KTM 990 Super Duke EU 2010 User manual

OWNER'S MANUAL 2010
990 Super Duke EU
990 Super Duke AUS/UK
990 Super Duke FR
990 Super Duke R EU
990 Super Duke R AUS/UK
990 Super Duke R FR
Art. no. 3211522en

DEAR KTM CUSTOMER 1
DEAR KTM CUSTOMER
Congratulations on your decision to purchase 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 in riding this vehicle.
Please enter the serial numbers of your vehicle below.
Chassis number/type label ( p. 16) Dealer's stamp
Engine number ( p. 17)
Key number ( p. 17)
The owner's manual contained the latest information for this model at the time of going to print. However, 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 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 form part of the regular scope of delivery.

DEAR KTM CUSTOMER 2
© 2009 KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
Reproduction, even in part, as well as copying of all kinds, 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

TABLE OF CONTENTS 3
TABLE OF CONTENTS
MEANS OF REPRESENTATION ............................................... 7
IMPORTANT INFORMATION ................................................... 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/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
Emergency OFF switch...................................................... 22
Electric starter button ....................................................... 23
Combination instrument.................................................... 23
Combination instrument - function buttons ......................... 24
Combination instrument - tachometer................................. 24
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 .............................................................. 28
Combination instrument - ODO display ............................... 29
Combination instrument - setting/resetting TRIP 1............... 29
Combination instrument - setting/resetting TRIP 2............... 30
Combination instrument - TRIP F display............................ 31
Combination instrument - ambient temperature display........ 31
Setting the temperature units ............................................ 32
Combination instrument - warning of slippery roads ............. 32
Combination instrument - coolant temperature indicator ...... 33
Opening the filler cap ....................................................... 34
Closing the filler cap......................................................... 35
Seat lock (Super Duke) ..................................................... 36
Seat lock (Super Duke R) .................................................. 36
Supporting strap (Super Duke)........................................... 37
Baggage lugs (Super Duke)................................................ 37
Tool set ........................................................................... 38
Helmet lock ..................................................................... 38
Passenger footrests (Super Duke)....................................... 39
Shift lever........................................................................ 39
Foot brake lever................................................................ 40
Side stand ....................................................................... 41
TIPS ON PUTTING INTO OPERATION .................................... 42
Information on first use..................................................... 42
Running in the engine....................................................... 43
Loading the vehicle .......................................................... 43
RIDING INSTRUCTIONS ....................................................... 46
Checks before putting into operation .................................. 46

TABLE OF CONTENTS 4
Starting ........................................................................... 47
Starting up ...................................................................... 48
Shifting, riding................................................................. 49
Braking ........................................................................... 52
Stopping, parking ............................................................. 53
Refueling......................................................................... 55
SERVICE SCHEDULE............................................................ 57
Service schedule .............................................................. 57
MAINTENANCE WORK ON FRAME AND ENGINE.................... 60
Jacking up motorcycle at the front ..................................... 60
Taking the front from the work stand .................................. 60
Jacking up motorcycle at the rear....................................... 61
Taking the rear from the workstand .................................... 61
Fork/shock absorber.......................................................... 62
Adjusting the compression damping of the fork ................... 62
Adjusting the rebound damping of the fork.......................... 64
Adjusting the spring preload of the fork .............................. 65
Bleeding the fork legs ....................................................... 66
Compression damping of the shock absorber ....................... 67
Adjusting the low-speed compression damping of the shock
absorber .......................................................................... 67
Adjusting the high-speed compression damping of the
shock absorber ................................................................. 69
Adjusting the rebound damping of the shock absorber.......... 70
Adjusting the spring preload of the shock absorber x......... 71
Steering damper (Super Duke R)........................................ 73
Adjusting the steering damper (Super Duke R) .................... 73
Handlebar position (Super Duke R) .................................... 74
Adjusting the handlebar position x(Super Duke R)............ 74
Checking the chain for dirt ................................................ 75
Cleaning the chain............................................................ 76
Checking the chain tension ............................................... 77
Adjusting the chain tension ............................................... 78
Checking the chain, rear sprocket and engine sprocket......... 80
Checking the front brake discs........................................... 82
Checking the rear brake disc.............................................. 83
Adjusting the basic position of the hand brake lever............. 84
Checking the front brake fluid level .................................... 84
Adding front brake fluid x............................................... 85
Brake linings.................................................................... 86
Checking the front brake linings......................................... 87
Checking the rear brake fluid level ..................................... 88
Adding rear brake fluid x................................................ 88
Checking the rear brake linings.......................................... 90
Removing the front wheel x............................................. 91
Installing the front wheel x.............................................. 92
Removing the rear wheel x.............................................. 94
Installing the rear wheel x............................................... 95
Checking rear hub shock absorbers x............................... 97
Checking the tire condition................................................ 98
Checking the tire air pressure .......................................... 100
Removing the front spoiler............................................... 101
Installing the front spoiler ............................................... 101
Removing the seat.......................................................... 102
Mounting the seat .......................................................... 103
Seat height (Super Duke R) ............................................. 104
Adjusting the seat height (Super Duke R).......................... 104
Mounting the helmet lock on the vehicle........................... 105

TABLE OF CONTENTS 5
Removing the spoiler ...................................................... 106
Installing the spoiler ....................................................... 107
Removing the battery x................................................. 109
Installing the battery x.................................................. 110
Recharging the battery x............................................... 111
Changing the main fuse .................................................. 113
Changing the fuses of individual power consumers............. 115
Changing the parking light bulb ....................................... 117
Changing the low beam bulb............................................ 118
Changing the high beam bulb .......................................... 120
Changing the turn signal bulb.......................................... 123
Changing the brake light bulb (Super Duke) ...................... 124
Changing the tail light bulbs (Super Duke)........................ 125
Changing the license plate lamp ...................................... 126
Checking the headlight setting......................................... 129
Adjusting headlight range................................................ 129
Cooling system ............................................................... 130
Checking the antifreeze and coolant level ......................... 131
Checking the coolant level in the compensating tank ......... 133
Draining the coolant x.................................................. 135
Filling/bleeding the cooling system x.............................. 136
Adjusting the basic position of the clutch lever.................. 138
Checking/correcting the fluid level of the hydraulic
clutch ........................................................................... 139
Checking the play in the throttle cable.............................. 140
Adjusting the play in the throttle cable x........................ 141
Checking the engine oil level ........................................... 141
Changing the engine oil and filter, cleaning the oil
screens x..................................................................... 142
Draining the engine oil and filter, cleaning the oil
screens x..................................................................... 143
Filling up with engine oil x............................................ 147
Adding engine oil ........................................................... 149
ENGINE CONTROL BLINK CODE......................................... 150
TROUBLESHOOTING.......................................................... 156
CLEANING......................................................................... 159
Cleaning motorcycle ....................................................... 159
PROTECTIVE TREATMENT FOR WINTER OPERATION........... 161
Conserving for winter operation ........................................ 161
STORAGE .......................................................................... 162
Storage.......................................................................... 162
Putting into operation after storage .................................. 163
TECHNICAL DATA - ENGINE............................................... 164
Capacity- engine oil ........................................................ 165
Capacity - coolant........................................................... 166
TECHNICAL DATA - ENGINE TIGHTENING TORQUES........... 167
TECHNICAL DATA - CHASSIS ............................................. 171
Lighting equipment ........................................................ 173
Tires ............................................................................. 174
Capacity - fuel................................................................ 174
TECHNICAL DATA - FORK................................................... 175
Super Duke.................................................................... 175
Super Duke R ................................................................ 176
TECHNICAL DATA - SHOCK ABSORBER .............................. 178
Super Duke.................................................................... 178
Super Duke R ................................................................ 179
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ......... 181
SUBSTANCES.................................................................... 184

TABLE OF CONTENTS 6
AUXILIARY SUBSTANCES................................................... 188
STANDARDS...................................................................... 190
INDEX ............................................................................... 191

MEANS OF REPRESENTATION 7
Symbols used
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 by 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).
Formats used
The typographical formats used in this document are explained below.
Specific name Identifies a proprietary name.
Name®Identifies a protected name.
Brand™ Identifies a brand available on the open market.

IMPORTANT INFORMATION 8
Use definition
(Super Duke)
KTM sport motorcycles are designed and constructed to meet the normal demands of regular road operation but not for use on race
courses or offroad.
Info
The motorcycle is authorized for public road traffic in the homologous version only.
(Super Duke R)
KTM sport motorcycles are designed and constructed to meet the normal demands of regular road and race track operation, but not for
use on dirt roads.
Info
The motorcycle is authorized for public road traffic in the homologous version only.
Maintenance
A prerequisite for fault-free operation and avoiding premature wear is compliance with the instructions for maintenance, care and adjust-
ments of the engine and suspension provided 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.
Warranty
The work prescribed in the service schedule must be carried out by 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.