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.
© 2009 by KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
Reproduction, even in part, is permitted only with the express written permission of the copyright owner.
ISO 9001(12 100 6061)
According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead to
the maximum possible quality of the products.
Issued by: TÜV Management Service
KTM-Sportmotorcycle AG
5230 Mattighofen, Austria
MEANS OF REPRESENTATION ............................................... 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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