KTM 990 Adventure 2009 Owner's manual

Congratulations on your decision to buy 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 riding this vehicle!

Please enter the serial numbers of your vehicle below.

Chassis number ( p. 16) Dealer's stamp

Engine number ( p. 17)

Key number ( p. 17)

The owner's manual corresponded to the latest state of this series at the time of printing. Slight deviations resulting from continuing development and design of our motorcycles cannot, however, be completely excluded.

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 belong to the regular scope of delivery.

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 ............................................... 7

IMPORTANT NOTES............................................................... 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................................................................ 16

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

Immobilizer ..................................................................... 22

Emergency OFF switch...................................................... 23

Electric starter button ....................................................... 23

Combination instrument.................................................... 24

Combination instrument - function buttons ......................... 24

Combination instrument - tachometer................................. 25

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 .............................................................. 29

Combination instrument - display ODO ............................... 29

Combination instrument - setting/resetting TRIP 1............... 30

Combination instrument - setting/resetting TRIP 2............... 30

Combination instrument - TRIP F display............................ 31

Combination instrument - ambient temperature display........ 32

Setting the temperature unit of measure............................. 32

Combination instrument - warning of slippery roads............. 33

Combination instrument - coolant temperature indicator ...... 33

Socket for electrical accessories......................................... 34

Hazard warning flasher switch/hazard warning flasher .......... 34

Opening the filler caps...................................................... 35

Closing the filler caps ....................................................... 35

Seat lock ......................................................................... 36

Unlocking the storage compartment ................................... 36

Locking the storage compartment....................................... 37

Opening the storage compartment...................................... 37

Closing the storage compartment ....................................... 38

Handrails......................................................................... 38

Luggage rack plate ........................................................... 39

Fuel taps ......................................................................... 39

Foot brake pedal .............................................................. 40

Shift lever........................................................................ 40

Side stand ....................................................................... 41

Center stand .................................................................... 42

Passenger footrests........................................................... 42

Tool set ........................................................................... 43

GENERAL TIPS AND HINTS ON PUTTING INTO

OPERATION......................................................................... 44

Information on first use..................................................... 44

Running in the engine....................................................... 45

Loading the vehicle .......................................................... 46

RIDING INSTRUCTIONS....................................................... 48

Checks before putting into operation .................................. 48

Starting ........................................................................... 49

Starting up ...................................................................... 51

Shifting, riding................................................................. 51

Braking ........................................................................... 55

Stopping, parking............................................................. 57

Refueling......................................................................... 59

SERVICE SCHEDULE............................................................ 62

Important service tasks to be carried out by an authorized

KTM workshop ................................................................. 62

Important service tasks to be carried out by an authorized

KTM workshop (as an additional order) ............................... 65

MAINTENANCE WORK ON CHASSIS AND ENGINE................. 66

Jacking up the vehicle on the center stand.......................... 66

Raising the vehicle off of the center stand .......................... 67

Removing the seat ............................................................ 67

Mounting the seat ............................................................ 68

Fork/shock absorber.......................................................... 68

Adjusting the compression damping of the fork ................... 69

Adjusting the rebound damping of the fork.......................... 70

Adjusting the spring preload of the fork .............................. 71

Compression damping of the shock absorber....................... 72

Adjusting the low-speed compression damping of the shock

absorber .......................................................................... 72

Adjusting the high-speed compression damping of the

shock absorber................................................................. 74

Adjusting the rebound damping of the shock absorber.......... 75

Adjusting the spring preload of the shock absorber .............. 77

Bleeding the fork legs ....................................................... 78

Cleaning the dust boots of the fork legs .............................. 78

Checking for chain dirt...................................................... 79

Cleaning the chain............................................................ 80

Checking the chain tension ............................................... 81

Adjusting the chain tension ............................................... 82

Checking the rear sprocket/engine sprocket for wear ............ 84

Checking chain wear......................................................... 85

ABS / antilock brake system (990 Adventure)...................... 86

Checking the brake discs................................................... 87

Checking the free travel of the hand brake lever .................. 88

Adjusting the free travel of the handbrake lever ................... 88

Checking the brake fluid level of the front brake.................. 89

Adding front brake fluid x............................................... 90

Checking the front brake linings......................................... 92

Checking the free travel of the foot brake lever .................... 92

Checking the rear brake fluid level ..................................... 93

Adding rear brake fluid x ................................................ 94

Checking the rear brake linings.......................................... 96

Removing the front wheel x............................................. 97

Installing the front wheel x.............................................. 99

Removing the rear wheel x............................................ 101

Installing the rear wheel x............................................. 103

Checking the rear hub rubber dampers x........................ 105

Checking the tire condition.............................................. 106

Checking the tire air pressure .......................................... 107

Checking spoke tension................................................... 108

Removing the underride guard x.................................... 109

Installing the underride guard x..................................... 110

Removing the battery x................................................. 110

Installing the battery x.................................................. 112

Recharging the battery x............................................... 113

Removing the right underride guard.................................. 116

Installing the right underride guard .................................. 116

Changing the main fuse .................................................. 117

Changing the ABS fuses (990 Adventure) ......................... 119

Changing the fuses in the fuse box................................... 120

Removing the front side cover.......................................... 123

Installing the front side cover .......................................... 123

Removing the headlight mask with the headlight ............... 124

Installing the headlight mask with the headlight................ 125

Changing the high beam bulb.......................................... 125

Changing the low beam bulb............................................ 126

Changing the parking light bulb in the headlight................ 127

Changing the turn signal bulb.......................................... 128

Changing the tail light bulb ............................................. 129

Changing the brake light bulb.......................................... 130

Checking the headlamp setting........................................ 131

Adjusting the headlight range .......................................... 132

Activating/deactivating the ignition key............................. 132

Removing the storage compartment and hanging it to one

side x.......................................................................... 135

Installing the storage compartment x ............................. 136

Removing the left fuel tank x ........................................ 137

Installing the left fuel tank x......................................... 138

Cooling system............................................................... 140

Checking the coolant level in the compensating tank ......... 141

Checking the coolant level in the radiator.......................... 143

Checking the antifreeze x.............................................. 144

Draining the coolant x .................................................. 145

Filling/bleeding the cooling system x.............................. 147

Removing the radiator guard............................................ 149

Installing the radiator guard............................................. 150

Adjusting the basic setting of the clutch lever ................... 151

Checking/rectifying the fluid level of the hydraulic clutch ... 151

Checking the play in the gas Bowden cable....................... 152

Adjusting the play in the gas Bowden cable x.................. 153

Checking the engine oil level ........................................... 153

Changing the engine oil and filter, cleaning the oil

screens x..................................................................... 154

Draining engine oil, cleaning oil screens x...................... 154

Removing the oil filter x................................................ 158

Installing the oil filter x................................................ 159

Filling up with engine oil x............................................ 159

Adding engine oil ........................................................... 161

Ignition curve plug-in connector....................................... 162

Adjusting the ignition curve to the fuel quality................... 162

IMMOBILIZER FLASH CODE ............................................... 164

ENGINE CONTROL FLASH CODE......................................... 166

TROUBLESHOOTING.......................................................... 172

CLEANING......................................................................... 175

Cleaning motorcycle ....................................................... 175

CONSERVING FOR WINTER OPERATION............................. 177

Conserving for winter operation........................................ 177

STORAGE .......................................................................... 178

Storage.......................................................................... 178

Putting into operation after storage .................................. 179

TECHNICAL DATA - ENGINE............................................... 180

Capacity- engine oil ........................................................ 181

Capacity - coolant........................................................... 181

TECHNICAL DATA - ENGINE TIGHTENING TORQUES........... 182

TECHNICAL DATA - CHASSIS ............................................. 185

Lighting equipment ........................................................ 187

Tires ............................................................................. 188

Capacity - fuel................................................................ 188

TECHNICAL DATA - FORK................................................... 189

990 Adventure............................................................... 189

990 Adventure R............................................................ 190

TECHNICAL DATA - SHOCK ABSORBER .............................. 192

990 Adventure............................................................... 192

990 Adventure R............................................................ 193

TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ......... 195

SUBSTANCES.................................................................... 198

AUXILIARY SUBSTANCES................................................... 202

STANDARDS...................................................................... 204

INDEX ............................................................................... 205

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 in an authorized KTM workshop! There, your motorcycle will be serviced optimally by specially trained experts using the specialist tools required.

Identifies a page reference (more information is provided on the specified page).

The typographical formats used in this document are explained below.

Identifies a proprietary name.

Identifies a protected name.

Identifies a trademark.

KTM sport motorcycles are designed and constructed to meet the normal demands of regular road and light offroad operation (dirt roads), but not for use on race courses.

The motorcycle is authorized for public road traffic in the homologous version only.

A prerequisite for fault-free operation and avoiding premature wear is compliance with the maintenance, care and adjustments to the engine and chassis described 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 service 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.

The work prescribed in the service schedule must be carried out in an authorized KTM workshop only and confirmed in the customer's service 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.

The fuels and lubricants named in the owner's manual must be used according to specifications.

For your own safety, only use spare parts and accessory products that have been approved and/or recommended by KTM and have them installed by an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage. Some of the spare parts and accessory products are specified in parentheses under the respective descriptions. Your KTM dealer will be glad to advise you.

You will find the current

for your vehicle on the KTM website.

International KTM Website: http://www.ktm.com

Special tools are necessary for some of the work. These are not included with the vehicle and can be ordered under the number in parentheses. Ex: valve spring mounter (59029019000) During assembly, non-reusable parts (e.g. self-locking screws and nuts, seals and seal rings, O-rings, pins, lock washers) must be replaced by new parts. If a thread lock (e.g. ) is used for screw connections, be sure to comply with the manufacturer's specific instructions on its usage. Parts that you want to reuse following repairs and servicing should be cleaned and checked for damage and wear. Change damaged or worn parts. Following repairs or servicing, the vehicle must be checked for roadworthiness.

The parked vehicle can roll away or fall over.

– Always place the vehicle on a firm and even surface.

Some vehicle components get very hot when the machine is driven.

– Do not place the vehicle where there are flammable or explosive substances. Do not place objects over the vehicle while it is still warm

from being run. Always let the vehicle cool first.

– Switch off the engine and remove the ignition key. – Secure the motorcycle against falling over or rolling away using straps or other suitable devices.

Motorcycling is a wonderful sport and we naturally hope that you can enjoy it to the full. However, it can also lead to problems with the environment and conflict with other persons. Responsible behavior in handling the motorcycle can help to avoid such problems and conflicts. To protect the future of motorcycle sport, make sure that you use your motorcycle legally, display environmental consciousness, and respect the rights of others.

Pay close attention to the notes/warnings.

Various information and warning labels are affixed to the vehicle. Do not remove information/warning labels. If they are missing, you or others may not recognize sources of danger and may therefore be injured.

Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken.

Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.

Identifies a danger that may lead to minor injuries if the appropriate measures are not taken.

Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.

Identifies a danger that will lead to environmental damage if the appropriate measures are not taken.

– Be sure to read this owner's manual carefully and completely before taking your first ride. It contains useful information and tips to

help you operate and handle your motorcycle. Only then will you find out how to best customize the motorcycle for your own use and how you can protect yourself from injury. The owner's manual also contains important information on servicing the motorcycle.

– The owner's manual is an important component of the motorcycle and should be handed over to the new owner if the vehicle is sold.

100540-10

1 Clutch lever 2 Seat 3 Seat lock 4 Luggage rack plate 5 Handrail 6 Front brake caliper 7 Underride guard 8 Side stand 9 Shift lever 10 Footrest 11 Center stand 12 Passenger footrest

100541-10

1 Storage compartment 2 Light switch, turn signal switch, horn button, headlight flasher switch 3 Hazard warning flasher switch 4 Accessories socket 5 Emergency OFF switch, electric starter button 6 Hand brake lever 7 Filler cap 8 Rear brake caliper 9 Foot brake pedal 10 Oil dipstick 11 Cooling system compensating tank

100542-10

The chassis number  is stamped on the right side of the steering head. The chassis number is also found on the type label.

100543-10

The type label  is located on the right frame tube in the vicinity of the oil tank.

700222-01

The key number  can be found on the .

You need the key number to order a spare key. Keep the in a safe place. Use the orange programming key to activate and deactivate the black ignition key. Keep the orange programming key in a safe place: it must only be used for learning and programming functions.

100544-10

The engine number  is stamped on the left side of the engine under the engine sprocket.

100545-10

The fork part number  is stamped on the inner side of the fork stub.

100546-10

The shock absorber part number  is stamped on the upper part of the shock absorber.

100505-10

The clutch lever  is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting.

100506-10

The hand brake lever  is fitted on the right side of the handlebar. The front brake is engaged using the hand brake lever.

100507-10

The light switch  is fitted on the left side of the handlebar.

Low beam on – The light switch is turned downwards. In this position, the low beam and tail light are switched on.

High beam on – The light switch is turned upwards. In this position, the high beam and tail light are switched on.

100508-10

The headlight flasher switch  is fitted on the left side of the handlebar.

• Headlight flasher switch in neutral position

• Headlight flasher switch pressed – The headlight flasher switch (high beam) is operated in this position.

100509-10

The turn signal switch  is fitted on the left side of the handlebar.

Turn signal off Turn signal, left, on – The turn signal switch is pressed to the left. The turn

signal switch automatically returns to the central position after use.

Turn signal, right, on – The turn signal switch is pressed to the right. The turn signal switch automatically returns to the central position after use.

To switch off the turn signal, press the turn signal switch towards the switch case.

100510-10

The horn button  is fitted on the left side of the handlebar.

• Horn button in neutral position

• Horn button

pressed – The horn is operated in this position.

100511-10

The ignition/steering lock  is in front of the upper triple clamp.

The ignition may only be switched on using a black ignition key. Use the orange programming key to activate and deactivate the black ignition key.

Ignition – In this position, the ignition circuit is interrupted, a running engine stops, and a non-running engine will not start. The black ignition key can be removed.

Ignition – In this position, the ignition circuit is closed and the engine can be started.

Steering locked – In this position, the ignition circuit is interrupted and the steering locked. The black ignition key can be removed.

100501-10

The electronic immobilizer secures the vehicle against unauthorized use. The immobilizer is activated automatically and the engine electronics are locked when the ignition key is withdrawn. The red warning lamp

flashes at 15 second intervals after one minute.

The red warning lamp can also indicate errors by flashing.

The ignition key contains electronic components. Never attach multiple ignition keys to a single key ring; this may cause mutual interference and lead to problems.

A lost black ignition key must be deactivated to prevent unauthorized persons from operating the vehicle. The second black ignition key is activated when the vehicle is shipped. Two additional spare ignition keys (key number on the ) can be ordered from an authorized KTM workshop, but they must be activated before use.

100547-10

The emergency OFF switch  is fitted on the right side of the handlebar.

Emergency OFF switch off – In this position, the ignition circuit is interrupted, a running engine stops, and the engine cannot be started.

Emergency OFF switch on – This position is necessary for operation as it closes the ignition circuit.

100548-10

The electric starter button  is fitted on the right side of the handlebar.

• Electric starter button in basic position

• Electric starter button

is pressed – The electric starter is actuated in this position.

100491-10

The combination instrument is installed in front of the handlebar. The combination instrument is divided into 4 function areas.

 Function buttons  Tachometer  Indicator lamps  Display

100492-10

You can change the display mode with the button . Possible display modes are the distance traveled (

), trip master 1 ( ), trip mas-

ter 2 (

) and the ambient temperature.

Press the

button  to reset the trip master 1 function ( ) and trip master 2 func-

tion (

) to .

Button  is used to switch off the ABS.

Button  has no function.

100497-10

The tachometer  shows the engine speed in revolutions per minute. The red marking  shows the overspeed range of the engine.

100498-10

The indicator lamps offer additional information about the operating state of the motorcycle.

The turn signal indicator lamp flashes green simultaneously with the turn signals – The turn signal is switched on.

The idle speed indicator lamp lights up green – The transmission is switched to idle.

The high beam indicator lamp lights up blue – The high beam is switched on.

The temperature warning lamp lights up red – Coolant has reached a critical value.

The fuel level warning lamp lights up orange – Fuel level has reached the reserve mark. The display switches to .

The oil indicator lamp lights up red – The oil pressure is too low.

The warning lamp ( ) lights up/flashes orange – The OBD has detected an emission- or safety-critical fault.

The immobilizer indicator lamp lights up or flashes red – Status or error message for immobilizer / alarm system.

The battery warning lamp lights up red – The voltage in vehicle system is too low.

The ABS warning lamp lights up/flashes red – ABS status or error messages (antilock brake system).

100493-10

When you switch on the ignition, all display segments light up for one second as a function test.

100494-10

Following the display function test, the wheel circumference is shown for one second.

2205 mm equals the circumference of the 21" front wheel with a series production tire.

The display then changes to the last selected mode.

100503-10

The speed  is shown in kilometers per hour or in miles per hour .

If you change the unit, the value is retained and converted accordingly. Making the setting according to the country.

The motorcycle is standing.

100503-11

– Switch on the ignition by turning the black ignition key to the position . – Press the button repeatedly until the mode is active. – Keep the

button pressed until the display mode changes from to or

from

to .

100502-10

The time is shown in area  of the display.

The time must be reset after the battery is reconnected or when the fuse is changed.

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