KTM 990 SUPER DUKE 2009 User manual

990 SUPER DUKE
990 SUPER DUKE R
KTM Sportmotorcycle AG
A–5230 Mattighofen
www.ktm.com
10/2008 FOTO: MITTERBAUER
KTM Group Partner
ART. NR. 3211372en
OWNER’S MANUAL 2009
*3211372en*
3211372en

INTRODUCTION »
All information contained is without obligation. KTM-Sportmotorcycle AG particularly reserves the right to modify any equipment, technical specifications, prices,
colors, shapes, materials, services, service work, constructions, equipment and the like so as to adapt them to local conditions or to cancel any of the above items,
all without previous announcement and without giving reasons. KTM may stop manufacturing certain models without previous notice. KTM shall not be held liable
for any deviations of availability and/or ability to deliver, illustrations, descriptions, printing and/or other errors. The illustrated models partly contain extra equip-
ment, which is not applied to standard models.
© 2008 by KTM-SPORTMOTORCYCLE AG, Mattighofen AUSTRIA; All rights reserved; Reprint, also in extracts, with written allowance of KTM-SPORTMOTORCYCLE AG,
Mattighofen only.
COMSUMER INFORMATION FOR AUSTRALIA ONLY Tampering with noise control system prohibited Owners are warned that the law may prohibit:
(a) The removal or rendering inoperative by any person other than for purposes of maintenance, repair or replacement, of any device or element of design incorpo-
rated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use; and
(b) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.
Frame number
Engine number
Key number
Stamp of dealer
We would like to congratulate you on your purchase of a KTM motorcycle. You are now the owner of a state-of-the-art sport motorcycle that guarantees to bring you
lots of fun and enjoyment, provided that you clean and maintain it appropriately.
Please insert the serial numbers of your motorcycle in the boxes below:
In accordance with the international quality management ISO 9001 standard, KTM uses quality assurance
processes that lead to the highest possible product quality.
1

IMPORTANT INFORMATION »
INTENDED PURPOSE
The 990 Super Duke is designed to resist the usual wear and tear of paved roads but is not designed for race courses or off-road use.
The 990 Super Duke R is designed to resist the usual wear and tear of paved roads or race courses but is not designed for off-road use.
OWNER'S MANUAL
Carefully read the entire Owner's Manual before you start riding your motorcycle, even if this will take a little time. It contains use-
ful tips and information on the best way to handle the motorcycle and how to protect yourself from injuries. The Manual also con-
tains important information on service and maintenance. In your own interest, pay particular attention to the information marked
as follows:
– Ignoring these instructions, can endanger your body and
your life.
– Ignoring these instructions could cause damage to parts
of your motorcycle or 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 enhancements to the motorcycle design cannot be entirely precluded. The Owner's Manual is an integral part
of the motorcycle and must be handed over to the new owner when the motorcycle is sold.
SERVICE
Observance of the service, maintenance and operating instructions for the engine and chassis specified in the Owner's Manual is
a prerequisite for faultless operation and the avoidance of premature wear. Please observe the prescribed breaking-in periods, inspec-
tion intervals and service intervals. Strict observance will significantly prolong the service life of your motorcycle.
The use of the motorcycle under extreme conditions, e.g. on the race course, can cause above average wear to components such
as the brakes. In this case it may become necessary to service or replace wear parts before the service limit specified in the main-
tenance schedule has been reached.
2

IMPORTANT INFORMATION »
WARRANTY
The service work specified in the „Lubrication and Maintenance Schedule“ must be performed by an authorized KTM workshop.
This is the only place that has the qualified technicians and the special tools required for the 990 Super Duke / R. Be sure to have
the workshop verify all service work carried out in the service manual to avoid losing your right to claim under the warranty.
The warranty or guarantee shall become void for damage and consequential damage caused by manipulations or conversions to the
motorcycle.
AUTOMOTIVE FLUIDS
The fuels, lubricants and liquids specified in the Owner's Manual or automotive fluids with 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 assume any liability for other products
or consequential damage resulting from the use of such products.
ENVIRONMENT
Motorcycle driving is a wonderful sport and we hope that you will be able to enjoy it to the full. It may, however, involve potential
problems for the environment or lead to conflicts with others. These problems or conflicts can be avoided if the motorcycle is used
responsibly. To safeguard the future of motorcycle sports, make sure that you use the motorcycle in accordance with the law, show
that you are environmentally conscious and respect the rights of others.
Enjoy driving your motorcycle !
KTM SPORTMOTORCYCLE AG
5230 MATTIGHOFEN, AUSTRIA
3

INDEX »4
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
IMPORTANT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . .2
SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . .6
Chassis number, Type label . . . . . . . . . . . . . . . . . . . . . . . . .6
Engine number, engine type . . . . . . . . . . . . . . . . . . . . . . . .6
OPERATION INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . . . .7
Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Combined instrument . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Function buttons on combined instrument . . . . . . . . . . . . .8
Combined instrument display . . . . . . . . . . . . . . . . . . . . . .8
Cooling liquid temperature display . . . . . . . . . . . . . . . . . .12
Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Indicator lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Ignition lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Combination switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Starter tip switch, Emergency OFF tip switch . . . . . . . . . .15
Filler cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Seat lock, removing the seat . . . . . . . . . . . . . . . . . . . . . .16
Baggage loops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Tool set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Helmet lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Holding strap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Side stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Foot brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Footrests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Compression damping of fork . . . . . . . . . . . . . . . . . . . . . .19
Rebound damping of fork . . . . . . . . . . . . . . . . . . . . . . . . .19
Spring preload of the fork . . . . . . . . . . . . . . . . . . . . . . . . .20
Damping action during compression of shock 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 . . . . . . . . . . . . . . . . . . . . . . . . . .23
DRIVING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . .24
Check the following before each start . . . . . . . . . . . . . . . .24
Starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Starting off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Shifting/Riding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Stopping and parking . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
MAINTENANCE WORK ON CHASSIS AND ENGINE . . . . . . . .36
Adjusting the fork and shock absorber . . . . . . . . . . . . . . .37
Adjusting compression damping of fork . . . . . . . . . . . . . . .37
Adjusting rebound damping of fork . . . . . . . . . . . . . . . . . .37
Adjusting the spring preload on the fork . . . . . . . . . . . . . . .38
Compression damping of shock absorber . . . . . . . . . . . . . .38
Rebound damping of shock absorber . . . . . . . . . . . . . . . . .39
Checking the chain tension . . . . . . . . . . . . . . . . . . . . . . .40
Correcting the chain tension . . . . . . . . . . . . . . . . . . . . . .40
Chain maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Checking the chain for wear . . . . . . . . . . . . . . . . . . . . . . .41
General information on KTM disk brakes . . . . . . . . . . . . . .42
Adjusting the basic position of the hand brake lever . . . . . .44
Checking the front brake fluid level . . . . . . . . . . . . . . . . .44

INDEX »5
Checking the front brake pads . . . . . . . . . . . . . . . . . . . . .45
Checking the rear brake fluid level . . . . . . . . . . . . . . . . . .46
Checking the rear brake pads . . . . . . . . . . . . . . . . . . . . . .46
Changing the seat height . . . . . . . . . . . . . . . . . . . . . . . . .47
Dismounting and remounting the front wheel . . . . . . . . . .48
Dismounting and mounting the rear wheel . . . . . . . . . . . . .50
Tires, air pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Removing and remounting the battery . . . . . . . . . . . . . . .53
Charging the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Jump start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Main fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Fuses for individual power consumers . . . . . . . . . . . . . . . .56
Replacing the headlight lamp . . . . . . . . . . . . . . . . . . . . .57
Adjusting the headlight range . . . . . . . . . . . . . . . . . . . . . .58
Replacing the brake light and taillight bulbs . . . . . . . . . . .59
Replacing the flasher bulbs . . . . . . . . . . . . . . . . . . . . . . .59
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
Checking the 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 oil level of the hydraulic clutch . . . . . . . . . . .64
Adjusting the handlebar tilt . . . . . . . . . . . . . . . . . . . . . . .64
How to change the handlebar position (Super Duke R) . . . .65
Adjusting the steering damper (Super Duke R) . . . . . . . . .65
Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Checking the engine oil level . . . . . . . . . . . . . . . . . . . . . .66
Refilling engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Changing the engine oil and the oil filter,
cleaning the oil screen . . . . . . . . . . . . . . . . . . . . . . . . . . .68
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
CONSERVATION FOR WINTER OPERATION . . . . . . . . . . . . . .77
STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
STARTING UP AFTER IMMOBILIZATION . . . . . . . . . . . . . . .78
TECHNICAL SPECIFICATIONS – CHASSIS . . . . . . . . . . . . . . .79
TECHNICAL SPECIFICATIONS – ENGINE . . . . . . . . . . . . . . .84
Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
HEAD WORD INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
CONSUMER INFORMATION FOR USA ONLY . . . . . . . . . . . . .87

Chassis number, Type label
The chassis number is stamped on the right side of the steering head tube. 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 side of the engine below
the engine sprocket. Enter this number on page 1.
SERIAL NUMBER LOCATIONS »6

Clutch lever
The clutch lever [1] is fitted on the left hand side of the handle bar. The adjusting screw [A]
is used to change the original position of the clutch lever (see maintenance work on 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 front
wheel brake.The adjusting screw [B] is used to change the original position of the hand brake
lever (see maintenance work on chassis and engine).
OPERATION INSTRUMENTS »7
B
2
1
A

OPERATION INSTRUMENTS »8
1
2
Combined instrument
The combined instrument is divided into 4 parts.
Function buttons: to select the display modes and basic settings in the display
Tachometer: displays the engine speed
Indicator lamps: provide additional information on the motorcycle operating condition
Display: shows the speed, cooling liquid temperature, time, ambient temperature,
distance traveled (ODO), trip master 1 (TRIP 1), trip master 2 (TRIP 2),
distance traveled since the reserve warning lamp went on (TRIP F)
Function buttons on combined instrument
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, cooling liquid temperature and time are always displayed.
SET [2]
Press the SET button to reset trip master 1 or 2 to 0.
The 3rd button is not programmed.
Combined instrument display
TEST
When you switch on the ignition, all of the display elements will light up for 1 second for
the function test.
LENGTH
The display will change for 1 second to display the circumference of the front wheel in mil-
limeters. 1870 mm corresponds to a 17" front wheel.
Then the display will change back to the mode that was activated when the ignition was
switched off.

OPERATION INSTRUMENTS »9
1
2
3
SPEED [1]
The speed can be displayed in kilometers per hour (km/h) or miles per hour (mph).
CHANGING THE SPEED DISPLAY FROM KM/H - MPH or MPH - KM/H
Switch on the ignition and press the MODE button more than 10 seconds in the ODO mode.
CLOCK [2]
The dots between the hours and minutes will blink in the CLOCK display.
The clock must be set if the battery was disconnected or if the fuse 7 was 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 button to set the hours. Use the SET button to set the minutes.
Then press the MODE and SET buttons simultaneously.
AMBIENT TEMPERATURE [3]
The ambient temperature can be displayed in Celsius (°C) or Fahrenheit (°F).
CHANGING THE AMBIENT TEMPERATURE DISPLAY FROM °C - °F or °F - °C
Switch on the ignition and press the MODE button more than 10 seconds in the ambient
temperature mode.
Press the MODE button to go to the next display mode.