KTM 990 Adventure EU 2009 User manual

Congratulations on your decision to buy a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will give you
enormous pleasure if you service and maintain it accordingly.
We wish you a lot of enjoyment riding this vehicle!
Please enter the serial numbers of your vehicle below.
Chassis number ( p. 16) Dealer's stamp
Engine number ( p. 17)
Key number ( p. 17)
The owner's manual corresponded to the latest state of this series at the time of printing. Slight deviations resulting from continuing devel-
opment and design of our motorcycles cannot, however, be completely excluded.
All specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifications,
prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt these
to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery options,
deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain special equipment
that does not belong to the regular scope of delivery.

© 2009 by KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
Reproduction, even in part, 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 processes that lead to
the maximum possible quality of the products.
Issued by: TÜV Management Service
KTM-Sportmotorcycle AG
5230 Mattighofen, Austria

MEANS OF REPRESENTATION ............................................... 7
IMPORTANT NOTES............................................................... 8
VIEW OF VEHICLE................................................................ 12
View of vehicle, front left side (vehicle differs slightly from
photo) ............................................................................. 12
View of vehicle, rear right side (vehicle differs slightly from
photo) ............................................................................. 14
LOCATION OF SERIAL NUMBERS ......................................... 16
Chassis number................................................................ 16
Type label........................................................................ 16
Key number ..................................................................... 17
Engine number................................................................. 17
Fork part number.............................................................. 18
Shock absorber part number.............................................. 18
CONTROLS.......................................................................... 19
Clutch lever ..................................................................... 19
Hand brake lever .............................................................. 19
Light switch ..................................................................... 20
Headlight flasher switch.................................................... 20
Turn signal switch ............................................................ 21
Horn button ..................................................................... 21
Ignition/steering lock ........................................................ 22
Immobilizer ..................................................................... 22
Emergency OFF switch...................................................... 23
Electric starter button ....................................................... 23
Combination instrument.................................................... 24
Combination instrument - function buttons ......................... 24
Combination instrument - tachometer................................. 25
Combination instrument - indicator lamps........................... 25
Combination instrument - display....................................... 26
Combination instrument - speedometer............................... 27
Setting kilometers or miles ................................................ 27
Combination instrument - time .......................................... 28
Setting the clock .............................................................. 29
Combination instrument - display ODO ............................... 29
Combination instrument - setting/resetting TRIP 1............... 30
Combination instrument - setting/resetting TRIP 2............... 30
Combination instrument - TRIP F display............................ 31
Combination instrument - ambient temperature display........ 32
Setting the temperature unit of measure............................. 32
Combination instrument - warning of slippery roads ............. 33
Combination instrument - coolant temperature indicator ...... 33
Socket for electrical accessories......................................... 34
Hazard warning flasher switch/hazard warning flasher .......... 34
Opening the filler caps...................................................... 35
Closing the filler caps ....................................................... 35
Seat lock ......................................................................... 36
Unlocking the storage compartment ................................... 36
Locking the storage compartment....................................... 37
Opening the storage compartment...................................... 37
Closing the storage compartment ....................................... 38
Handrails......................................................................... 38
Luggage rack plate ........................................................... 39
Fuel taps ......................................................................... 39
Foot brake pedal .............................................................. 40
Shift lever........................................................................ 40
Side stand ....................................................................... 41
Center stand .................................................................... 42

Passenger footrests........................................................... 42
Tool set ........................................................................... 43
GENERAL TIPS AND HINTS ON PUTTING INTO
OPERATION......................................................................... 44
Information on first use..................................................... 44
Running in the engine....................................................... 45
Loading the vehicle .......................................................... 46
RIDING INSTRUCTIONS ....................................................... 48
Checks before putting into operation .................................. 48
Starting ........................................................................... 49
Starting up ...................................................................... 51
Shifting, riding................................................................. 51
Braking ........................................................................... 55
Stopping, parking ............................................................. 57
Refueling......................................................................... 59
SERVICE SCHEDULE............................................................ 62
Important service tasks to be carried out by an authorized
KTM workshop ................................................................. 62
Important service tasks to be carried out by an authorized
KTM workshop (as an additional order) ............................... 65
MAINTENANCE WORK ON CHASSIS AND ENGINE................. 66
Jacking up the vehicle on the center stand.......................... 66
Raising the vehicle off of the center stand .......................... 67
Removing the seat............................................................ 67
Mounting the seat ............................................................ 68
Fork/shock absorber.......................................................... 68
Adjusting the compression damping of the fork ................... 69
Adjusting the rebound damping of the fork.......................... 70
Adjusting the spring preload of the fork .............................. 71
Compression damping of the shock absorber ....................... 72
Adjusting the low-speed compression damping of the shock
absorber .......................................................................... 72
Adjusting the high-speed compression damping of the
shock absorber ................................................................. 74
Adjusting the rebound damping of the shock absorber.......... 75
Adjusting the spring preload of the shock absorber .............. 77
Bleeding the fork legs ....................................................... 78
Cleaning the dust boots of the fork legs .............................. 78
Checking for chain dirt...................................................... 79
Cleaning the chain............................................................ 80
Checking the chain tension ............................................... 81
Adjusting the chain tension ............................................... 82
Checking the rear sprocket/engine sprocket for wear ............ 84
Checking chain wear......................................................... 85
ABS / antilock brake system (990 Adventure)...................... 86
Checking the brake discs................................................... 87
Checking the free travel of the hand brake lever .................. 88
Adjusting the free travel of the handbrake lever ................... 88
Checking the brake fluid level of the front brake.................. 89
Adding front brake fluid x............................................... 90
Checking the front brake linings......................................... 92
Checking the free travel of the foot brake lever .................... 92
Checking the rear brake fluid level ..................................... 93
Adding rear brake fluid x................................................ 94
Checking the rear brake linings.......................................... 96
Removing the front wheel x............................................. 97
Installing the front wheel x.............................................. 99
Removing the rear wheel x............................................ 101
Installing the rear wheel x............................................. 103

Checking the rear hub rubber dampers x........................ 105
Checking the tire condition.............................................. 106
Checking the tire air pressure .......................................... 107
Checking spoke tension................................................... 108
Removing the underride guard x.................................... 109
Installing the underride guard x..................................... 110
Removing the battery x................................................. 110
Installing the battery x.................................................. 112
Recharging the battery x............................................... 113
Removing the right underride guard.................................. 116
Installing the right underride guard .................................. 116
Changing the main fuse .................................................. 117
Changing the ABS fuses (990 Adventure) ......................... 119
Changing the fuses in the fuse box................................... 120
Removing the front side cover.......................................... 123
Installing the front side cover .......................................... 123
Removing the headlight mask with the headlight ............... 124
Installing the headlight mask with the headlight................ 125
Changing the high beam bulb .......................................... 125
Changing the low beam bulb............................................ 126
Changing the parking light bulb in the headlight................ 127
Changing the turn signal bulb.......................................... 128
Changing the tail light bulb ............................................. 129
Changing the brake light bulb.......................................... 130
Checking the headlamp setting ........................................ 131
Adjusting the headlight range .......................................... 132
Activating/deactivating the ignition key............................. 132
Removing the storage compartment and hanging it to one
side x.......................................................................... 135
Installing the storage compartment x............................. 136
Removing the left fuel tank x........................................ 137
Installing the left fuel tank x......................................... 138
Cooling system ............................................................... 140
Checking the coolant level in the compensating tank ......... 141
Checking the coolant level in the radiator.......................... 143
Checking the antifreeze x.............................................. 144
Draining the coolant x.................................................. 145
Filling/bleeding the cooling system x.............................. 147
Removing the radiator guard............................................ 149
Installing the radiator guard............................................. 150
Adjusting the basic setting of the clutch lever ................... 151
Checking/rectifying the fluid level of the hydraulic clutch ... 151
Checking the play in the gas Bowden cable....................... 152
Adjusting the play in the gas Bowden cable x.................. 153
Checking the engine oil level ........................................... 153
Changing the engine oil and filter, cleaning the oil
screens x..................................................................... 154
Draining engine oil, cleaning oil screens x...................... 154
Removing the oil filter x................................................ 158
Installing the oil filter x................................................ 159
Filling up with engine oil x............................................ 159
Adding engine oil ........................................................... 161
Ignition curve plug-in connector....................................... 162
Adjusting the ignition curve to the fuel quality................... 162
IMMOBILIZER FLASH CODE ............................................... 164
ENGINE CONTROL FLASH CODE......................................... 166
TROUBLESHOOTING.......................................................... 172

CLEANING......................................................................... 175
Cleaning motorcycle ....................................................... 175
CONSERVING FOR WINTER OPERATION ............................. 177
Conserving for winter operation ........................................ 177
STORAGE .......................................................................... 178
Storage.......................................................................... 178
Putting into operation after storage .................................. 179
TECHNICAL DATA - ENGINE............................................... 180
Capacity- engine oil ........................................................ 181
Capacity - coolant........................................................... 181
TECHNICAL DATA - ENGINE TIGHTENING TORQUES........... 182
TECHNICAL DATA - CHASSIS ............................................. 185
Lighting equipment ........................................................ 187
Tires ............................................................................. 188
Capacity - fuel................................................................ 188
TECHNICAL DATA - FORK................................................... 189
990 Adventure ............................................................... 189
990 Adventure R............................................................ 190
TECHNICAL DATA - SHOCK ABSORBER .............................. 192
990 Adventure ............................................................... 192
990 Adventure R............................................................ 193
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ......... 195
SUBSTANCES.................................................................... 198
AUXILIARY SUBSTANCES................................................... 202
STANDARDS...................................................................... 204
INDEX ............................................................................... 205

The meaning of specific symbols is described below.
Indicates an expected reaction (e.g. of a work step or a function).
Indicates an unexpected reaction (e.g. of a work step or a function).
All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your
own safety, have these jobs performed in an authorized KTM workshop! There, your motorcycle will be serviced opti-
mally by specially trained experts using the specialist tools required.
Identifies a page reference (more information is provided on the specified page).
The typographical formats used in this document are explained below.
Identifies a proprietary name.
Identifies a protected name.
Identifies a trademark.

KTM sport motorcycles are designed and constructed to meet the normal demands of regular road and light offroad operation (dirt roads),
but not for use on race courses.
The motorcycle is authorized for public road traffic in the homologous version only.
A prerequisite for fault-free operation and avoiding premature wear is compliance with the maintenance, care and adjustments to the
engine and chassis described in the owner's manual. Poor adjustment and tuning of the engine and suspension can lead to damage and
breakage of components.
Using the motorcycle in extreme conditions such as very muddy 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 specified in the ser-
vice schedule is reached.
Pay careful attention to the prescribed running-in period and inspection and maintenance intervals. Close adherence to these periods will
significantly lengthen the service life of your motorcycle.
The work prescribed in the service schedule must be carried out in an authorized KTM workshop only and confirmed in the customer's ser-
vice record; otherwise, all warranty claims will be void. No warranty claim can be honored for damage resulting from manipulation and/or
other changes to the vehicle.
The fuels and lubricants named in the owner's manual must be used according to specifications.

For your own safety, only use spare parts and accessory products that have been approved and/or recommended by KTM and have them
installed by an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage.
Some of the spare parts and accessory products are specified in parentheses under the respective descriptions. Your KTM dealer will be
glad to advise you.
You will find the current for your vehicle on the KTM website.
International KTM Website: http://www.ktm.com
Special tools are necessary for some of the work. These are not included with the vehicle and can be ordered under the number in paren-
theses. Ex: valve spring mounter (59029019000)
During assembly, non-reusable parts (e.g. self-locking screws and nuts, seals and seal rings, O-rings, pins, lock washers) must be replaced
by new parts.
If a thread lock (e.g. ) is used for screw connections, be sure to comply with the manufacturer's specific instructions on its usage.
Parts that you want to reuse following repairs and servicing should be cleaned and checked for damage and wear. Change damaged or
worn parts.
Following repairs or servicing, the vehicle must be checked for roadworthiness.
The parked vehicle can roll away or fall over.
–Always place the vehicle on a firm and even surface.
Some vehicle components get very hot when the machine is driven.
–Do not place the vehicle where there are flammable or explosive substances. Do not place objects over the vehicle while it is still warm
from being run. Always let the vehicle cool first.

–Switch off the engine and remove the ignition key.
–Secure the motorcycle against falling over or rolling away using straps or other suitable devices.
Motorcycling is a wonderful 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 motorcycle can help to avoid such problems and con-
flicts. To protect the future of motorcycle sport, make sure that you use your motorcycle legally, display environmental consciousness, and
respect the rights of others.
Pay close attention to the notes/warnings.
Various information and warning labels are affixed to the vehicle. Do not remove information/warning labels. If they are missing,
you or others may not recognize sources of danger and may therefore be injured.

Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not
taken.
Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.
Identifies a danger that may lead to minor injuries if the appropriate measures are not taken.
Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.
Identifies a danger that will lead to environmental damage if the appropriate measures are not taken.
–Be sure to read this owner's manual carefully and completely before taking your first ride. It contains 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 injury. The owner's manual also contains important information on servicing the motorcycle.
–The owner's manual is an important component of the motorcycle and should be handed over to the new owner if the vehicle is sold.

100540-10

1 Clutch lever
2 Seat
3 Seat lock
4 Luggage rack plate
5 Handrail
6 Front brake caliper
7 Underride guard
8 Side stand
9 Shift lever
10 Footrest
11 Center stand
12 Passenger footrest

100541-10

1 Storage compartment
2 Light switch, turn signal switch, horn button, headlight flasher switch
3 Hazard warning flasher switch
4 Accessories socket
5 Emergency OFF switch, electric starter button
6 Hand brake lever
7 Filler cap
8 Rear brake caliper
9 Foot brake pedal
10 Oil dipstick
11 Cooling system compensating tank

100542-10
The chassis number is stamped on the right side of the steering head.
The chassis number is also found on the type label.
100543-10
The type label is located on the right frame tube in the vicinity of the oil tank.

700222-01
The key number can be found on the .
You need the key number to order a spare key. Keep the in a safe
place.
Use the orange programming key to activate and deactivate the black ignition key.
Keep the orange programming key in a safe place: it must only be used for learning
and programming functions.
100544-10
The engine number is stamped on the left side of the engine under the engine sprocket.

100545-10
The fork part number is stamped on the inner side of the fork stub.
100546-10
The shock absorber part number is stamped on the upper part of the shock absorber.