KTM 990 Supermoto R USA 2010 User manual

OWNER'S MANUAL 2010
990 Supermoto R USA
990 Supermoto T USA
Art. no. 3211562en
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DEAR KTM CUSTOMER 1
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. 32) Dealer's stamp
Engine number ( p. 34)
Key number ( p. 33)
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.
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DEAR KTM CUSTOMER 2
© 2010 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
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TABLE OF CONTENTS 3
MEANS OF REPRESENTATION ............................................... 7
IMPORTANT INFORMATION ................................................... 8
Overview of labels (Supermoto T) ....................................... 12
Overview of labels (Supermoto R)....................................... 18
VIEW OF VEHICLE................................................................ 28
View of vehicle, front left side (vehicle differs slightly from
photo) ............................................................................. 28
View of vehicle, rear right side (vehicle differs slightly from
photo) ............................................................................. 30
LOCATION OF SERIAL NUMBERS ......................................... 32
Chassis number/type label................................................. 32
Key number ..................................................................... 33
Engine number................................................................. 34
Fork part number.............................................................. 34
Shock absorber part number.............................................. 35
CONTROLS.......................................................................... 36
Clutch lever ..................................................................... 36
Hand brake lever .............................................................. 36
Light switch ..................................................................... 37
Headlight flasher switch.................................................... 37
Turn signal switch ............................................................ 38
Horn button ..................................................................... 38
Ignition/steering lock ........................................................ 39
Immobilizer ..................................................................... 39
Emergency OFF switch...................................................... 40
Electric starter button ....................................................... 40
Combination instrument.................................................... 41
Combination instrument - function buttons ......................... 41
Combination instrument - tachometer................................. 42
Combination instrument - indicator lamps........................... 42
Combination instrument - display....................................... 43
Combination instrument - speedometer............................... 44
Setting kilometers or miles ................................................ 44
Combination instrument - time .......................................... 45
Setting the clock .............................................................. 46
Combination instrument - ODO display ............................... 46
Combination instrument - setting/resetting TRIP 1............... 47
Combination instrument - setting/resetting TRIP 2............... 47
Combination instrument - TRIP F display............................ 48
Combination instrument - ambient temperature display........ 49
Setting the temperature units ............................................ 49
Combination instrument - warning of slippery roads ............. 50
Combination instrument - coolant temperature indicator ...... 50
Opening the filler cap ....................................................... 51
Closing the filler cap......................................................... 51
Handrails......................................................................... 52
Seat lock ......................................................................... 52
Tool set ........................................................................... 53
Helmet lock ..................................................................... 53
Passenger footrests........................................................... 54
Shift lever........................................................................ 54
Foot brake lever................................................................ 55
Side stand ....................................................................... 56
TIPS ON PUTTING INTO OPERATION .................................... 57
Information on first use..................................................... 57
Running in the engine....................................................... 58
Loading the vehicle .......................................................... 58
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TABLE OF CONTENTS 4
RIDING INSTRUCTIONS ....................................................... 61
Checks before putting into operation .................................. 61
Starting ........................................................................... 62
Starting up ...................................................................... 63
Shifting, riding................................................................. 64
Braking ........................................................................... 67
Stopping, parking ............................................................. 68
Refueling......................................................................... 70
SERVICE SCHEDULE............................................................ 72
Service schedule .............................................................. 72
MAINTENANCE WORK ON FRAME AND ENGINE.................... 75
Jacking up motorcycle at the front ..................................... 75
Taking the front from the work stand .................................. 75
Jacking up motorcycle at the rear....................................... 76
Taking the rear from the workstand .................................... 76
Fork/shock absorber.......................................................... 77
Adjusting the compression damping of the fork ................... 77
Adjusting the rebound damping of the fork.......................... 79
Adjusting the spring preload of the fork .............................. 80
Bleeding the fork legs ....................................................... 81
Compression damping of the shock absorber ....................... 82
Adjusting the low-speed compression damping of the shock
absorber .......................................................................... 82
Adjusting the high-speed compression damping of the
shock absorber ................................................................. 84
Adjusting the rebound damping of the shock absorber.......... 85
Adjusting the spring preload of the shock absorber x......... 86
Checking the chain for dirt ................................................ 88
Cleaning the chain............................................................ 88
Checking the chain tension ............................................... 90
Adjusting the chain tension ............................................... 91
Checking the chain, rear sprocket and engine sprocket......... 93
Checking the front brake discs........................................... 95
Checking the rear brake disc.............................................. 96
Adjusting the basic position of the hand brake lever............. 97
Checking the free travel of the foot brake lever .................... 97
Checking the front brake fluid level .................................... 98
Adding front brake fluid x............................................... 99
Brake linings.................................................................. 100
Checking the front brake linings....................................... 100
Checking the rear brake fluid level ................................... 102
Adding rear brake fluid x.............................................. 102
Checking the rear brake linings........................................ 104
Removing the front wheel x........................................... 105
Installing the front wheel x............................................ 106
Removing the rear wheel x............................................ 108
Installing the rear wheel x............................................. 109
Checking rear hub shock absorbers x............................. 111
Checking the tire condition.............................................. 112
Checking the tire air pressure .......................................... 114
Removing the seat.......................................................... 115
Mounting the seat .......................................................... 115
Mounting the helmet lock on the vehicle........................... 116
Removing the battery x................................................. 116
Installing the battery x.................................................. 118
Recharging the battery x............................................... 119
Changing the main fuse .................................................. 121
Changing the fuses of individual power consumers............. 123
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TABLE OF CONTENTS 5
Changing the headlight bulb............................................ 125
Changing the parking light bulb ....................................... 128
Changing the turn signal bulb.......................................... 131
Changing the brake light bulb.......................................... 132
Changing the tail light bulbs............................................ 136
Changing the license plate lamp ...................................... 140
Checking the headlight setting......................................... 141
Adjusting headlight range................................................ 142
Activating/deactivating the ignition key............................. 143
Cooling system ............................................................... 146
Checking the antifreeze and coolant level ......................... 147
Checking the coolant level in the compensating tank ......... 149
Draining the coolant x.................................................. 150
Filling/bleeding the cooling system x.............................. 151
Reinstalling the fuel tank ................................................ 154
Positioning the fuel tank ................................................. 155
Removing the mask spoiler (Supermoto T) ........................ 157
Installing the mask spoiler (Supermoto T) ......................... 158
Adjusting the basic position of the clutch lever.................. 159
Checking/rectifying the fluid level of the hydraulic clutch ... 160
Checking the play in the throttle cable.............................. 161
Adjusting the play in the throttle cable x........................ 162
Checking the engine oil level ........................................... 162
Changing the engine oil and filter, cleaning the oil
screens x..................................................................... 163
Draining the engine oil and filter, cleaning the oil
screens x..................................................................... 164
Filling up with engine oil x............................................ 168
Adding engine oil ........................................................... 170
Ignition curve plug-in connector....................................... 171
Adjusting the ignition curve to the fuel quality................... 171
IMMOBILIZER BLINK CODE................................................ 173
ENGINE CONTROL BLINK CODE......................................... 175
TROUBLESHOOTING.......................................................... 181
CLEANING......................................................................... 184
Cleaning motorcycle ....................................................... 184
PROTECTIVE TREATMENT FOR WINTER OPERATION........... 186
Conserving for winter operation ........................................ 186
STORAGE .......................................................................... 187
Storage.......................................................................... 187
Putting into operation after storage .................................. 188
TECHNICAL DATA - ENGINE............................................... 189
Capacity- engine oil ........................................................ 190
Capacity - coolant........................................................... 190
TECHNICAL DATA - ENGINE TIGHTENING TORQUES........... 191
TECHNICAL DATA - CHASSIS ............................................. 195
Lighting equipment ........................................................ 196
Tires ............................................................................. 197
Capacity - fuel................................................................ 197
TECHNICAL DATA - FORK................................................... 198
Supermoto R.................................................................. 198
Supermoto T .................................................................. 199
TECHNICAL DATA - SHOCK ABSORBER .............................. 200
Supermoto R.................................................................. 200
Supermoto T .................................................................. 201
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ......... 203
SUBSTANCES.................................................................... 206
AUXILIARY SUBSTANCES................................................... 210
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TABLE OF CONTENTS 6
STANDARDS...................................................................... 212
INDEX ............................................................................... 213
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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.
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IMPORTANT INFORMATION 8
Use definition
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.
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.
Fuels, oils, etc.
The fuels and lubricants named in the owner's manual must be used according to specifications.
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