990 SUPER DUKE
990 SUPER DUKE
990 SUPER DUKE R
ART. NR. 3.211.151 EN
OWNER’S MANUAL 2007
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.
© 2006 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
PERIODIC MAINTENANCE 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
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 . . . . . . . . . . . . . . .83
Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
HEAD WORD INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
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 6 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.
OPERATION INSTRUMENTS »
10
1
2
FROST WARNING [1]
The frost symbol will start to blink regardless of the mode if the ambient temperature drops
below 3°C (37.5°F).
ODO [2]
Displays the total kilometers or miles traveled.
This figure will not be cleared if the battery is disconnected.
OPERATION INSTRUMENTS »
11
3
2
1
TRIP 1 [1]
The trip meter 1 is always active and counts up to 999.9. It is used to measure the length
of the trip or the distance between 2 refueling stops.
TO RESET TRIP 1
To reset the trip meter 1 to zero, switch on the ignition, select the TRIP 1 display mode and
press the SET button more than 2 seconds.
Press the MODE button to go to the next display mode.
TRIP 2 [2]
The trip meter 2 is always active and counts up to 999.9. It is used just like TRIP 1.
TO RESET TRIP 2
To reset the trip meter 2 to zero, switch on the ignition, select the TRIP 2 display mode and
press the SET button more than 2 seconds.
Press the MODE button to go to the next display mode.
TRIP F [3]
When the fuel level reaches the reserve mark, the display will automatically switch to TRIP
F and begin to count (no matter which display mode was active before). At the same time,
the fuel warning lamp will light up. You will still have enough reserve fuel for at least 30
kilometers.
After refueling, it will take approx. 3 minutes for the fuel lamp to go out, TRIP F to auto-
matically reset to 0 and to return to the previous display mode.
NOTE:
Press the SET button for 2 seconds to switch off the fuel warning lamp.
Tachometer
The tachometer [3] shows the engine speed in revolutions per minute. Do not run the engine
beyond the orange mark at 9500 rpm.
The speed limiter will set in at 9600 rpm, drastically reducing the engine power above this
rotational speed.
Cooling liquid temperature display
The temperature display [1] is shown in 12 bars. The more bars that light up, the hotter the
cooling liquid. When the upper bar lights up 120°C (248°F), all of the bars will start to blink
and the red warning lamp [2] will light up.
Possible causes for an increase in temperature, causing the red warning light for the cool-
ing liquid temperature to light up:
– Driving too slowly and driving with a heavy load at high air temperatures
– Not enough cooling liquid in the system
– The ventilator on the left radiator is not running
– Improper use of the clutch when driving slowly
OPERATION INSTRUMENTS »
12
1
2
3
heiß/hot/caldo/chaud/caliente
normal
normally
normalemente
normalment
normalmente
kalt / cold / freddo / froid / frío
Indicator lamps
The green indicator lamp will blink in the blinker rhythm when the blinker is
switched on.
NOTE: The indicator lamp will blink slower when a blinker is broken.
The green indicator lamp will light up when the gearbox is in an idling position.
The blue indicator lamp will light up when the high beams are switched on.
The red warning light will light up when the cooling liquid has reached a tempera-
ture of approx. 120°C (248°F).
The orange warning lamp will light up when the fuel level has reached the reserve mark.
At the same time the display will automatically change to TRIP F (see TRIP F).
The red warning lamp lights up when the ignition is switched on but the engine is
not running. When the engine is started, the warning lamp will go out as soon as the
oil pressure is high enough.
The orange warning lamp (fuel injection) briefly lights up when the ignition is switched
on. It will go out when the gasoline pressure is high enough.
If this warning lamp lights up while driving, a component in the injection system is
defective. The error can be identified by means of a blink code (see Trouble shoot-
ing).
The red warning lamp will light up if the voltage in the on-board electrics drops below
10 volts. Immediately drive to the nearest authorized KTM workshop and have the
electrical system checked.
OPERATION INSTRUMENTS »
13
Ignition lock
The ignition lock has 3 switching positions.
Ignition off, (engine can't be started)
Ignition on, (engine can be started)
Ignition off, handlebar blocked
To switch the ignition to position turn the ignition key to position and firmly press it
into the lock. Turn the handlebar to the left, then turn the ignition key to the left.
The ignition key can be withdrawn in position and .
Combination switch
The rocker switch LIGHTS [1] actuates the high beam or low beam.
High-beam light
Low-beam light
The light signal (high beam) is actuated with button [2].
The indicator switch [3] returns to central position after actuation. Press flasher
switch towards switch housing to switch off the flasher.
The horn is sounded with button [4].
OPERATION INSTRUMENTS »
14
2
1
1
3
4
Starter tip switch, Emergency OFF tip switch
The emergency off switch [1] is provided for emergency situations and should not be used
to switch off the engine.
The engine is ready for operation in position (ignition circuit and starter circuit are switched
on).
The engine cannot be started in position (ignition circuit and starter circuit are inter-
rupted).
Use the starter tip switch [3] to operate the electric starter.
Filler cap
The filler cap [4] can be locked. It is equipped with a tank ventilation system.
To open, insert the ignition key, turn 45° in a clockwise direction and tilt the filler cap back.
After refueling, pull out the ignition key and press down on the filler cap until the lock engages.
OPERATION INSTRUMENTS »
15
4
1
3
Seat lock, removing the seat
The seat lock [1] can be locked with the ignition key.
To remove the seat, insert the ignition key and turn 90° in a clockwise direction. Lift the
seat in the back while pressing near the holding strap and pull off towards the back.
To mount the seat, place it on the motorcycle and position the hooks [2] on the bottom of
the seat behind the dollies [3] on the subframe. Press down on the seat near the holding
strap while sliding it forwards. The two tabs [4] must hook onto the tank. Turn the ignition
key in the seat lock 90° in a counterclockwise direction and pull off. Check whether the seat
is mounted correctly.
Baggage loops
4 loops [5] are mounted on the bottom of the seat to which small pieces of baggage can be
fastened. Fold the loops towards the outside to make them accessible when the seat is mounted.
Baggage weight: max. 5 kg
OPERATION INSTRUMENTS »
16
1
2
4
3
5
5
Tool set
The tool set [1] is located in the storage compartment under the seat.
Helmet lock
The steel rope [2] in the tool bag can be used to secure a helmet.
To secure, remove the seat, run the rope through the helmet, attach both ends to the hook
[3] and mount the seat.
The helmet lock is provided to secure the helmet to the motorcycle when parked. Do not
attach the helmet or other objects to the steel rope while driving. You can easily lose con-
trol of the motorcycle.
Holding strap
The passenger should hold on to the holding strap [4] or the driver while riding.
OPERATION INSTRUMENTS »
17
1
3
2
4
Shift lever
The shift lever is mounted on the left side of the engine. The position of the gears is shown
in the illustration. Neutral, or the idle speed, is located between first and second gear.
The basic position of the shift lever can be adjusted according to your seating position (see
Maintenance work).
Side stand
Fold the side stand [1] forward to the stop with your foot and put the weight of the motor-
cycle on the stand. Make sure it is standing securely on a firm surface. The side stand is
linked to the safety start system; follow the driving instructions.
Foot brake pedal
The foot brake pedal [2] is located in front of the right footrest. Its basic position can be
adjusted to your seat position.
OPERATION INSTRUMENTS »
18
1
N
2,3,4,5,6
1
2
Footrests
The passenger footrests [1] fold up.
Compression damping of fork
The fork's damping action during compression travel (compression damping) can be adjusted.
This allows you adjust the damping behavior to match your driving style and the payload.
The adjusting screws [2] are located on the fork leg axle passage.
More information is provided in the chapter „Adjusting the fork and shock absorber“.
Rebound damping of fork
The fork's damping action during rebound travel (rebound damping) can also be adjusted.
This allows you adjust the damping behavior to match your driving style and the payload.
The adjusting screws [3] are located on the upper end of the fork legs.
More information is provided in the chapter "Adjusting the fork and shock absorber.“
OPERATION INSTRUMENTS »
19
1
3
2
Spring preload of the fork
The fork's preload can be adjusted by means of the adjusting screws [1].
More information is provided in the chapter „Adjusting the fork and shock absorber“.
Damping action during compression of shock absorber
The shock absorber's damping action during compression travel (compression damping) can
be adjusted. This allows you adjust the shock absorber's damping behavior to match your
driving style and the payload.
The damping rate can be adjusted in the low and high-speed range (Dual Compression Control).
The designation low and high-speed refers to the movement of the shock absorber and not
to the motorcycle's driving speed.
The adjusting screw [2] for the low-speed range can be adjusted with a screwdriver.
The adjusting screw [3] for the high-speed range can be adjusted with a 17 mm socket wrench.
More information is provided in the chapter „Adjusting the fork and shock absorber“.
OPERATION INSTRUMENTS »
20
1
2
3
Rebound damping of shock absorber
The shock absorber's damping action during rebound travel (rebound damping) can also be
adjusted. This allows you adjust the damping behavior to match your driving style and the
payload.
The adjusting screw [1] is located on the bottom of the shock absorber.
More information is provided in the chapter "Adjusting the fork and shock absorber.“
OPERATION INSTRUMENTS »
21
1
Instructions for initial operation
– Make sure the work for the „pre-delivery
inspection“ was performed by your author-
ized KTM workshop. The DELIVERY CER-
TIFICATE and SERVICE MANUAL will
be handed over when you pick up your
vehicle.
– Read these operating instructions care-
fully before your first ride.
– Enter the chassis, engine and key num-
bers on page 1.
– Familiarize yourself with the operating
elements.
– Adjust the clutch lever, the hand brake
lever, the foot brake lever and the shift
lever in the position that is most conven-
ient for you.
– This motorcycle is equipped with a three-
way catalytic converter. Leaded fuel will
destroy the converter. Always use unleaded
fuel.
– Get used to handling the motorcycle on
an empty parking lot, before starting on
a longer drive. Also try to drive as slowly
as possible and in standing position, to
improve your feeling for the vehicle.
– You may only be accompanied by a pas-
senger if your motorcycle is fitted and reg-
istered for such purposes. The passenger
must hold on to the supporting strap or
the driver and keep his feet on the pas-
senger footrests throughout the ride.
–
Hold the handlebars with both hands
and leave your feet on the foot rests while
driving.
– Remove your foot from the foot brake
lever when you are not braking. If the foot
brake lever is not released the brake pads
rub continuously and the braking system
is overheated.
– Do not make any alterations to the motor-
cycle and always use ORIGINAL KTM
SPARE PARTS. Spare parts from other
manufacturers can impair the safety of
the motorcycle.
– New tires have a smooth surface, which
means that they must be run in to achieve
full grip. For this purpose, ride the motor-
cycle carefully at moderate speed during
the first 200 kilometers with new tires,
tilting the vehicle at different angles so
that all sections are properly roughened.
Tires will not display their full grip char-
acteristics until they are properly run in.
– Motorcycles are sensitive to changes in
the weight distribution. Read the section
on „Accessories and payload“ when car-
rying luggage.
– Pay attention to running-in procedure.
Running in the LC8 engine
Even finely machined surfaces of engine
parts have rougher surfaces than parts that
slide on each other for a long time. Therefore,
every engine must be run in. For this reason,
do not demand maximum performance from
the engine for the first 1000 kilometers (620
miles). The vehicle must be run in at low,
changing performance level for the first 1000
km (620 miles). The maximum number of
revolutions per minute must not go exceed
6500 rpm. Once you have run your engine
in for 1000 km, you may push it to its 9500
rpm limit , i.e. up to the orange zone indi-
cated in the tachometer. Exceeding the above
listed rotations as well as pushing high rpm
when the engine is cold will have an adverse
effect on the life of your engine.
– Wear suitable clothing when driving a
motorcycle. Clever KTM drivers always
wear a helmet, boots, gloves and a jacket,
regardless of whether driving all day or
just for a short trip. The protective cloth-
ing should be brightly colored so that
other vehicle can see you as early as
possible. Your passenger will also need
suitable protective clothing.
– Do not drive after having consumed
alcohol.
– Always turn on the light to make sure
that other drivers become aware of you
as early as possible.
– Drive at a moderate speed for the first few
kilometers of each trip to allow the tires
to reach the necessary operating temper-
ature. Maximum road grip is assured when
the tires are warm.
– The front and rear wheel are allowed to
be fitted only with tires that have the
same profile type.
GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE »
22
– The tires must be designed for a speed
of over 240 KPH (speed symbol ZR) and
must be released by KTM.
– New tires have a smooth surface, which
means that they must be run in to achieve
full grip. For this purpose, ride the motor-
cycle carefully at moderate speed during
the first 200 kilometers with new tires,
tilting the vehicle at different angles so
that all sections are properly roughened.
Tires will not display their full grip char-
acteristics until they are properly run in.
– Wheels with a different rim diameter or
other rim width may not be mounted oth-
erwise the vehicle handling will no longer
be safe.
– Observe the traffic regulations, drive
defensively and trying to look ahead as
far as possible so that any hazards can
be recognized as early as possible.
– The faster you drive, the more sensitive
your motorcycle will be to crosswind and
changing road conditions. Your motorcy-
cle can easily go out of control at high
speeds.
– Choose your driving speed according to
the conditions and your driving skills.
– Drive carefully on unknown roads or on
unfamiliar trials.
– Renew the vizor on your helmet on time
so as to ensure optimum vision in any sit-
uation. When light shines directly on
scratched visor, the operator will be
blinded.
– You may only be accompanied by a pas-
senger if your motorcycle is fitted and reg-
istered for such purposes.
– Never leave your motorcycle without super-
vision if the engine is running.
Accessories and payload
Accessory parts and baggage can signifi-
cantly decrease a motorcycle's driving stabil-
ity. Please observe the following warnings.
– Never drive faster than 130 kph (80 mph)
if you have mounted accessory parts on
your motorcycle. Accessory parts can sig-
nificantly impair the motorcycle's han-
dling, especially in the maximum speed
range.
– Never drive faster than 130 kph (80 mph)
if your motorcycle is loaded with cases
or other baggage. They will impair the
motorcycle's handling at higher speeds and
can easily cause it to go out of control
– If you have cases mounted, do not exceed
the manufacturer's recommended maxi-
mum payload.
– Four loops are provided on the bottom of
the seat to attach your luggage. Make
sure your luggage does not extend beyond
the silencer, otherwise it may become
singed from the heat.
– Make sure your luggage does not cover
the tail light.
– Baggage must be securely and adequately
fastenend; loose baggage will significantly
impair driving safety.
– A high payload will change the motorcy-
cle's handling and considerably increase
the braking distance; adapt your driving
speed accordingly.
– Never exceed the maximum permissible
laden weight and the axle weights. The
maximum permissible laden weight is
made up of the following components:
– Motorcycle ready for operation and tank
full
– Luggage
– Driver and passenger with protective
clothing and helmet
GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE »
23
Check the following before each start
When you start, the motorcycle must be in perfect mechanical condition. For safety reasons,
you should make a habit of performing an overall check of your motorcycle before each start.
The following checks should be performed:
1 FUEL
Check the fuel quantity in the tanks.
2 CHAIN
Check the tension and condition of the chain.
A loose chain can fall off the sprockets and a worn-out chain can tear. In both cases this
can damage other motorcycle components and cause the motorcycle to go out of con-
trol. A chain that is too tight or not greased will cause unnecessary wear to the chain
and sprockets.
3 TIRES
Check for damaged tires. Tires showing cuts or dents must be replaced. The tread depth
must comply with the legal regulations. Also check the air pressure. Insufficient tread
and incorrect air pressure deteriorate the driving performance.
4 BRAKES
Check correct functioning of the braking system. Check for sufficient brake fluid in the
reservoir. The reservoirs have been designed in such a way that brake fluid does not need
to be refilled even when the brake pads are worn. If the level of brake fluid falls below
the minimum value, this indicates a leak in the braking system or completely worn out
brake pads. Arrange for the braking system to be checked by a KTM specialist, as com-
plete failure of the braking system can be avoided.
Also check the state of the brake hose and the thickness of the brake linings.
Check free travel at hand brake lever and foot brake lever.
5 CABLES
Check the throttle cable for correct adjustment and smooth operation.
DRIVING INSTRUCTIONS »
24
6 COOLING FLUID
Check the level of cooling fluid when the engine is cold.
7 ELECTRICAL SYSTEM
Start the engine and check the headlight, tail lamp, brake light, turn signals, indicator
lamps, horn and emergency-off switch for proper functioning.
8 CHECK OIL LEVEL
Insufficient oil results in premature wear and consequently to engine damage.
9 BAGGAGE, PAYLOAD
Never exceed the maximum total weight (387 kg, 853 lbs) and the motorcycle's wheel
loads. The maximum total weight is comprised of:
– the motorcycle in a running condition and refueled (199 kg, 439 lbs)
– the baggage and accessories
– the driver and passenger with protective gear and helmet
Adjust the tire inflation pressure as well as the preload and damping properties of the
fork and shock absorber to the total weight.
Make sure your luggage is correctly fastened before you drive off.
10 REAR MIRROR
Sit on the motorcycle and check the adjustment of the rear mirror.
DRIVING INSTRUCTIONS »
25
Starting the engine
1 Switch on emergency OFF switch [1].
2 Switch on ignition (turn ignition key [2] into position ).
NOTE:
You will hear the operation of the fuel pump for approx. 2 seconds after switching on
the ignition. The FI indicator lamp will also light up during this time and the engine can-
not be started.
3 Switch transmission to idle (green indicator lamp N [3] lights up).
4 Do not accelerate; operate starter button [5].
NOTE:
If you accelerate during the starting process you will hear a loud, metallic
sound caused by the torque limiter. The torque limiter protects the
components in the starter drive from being damaged.
5 The oil pressure warning lamp [4] should go out as soon as the engine is running.
6 Take the load off the side stand and fold the side stand all the way up.
– Do not start the engine and allow it to idle in a closed room. Exhaust fumes are poison-
ous and can cause loss of consciousness and death. Always provide adequate ventila-
tion while the engine is running.
– Never operate the motorcycle with a run-down battery or without the battery. This can
damage the electronic components or safety equipment in either caseand the motorcy-
cle will no longer be roadworthy.
– If you accelerate while starting, the engine management will not inject any fuel and the
engine will not start. Do not accelerate while starting!
– If the oil pressure warning lamp does not go out as soon as the engine is running, imme-
diately switch off the engine. If the engine is not switched off, engine damage will occur
within a short period of time. Check the engine oil level or contact a ktm workshop.
– Maximum period for continuous starting: 5 seconds. Wait at least 5 seconds before try-
ing again.
– Don’t ride your motorcycle with full load and don’t rev engine when cold. Because the
piston is warming up faster than the water cooled cylinder, it can cause engine damage.
Always let the engine warm up before and refrain from driving with full load until the
engine is warm.
DRIVING INSTRUCTIONS »
26
1
3
4
2
5
IF THE ENGINE IS DOES NOT CRANK WHEN
YOU ACTUATE THE STARTER TIP SWITCH:
– whether you accelerated while starting
– the transmission is switched to idle
– Check if the emergency OFF switch is on
– Check if the ignition is on
– the headlight is on
– If this is not the case, the battery is dis-
charged
– If the lights are on, proceed as described
in the „Trouble-shooting“ section or
contact a KTM dealer.
IF THE ENGINE CRANKS BUT DOES NOT
START, WHEN YOU ACTUATE THE STARTER
TIP SWITCH:
– whether you accelerated while starting
– whether the FI indicator lamp is blinking
– if yes, check Troubleshooting - Blink
codes table
– Check if sufficient fuel is in the tank
– If this is not the case, refill the tank
– if sufficient fuel is in the tank, pro-
ceed as described in the „Trouble-
shooting“ section or contact a KTM
dealer.
NOTE:
This motorcycle is equipped with a safety start-
ing system. The engine can only be started
if the transmission is in neutral or the clutch
lever is pulled. If the side stand is folded down,
the engine can only be started if the trans-
mission is in neutral or the clutch lever is
pulled. The engine will stall if a gear is
engaged and the clutch lever is released with
the side stand folded down.
Starting off
Pull the clutch lever and engage 1st gear.
Slowly release the clutch lever while you gen-
tly accelerate.
Do not attach a helmet or other objects to
the helmet lock rope while driving. You can
easily lose control of the motorcycle.
Shifting/Riding
You are now in first gear, refered to as the
drive or uphill gear. Depending on the con-
ditions (traffic, road gradient, etc.), you can
shift to a higher gear. Close throttle, at the
same time pull clutch lever and shift to the
next higher gear. Let clutch lever go again
and carefully open throttle. Do not shift gears
and accelerate carefully in curves.
Only accelerate to the extent that road and
weather conditions allow. Be especially care-
ful when you accelerate in curves. Abrupt
opening of the throttle can cause the motor-
cycle to go out of control and also increases
fuel consumption.
By shifting down, use the brakes if neces-
sary and close throttle at the same time. Pull
clutch lever and shift down to the next gear.
Let clutch lever go slowely and open throt-
tle or shift down again.
If the engine is killed f.ex. at a crossing, sim-
ply pull the clutch lever and start. It is not
necessary to switch the gear to NEUTRAL.
Stop immediately if the FI indicator lamp lights
up while driving. The FI indicator lamp will
start blinking as soon as the transmission is
in neutral. The rhythm of the blinking lamp
will let you determine the two-digit „blink
code“, e.g.:
Blink code 34: FI blinks 3x long, 4x short,
pause,
Blink code 06: FI blinks 6x short, pause
The blink code will indicate which compo-
nent is defective (see Troubleshooting). This
makes it possible to pinpoint the defect if a
diagnostic tool is unavailable.
– Avoid abrupt load changes while riding
around bends and on wet or slippery
ground. Otherwise you might easily lose
control over your motorcycle.
DRIVING INSTRUCTIONS »
27
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