KTM 990 Super Duke EU 2011 Manual

SETUP INSTRUCTIONS 2011
990 Super Duke EU
990 Super Duke FR
990 Super Duke AUS/UK
990 Super Duke R EU
990 Super Duke R FR
990 Super Duke R AUS/UK
Art. no. 3211743en

INTRODUCTION 1
INTRODUCTION
The work described in these setup instructions must be performed before the vehicle is delivered to the customer.
Read the setup instructions in their entirety before beginning work.
Print out the current PDI form found on the KTM DEALER.NET.
These setup instructions were written to correspond to the latest state of this series. We reserve the right to make changes in the inter-
est of technical advancement without at the same time updating this manual.
We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop are not specified here.
It is assumed that the work will be performed by a fully trained mechanic.
All specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifica-
tions, 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 spe-
cial equipment that does not belong to the regular scope of delivery.
© 2011 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

MEANS OF REPRESENTATION 2
Symbols used
The symbols used are explained in the following.
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).
Identifies a page reference (more information is provided on the specified page).
Denotes additional information or tips.
Denotes the result of a test step.
Denotes a voltage measurement.
Denotes a current measurement.
Denotes a resistance measurement.
Formats used
The following typographical formats are used.
Specific name Identifies a proprietary name.
Name®Identifies a protected name.
Brand™ Identifies a brand in merchandise traffic.

SET‑UP 3
2.1Unpacking and setting up the vehicle
101252-10
–Remove the carton.
–Remove the adhesive tape in the upper area of the motorcycle.
101253-10
–Roll down the film at the sides.
Info
To avoid damaging the motorcycle during unpacking, leave the other films
on the vehicle until you have finished work on the vehicle.
–Unpack the separate enclosure and check its contents on the basis of the enclosure
list.
–Check the vehicle for transport damage.
101254-01
–Remove the controls from the transport holder. Remove the screws and handlebar
clamps. Remove the transport holder.
101255-10
–Remove the right-hand handlebar weight.
–Position the controls on the right half of the handlebar but do not tighten.
–Position the handlebar.
–Position the handlebar clamps. Fit and slightly tighten the four screws.
–Position the handlebar exactly.
The third marking of the scale on the handlebar must align with the edge 
of the handlebar support.
–Tighten the four screws evenly.
Guideline
Screw, handlebar clamp M8 20 Nm
(14.8 lbf ft)
101205-10
–Position the right combination switch. Tighten the screws.
Info
Position holding lug in bore .

SET‑UP 4
101256-01
–Position the hand brake cylinder. Tighten the screws.
Guideline
Remaining chassis screws M6 10 Nm (7.4 lbf ft)
–Position the throttle grip. Tighten the screws.
Guideline
Remaining chassis screws M5 5 Nm (3.7 lbf ft)
–Mount and tighten the right handlebar weight.
Guideline
Remaining chassis screws M6 10 Nm (7.4 lbf ft)
101207-10
–Position the left combination switch. Tighten the screws.
Info
Position holding lug in bore .
101257-01
–Position the clutch master cylinder and tighten the screw.
Guideline
Remaining chassis screws M6 10 Nm (7.4 lbf ft)
101258-01
–Mount and tighten the rear mirror adapter and rear mirror on both sides.
101259-01
–Mount the reflector.

SET‑UP 5
101260-10
–Insert connector into the starter relay.
–Recharge the battery. ( p. 6)
101261-10
–Remove the seat. ( p. 6)
–Secure tool set with the rubber strap.
–Remove the protective film from the seat.
–Mount the seat. ( p. 6)
101262-01
–Carefully loosen and remove the tensioning belt over the link fork.
Info
An assistant prevents the motorcycle from falling over.
–Carefully loosen and remove the tensioning belts around the lower triple clamp.
The vehicle is released at the front.
–Together with an assistant, take the vehicle off of the palette.
–Remove the protective plastic.
–Install the front spoiler. ( p. 10)
–Refuel. ( p. 8)
–Print out the current PDI form found on KTM DEALER.NET and perform the delivery
inspection.
–Set kilometers or miles. ( p. 9)
–Set the clock. ( p. 9)

WORK 6
3.1Removing the seat
B00165-10
(Super Duke)
–Insert the ignition key in the seat lock and turn it clockwise.
–Raise the rear of the seat, push it towards the rear, and remove it upwards.
B00187-10
(Super Duke R)
–Insert the ignition key in the seat lock and turn it clockwise.
–Raise the rear of the seat, push it towards the rear, and remove it upwards.
3.2Mounting the seat
B00188-10
(Super Duke)
–Hook the tabs of the seat onto the fuel tank, lower the rear and push for-
ward. The two hooks must engage in the subframe.
–Turn the ignition key counterclockwise in the seat lock and withdraw it.
–Finally, check that the seat is correctly mounted.
B00189-01
(Super Duke R)
–Position the seat on the motorcycle and push it forward.
–Turn the ignition key counterclockwise in the seat lock and withdraw it.
–Finally, check that the seat is correctly mounted.
3.3Recharging the battery
Warning
Risk of injury Battery acid and battery gases cause serious chemical burns.
–Keep batteries out of the reach of children.
–Wear suitable protective clothing and goggles.
–Avoid contact with battery acid and battery gases.
–Keep the battery away from sparks or open flames. Charge only in well-ventilated areas.
–In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least
15 minutes and contact a physician.
Warning
Environmental hazard The battery contains elements that are harmful to the environment.
–Do not discard batteries with the household trash. Dispose of a defective battery in an environmentally compatible manner.
Give the battery to your KTM dealer or to a recycling center that accepts used batteries.

WORK 7
Warning
Environmental hazard Hazardous substances cause environmental damage.
–Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
Info
Even when there is no load on the battery, it discharges steadily.
The charge state and the type of charge are very important for the service life of the battery.
Rapid recharging with a high charging current shortens the battery's service life.
If the charging current, charging voltage and charging time are exceeded, 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 is left in a discharged state for an extended period, it will become over-discharged and sulfate, destroying the
battery.
The battery is maintenance-free, i.e., the acid level does not have to be checked.
–Switch off all power consumers and switch off the engine.
–Remove the battery.
700588-01
–Connect the battery charger to the battery. Switch on the battery charger.
Battery charger (58429074000)
You can also use the battery charger to test the rest potential and start potential of
the battery, and to test the alternator. With this device, you cannot overcharge the
battery.
Info
Never remove lid .
Charge the battery at no more than 10% of the capacity specified on battery
housing .
–Switch off the charger after charging.
Guideline
The charge current, charge voltage and charge time must not be exceeded.
Charge the battery regularly when the
motorcycle is not in use
3 months
–Install the battery.
3.4Opening the filler cap
Danger
Fire hazard Fuel is highly flammable.
–Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no
fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
–Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See the notes on refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immedi-
ately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, con-
tact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according
to regulations and keep it out of the reach of children.
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
–Do not allow fuel to get into the ground water, the ground, or the sewage system.

WORK 8
B00162-10
–Lift the cover of the filler cap and insert the ignition key in the lock.
Note
Danger of damage Ignition key breakage.
–To take pressure off of the ignition key, push down on the filler cap. Damaged
ignition keys must be replaced.
–Turn the ignition key clockwise.
–Open the filler cap.
3.5Closing the filler cap
B00163-01
Warning
Fire hazard Fuel is highly flammable, poisonous and harmful to your
health.
–When closing the filler cap, ensure that it is closed correctly. Change
clothing that came into contact with fuel. Immediately clean skin that
came into contact with fuel using soap and water.
–Close the filler cap. Push down the filler cap until the lock engages.
–Remove the ignition key and close the cover.
3.6Refueling
Danger
Fire hazard Fuel is highly flammable.
–Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no
fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
–Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See the notes on refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–Avoid contact of the fuel with skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse imme-
diately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed,
contact a doctor immediately. Change clothing that has come into contact with fuel.
Note
Material damage Premature clogging of the fuel filter.
–In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with
the fuel system.

WORK 9
–Only refuel with clean fuel that meets the specified standards.
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
–Do not allow fuel to get into the ground water, the ground, or the sewage system.
11
B00243-01
–Switch off the engine.
–Open the filler cap. ( p. 7)
–Fill the fuel tank with fuel no higher than the lower edge of the filler neck.
Total fuel tank
capacity, approx.
18.5 l
(4.89 US gal)
Super unleaded (ROZ 95/RON 95/PON
91) ( p. 13)
–Close the filler cap. ( p. 8)
400970-12
–Press the SET button for two seconds.
The low fuel warning lamp goes out. TRIP F is set to 0.0 and the display
returns to the previous display mode.
Info
If the SET button is not pressed, the value is automatically reset after
approx. 3 minutes.
3.7Setting kilometers or miles
Info
If you change the unit, the value ODO is retained and converted accordingly.
Making the setting according to the country.
Condition
The motorcycle is stationary.
400893-10
–Switch on the ignition by turning the ignition key to the ON position.
–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.
3.8Setting the clock
Condition
The motorcycle is stationary.
400893-12
–Switch on the ignition by turning the ignition key to the ON position.
–Press the MODE button repeatedly until the ODO mode is active.
–Keep the MODE button and the 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 simultaneously.
The time is set.

WORK 10
3.9Installing the front spoiler
00
0
11
11
22
B00245-10
–Position the front spoiler.
–Mount and tighten screws with the washer.
Guideline
Screw, front spoiler M6 10 Nm
(7.4 lbf ft)
Loctite®243™
–Fully tighten screws .

TECHNICAL DATA - CHASSIS TIGHTENING TORQUES 11
Screw, side stand switch M4 2 Nm (1.5 lbf ft) Loctite®243™
Remaining chassis screws M5 5 Nm (3.7 lbf ft) –
Screw, chain sliding guard M5 5 Nm (3.7 lbf ft) –
Screw, fuel level indicator M5 3 Nm (2.2 lbf ft) –
Screw, fuel tank cover M5 5 Nm (3.7 lbf ft) –
Screw, seat bracket on fuel tank
(Super Duke)
M5 4 Nm (3 lbf ft) –
Nut, tail light (Super Duke) 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) –
Screw, chain sliding guard M6 6 Nm (4.4 lbf ft) Loctite®243™
Screw, foot brake cylinder M6 10 Nm (7.4 lbf ft) Loctite®243™
Screw, front spoiler M6 10 Nm (7.4 lbf ft) Loctite®243™
Screw, fuel pump M6 6 Nm (4.4 lbf ft) –
Screw, fuel tank holder M6 6 Nm (4.4 lbf ft) –
Screw, heel protector M6 2 Nm (1.5 lbf ft) Loctite®243™
Screw, push rod ball joint on foot
brake cylinder
M6 10 Nm (7.4 lbf ft) Loctite®243™
Screw, shift rod M6 12 Nm (8.9 lbf ft) Loctite®243™
Screw, shift shaft deflector on shift
shaft
M6 18 Nm (13.3 lbf ft) Loctite®243™
Screw, splash protector, rear wheel M6 6 Nm (4.4 lbf ft) Loctite®243™
Screw, spoiler M6 6 Nm (4.4 lbf ft) –
Screw, steering damper pipe clamp
(Super Duke R)
M6 4 Nm (3 lbf ft) Loctite®243™
Remaining chassis nuts M8 30 Nm (22.1 lbf ft) –
Remaining chassis screws M8 25 Nm (18.4 lbf ft) –
Screw, bottom triple clamp M8 15 Nm (11.1 lbf ft) –
Screw, exhaust clamp on main silencer M8 35 Nm (25.8 lbf ft) –
Screw, exhaust clamp on manifold M8 8 Nm (5.9 lbf ft) –
Screw, foot brake lever M8 25 Nm (18.4 lbf ft) Loctite®243™
Screw, fork stub M8 15 Nm (11.1 lbf ft) –
Screw, front brake disc M8 30 Nm (22.1 lbf ft) Loctite®243™
Screw, front footrest bracket M8 25 Nm (18.4 lbf ft) Loctite®243™
Screw, handlebar clamp M8 20 Nm (14.8 lbf ft) –
Screw, ignition lock (ratchet screw) M8 Loctite®243™
Screw, lower subframe M8 25 Nm (18.4 lbf ft) –
Screw, rear brake disc M8 30 Nm (22.1 lbf ft) Loctite®243™
Screw, rear footrest bracket
(Super Duke)
M8 25 Nm (18.4 lbf ft) Loctite®243™
Screw, shift lever M8 25 Nm (18.4 lbf ft) Loctite®243™
Screw, shift shaft relay lever M8 25 Nm (18.4 lbf ft) Loctite®243™
Screw, spring holder on side stand
bracket
M8 25 Nm (18.4 lbf ft) Loctite®243™
Screw, steering damper clamp
(Super Duke R)
M8 10 Nm (7.4 lbf ft) Loctite®243™
Screw, steering damper on clamp
(Super Duke R)
M8 10 Nm (7.4 lbf ft) Loctite®243™
Screw, steering damper pipe clamp
(Super Duke R)
M8 10 Nm (7.4 lbf ft) Loctite®243™
Screw, steering stem M8 20 Nm (14.8 lbf ft) –
Screw, top triple clamp M8 12 Nm (8.9 lbf ft) –
Screw, upper subframe M8 25 Nm (18.4 lbf ft) –
Remaining chassis nuts M10 50 Nm (36.9 lbf ft) –

TECHNICAL DATA - CHASSIS TIGHTENING TORQUES 12
Remaining frame bolts M10 45 Nm (33.2 lbf ft) –
Screw connection, engine mounting
bracket
M10 45 Nm (33.2 lbf ft) –
Screw, fuel tank holder M10 15 Nm (11.1 lbf ft) –
Screw, handlebar support (Super Duke) M10 20 Nm (14.8 lbf ft) –
Screw, handlebar support
(Super Duke R)
M10 45 Nm (33.2 lbf ft) –
Screw, side stand M10 35 Nm (25.8 lbf ft) Loctite®243™
Screw, side stand bracket M10 45 Nm (33.2 lbf ft) Loctite®243™
Screw, side stand holder M10 45 Nm (33.2 lbf ft) Loctite®243™
Rear sprocket bolt M10x1.25 50 Nm (36.9 lbf ft) Loctite®243™
Screw, front brake caliper M10x1.25 45 Nm (33.2 lbf ft) Loctite®243™
Oil drain plug with magnet M12x1.5 25 Nm (18.4 lbf ft) –
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
Lambda sensor M18x1.5 45 Nm (33.2 lbf ft) –
Nut, seat lock M19x1 8 Nm (5.9 lbf ft) –
Nut, swingarm pivot M19x1.5 130 Nm (95.9 lbf ft) Thread greased
Screw, steering head M20x1.5 12 Nm (8.9 lbf ft) –
Bolt, front axle M25x1.5 45 Nm (33.2 lbf ft) –
Nut, rear wheel spindle M25x1.5 90 Nm (66.4 lbf ft) Thread greased

SUBSTANCES 13
Super unleaded (ROZ 95/RON 95/PON 91)
According to
–DIN EN 228 (ROZ 95/RON 95/PON 91)
Guideline
–Only use unleaded super fuel that matches or is equivalent to the specified fuel grade.
–Fuel with an ethanol content of up to 10 % (E10 fuel) is safe to use.
Info
Do not use fuel containing methanol (e. g. M15, M85, M100) or more than 10 % ethanol (e. g. E15, E25, E85, E100).

*3211743en*
3211743en
KTM-Sportmotorcycle AG
5230 Mattighofen/Austria
http://www.ktm.com
03/2011
Photo: Mitterbauer