KTM 990 SUPER DUKE Manual

SETUP INSTRUCTIONS 2012
990 Super Duke FR
990 Super Duke R EU
990 Super Duke R FR
990 Super Duke R AUS/UK
Art. no. 3211887en

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.
© 2012 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

1 MEANS OF REPRESENTATION 2
1.1 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).
Indicates a page reference (more information is provided on the specified page).
Indicates information with more details or tips.
Indicates the result of a testing step.
Denotes a voltage measurement.
Denotes a current measurement.
Denotes a resistance measurement.
1.2 Formats used
The typographical formats used in this document are explained below.
Proprietary name Identifies a proprietary name.
Name®Identifies a protected name.
Brand™ Identifies a trademark.

2 SETUP 3
2.1 Unpacking 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 1of the scale on the handlebar must align with the edge 2
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 Ain bore B.

2 SETUP 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 Cin bore D.
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.

2 SETUP 5
101260-10
–Insert connector 3into the starter relay.
–Recharge the battery. ( p. 7)
101261-10
–Remove the seat. ( p. 6)
–Secure tool set 4with the rubber holder.
–Remove the protective film from the seat.
–Mount the seat. ( p. 6)
101262-01
–Carefully loosen and remove the tensioning belt over the swingarm.
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. 9)
–Refuel. ( p. 10)
–Print out the current PDI form found on KTM DEALER.NET and perform the delivery
inspection.
–Set kilometers or miles. ( p. 11)
–Set the clock. ( p. 11)

3 WORK 6
3.1 Removing the seat
B00165-10
–Insert the ignition key in the seat lock 1and turn it clockwise.
–Raise the rear of the seat, push it towards the rear, and remove it upwards.
3.2 Mounting the seat
B00188-10
–Hook the tabs 1of the seat onto the fuel tank, lower the rear and push forward.
The two hooks 2must engage in the subframe.
–Turn the ignition key counterclockwise in the seat lock and withdraw it.
–Finally, check that the seat is correctly mounted.
3.3 Removing 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.
Caution
Danger of accidents If the vehicle is operated with a discharged battery or without a battery, electronic components and safety
equipment may be damaged.
–Never operate the vehicle with a discharged battery or without a battery.
Preparatory work
–Switch off all power consumers and switch off the engine.
–Remove the front spoiler. ( p. 8)
B00191-10
Main work
–Remove the cable binder.
–Detach the connector from the start relay.
–Push the wiring harness to the side.
–Remove screws 1.
–Fold cover 2down.

3 WORK 7
B00192-10
–Disconnect negative cable 3of the battery.
–Disconnect the positive (plus) cable 4of the battery.
–Take the battery 5out of the battery compartment.
Info
Never operate the motorcycle with a discharged battery or without a battery.
In both cases, electrical components and safety equipment can be dam-
aged. The vehicle is then no longer safe to ride.
3.4 Installing the battery
B00192-11
Main work
–Position the battery in the battery compartment.
–Connect positive cable 1.
–Connect negative cable 2.
B00191-11
–Fold cover 3up.
–Mount and tighten screws 4.
–Attach the connector to the start relay.
–Position the wiring harness and fasten it with cable binders.
Finishing work
–Install the front spoiler. ( p. 9)
–Set the clock. ( p. 11)
3.5 Recharging 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.
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.

3 WORK 8
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.
Preparatory work
–Switch off all power consumers and switch off the engine.
–Remove the front spoiler. ( p. 8)
–Remove the battery. ( p. 6)
700588-01
Main work
–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 1.
Charge the battery at no more than 10% of the capacity specified on battery
housing 2.
–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
Finishing work
–Install the battery. ( p. 7)
–Install the front spoiler. ( p. 9)
–Set the clock. ( p. 11)
3.6 Removing the front spoiler
00
0
11
11
22
B00245-10
–Remove screws 1with the washer.
–Loosen screws 2and remove the front spoiler from the front.