 108 Refueling fuel 70 Riding 64 starting up 63 S Seat mounting 11...

Page 219: ...0 engine tightening torques 191 194 fork 198 199 shock absorber 200 202 Tire air pressure checking 114 Tire condition checking 112 Tool set 53 Transport 9 Troubleshooting 181 183 Turn signal bulb chan...

Page 220: ...KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com 01 2010 Photo Mitterbauer 3211562en 3211562en...

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KTM 990 Supermoto R USA 2010, Owner'S Manual

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