KTM 990 Adventure 2010 Owner's manual

5 (1)

OWNER'S MANUAL 2010

990 Adventure USA

990 Adventure R USA

Art. no. 3211515en

DEAR KTM CUSTOMER

We would like to congratulate you on deciding to purchase a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will give you enormous pleasure if you service and maintain it accordingly.

We wish you a lot of enjoyment in riding this vehicle.

Please enter the serial numbers of your vehicle below.

Chassis number ( p. 26)

Dealer's stamp

Engine number ( p. 27)

Key number ( p. 27)

The owner's manual contained the latest information for this model at the time of going to print. Minor differences due to developments in design cannot be ruled out completely.

All specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifications, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt these to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery options,

deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain special equipment that does not form part of the regular scope of delivery.

DEAR KTM CUSTOMER

Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright owner.

ISO 9001(12 100 6061)

According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead to the maximum possible quality of the products.

Issued by: TÜV Management Service

KTM-Sportmotorcycle AG

5230 Mattighofen, Austria

TABLE OF CONTENTS

MEANS OF REPRESENTATION ...............................................	7
IMPORTANT INFORMATION ...................................................	8
Overview of labels.............................................................	12
VIEW OF VEHICLE................................................................	22
View of vehicle, front left side (vehicle differs slightly from
photo) .............................................................................	22
View of vehicle, rear right side (vehicle differs slightly from
photo) .............................................................................	24
LOCATION OF SERIAL NUMBERS .........................................	26
Chassis number................................................................	26
Type label........................................................................	26
Key number .....................................................................	27
Engine number.................................................................	27
Fork part number..............................................................	28
Shock absorber part number..............................................	28
CONTROLS ..........................................................................	29
Clutch lever .....................................................................	29
Hand brake lever ..............................................................	29
Light switch .....................................................................	30
Headlight flasher switch....................................................	30
Turn signal switch ............................................................	31
Horn button .....................................................................	31
Ignition/steering lock ........................................................	32
Immobilizer .....................................................................	32
Emergency OFF switch......................................................	33
Electric starter button .......................................................	33
Combination instrument....................................................	34
Combination instrument - function buttons .........................	34
Combination instrument - tachometer.................................	35

Combination instrument - indicator lamps...........................	35
Combination instrument - display.......................................	36
Combination instrument - speedometer...............................	37
Setting kilometers or miles ................................................	37
Combination instrument - time ..........................................	38
Setting the clock ..............................................................	39
Combination instrument - display ODO ...............................	39
Combination instrument - setting/resetting TRIP 1...............	40
Combination instrument - setting/resetting TRIP 2...............	40
Combination instrument - TRIP F display............................	41
Combination instrument - ambient temperature display........	42
Setting the temperature unit of measure.............................	42
Combination instrument - warning of slippery roads .............	43
Combination instrument - coolant temperature indicator ......	43
Socket for electrical accessories.........................................	44
Hazard warning flasher switch/hazard warning flasher ..........	44
Opening the filler caps......................................................	45
Closing the filler caps .......................................................	45
Seat lock .........................................................................	46
Unlocking the storage compartment ...................................	46
Locking the storage compartment.......................................	47
Opening the storage compartment......................................	47
Closing the storage compartment .......................................	48
Handrails.........................................................................	48
Luggage rack plate ...........................................................	49
Fuel taps .........................................................................	49
Foot brake lever................................................................	50
Shift lever........................................................................	50
Side stand .......................................................................	51

TABLE OF CONTENTS

Center stand ....................................................................	52
Passenger footrests...........................................................	52
Tool set ...........................................................................	53
GENERAL TIPS AND HINTS ON PUTTING INTO
OPERATION.........................................................................	54
Information on first use.....................................................	54
Running in the engine.......................................................	55
Loading the vehicle ..........................................................	56
RIDING INSTRUCTIONS .......................................................	58
Checks before putting into operation ..................................	58
Starting ...........................................................................	59
Starting up ......................................................................	61
Shifting, riding.................................................................	61
Braking ...........................................................................	65
Stopping, parking .............................................................	67
Refueling.........................................................................	69
SERVICE SCHEDULE............................................................	72
Service schedule ..............................................................	72
MAINTENANCE WORK ON FRAME AND ENGINE....................	75
Jacking up the vehicle on the center stand..........................	75
Raising the vehicle off of the center stand ..........................	76
Removing the seat ............................................................	76
Mounting the seat ............................................................	77
Fork/shock absorber..........................................................	77
Adjusting the compression damping of the fork ...................	78
Adjusting the rebound damping of the fork..........................	79
Adjusting the spring preload of the fork ..............................	80
Compression damping of the shock absorber .......................	81

Adjusting the low-speed compression damping of the shock
absorber ..........................................................................	81
Adjusting the high-speed compression damping of the
shock absorber .................................................................	83
Adjusting the rebound damping of the shock absorber..........	84
Adjusting the spring preload of the shock absorber ..............	86
Bleeding the fork legs .......................................................	87
Cleaning the dust boots of the fork legs ..............................	87
Checking the steering head bearing play .............................	88
Checking for chain dirt......................................................	90
Cleaning the chain............................................................	90
Checking the chain tension ...............................................	91
Adjusting the chain tension ...............................................	92
Checking the chain, rear sprocket and engine sprocket.........	94
ABS / antilock brake system (990 Adventure USA) ..............	97
Checking the brake discs...................................................	98
Checking the free travel of the hand brake lever ..................	99
Adjusting the free travel of the hand brake lever ..................	99
Checking the front brake fluid level ..................................	100
Adding front brake fluid x.............................................	101
Checking the front brake linings.......................................	103
Checking the free travel of the foot brake lever ..................	103
Checking the rear brake fluid level ...................................	104
Adding rear brake fluid x ..............................................	105
Checking the rear brake linings ........................................	107
Removing the front wheel x...........................................	108
Installing the front wheel x............................................	110
Removing the rear wheel x............................................	112
Installing the rear wheel x.............................................	114

TABLE OF CONTENTS

Checking the rear hub rubber dampers x........................	116
Checking the tire condition..............................................	117
Checking the tire air pressure ..........................................	118
Checking spoke tension...................................................	119
Removing the underride guard x....................................	120
Installing the underride guard x.....................................	121
Removing the battery x.................................................	121
Installing the battery x..................................................	123
Recharging the battery x...............................................	124
Removing the right underride guard..................................	127
Installing the right underride guard ..................................	127
Changing the main fuse ..................................................	128
Changing the ABS fuses (990 Adventure USA)..................	130
Changing the fuses in the fuse box...................................	131
Removing the front side cover..........................................	134
Installing the front side cover ..........................................	134
Removing the headlight mask with the headlight ...............	135
Installing the headlight mask with the headlight................	136
Changing the headlight bulb............................................	136
Changing the parking light bulb in the headlight................	137
Changing the turn signal bulb ..........................................	138
Changing the tail light bulb .............................................	139
Changing the brake light bulb ..........................................	140
Checking the headlight setting.........................................	141
Adjusting the headlight range ..........................................	142
Activating/deactivating the ignition key.............................	142
Removing the storage compartment and hanging it to one
side x..........................................................................	145
Installing the storage compartment x.............................	146

Removing the left fuel tank x........................................	147
Installing the left fuel tank x.........................................	148
Cooling system ...............................................................	150
Checking the coolant level in the compensating tank .........	151
Checking the antifreeze and coolant level .........................	152
Draining the coolant x..................................................	155
Filling/bleeding the cooling system x..............................	156
Removing the radiator guard............................................	159
Installing the radiator guard.............................................	160
Adjusting the basic setting of the clutch lever ...................	161
Checking/rectifying the fluid level of the hydraulic clutch ...	161
Checking the play in the throttle cable..............................	162
Adjusting the play in the throttle cable x........................	163
Checking the engine oil level ...........................................	163
Changing the engine oil and filter, cleaning the oil
screens x.....................................................................	164
Draining engine oil, cleaning oil screens x......................	164
Removing the oil filter x................................................	168
Installing the oil filter x................................................	170
Filling up with engine oil x............................................	170
Adding engine oil ...........................................................	172
Ignition curve plug-in connector.......................................	173
Adjusting the ignition curve to the fuel quality...................	173
IMMOBILIZER BLINK CODE................................................	175
ENGINE CONTROL BLINK CODE.........................................	177
TROUBLESHOOTING..........................................................	183
CLEANING.........................................................................	186
Cleaning motorcycle .......................................................	186

TABLE OF CONTENTS	6
PROTECTIVE TREATMENT FOR WINTER OPERATION...........	188
Protective treatment for winter operation ..........................	188
STORAGE ..........................................................................	189
Storage..........................................................................	189
Putting into operation after storage ..................................	190
TECHNICAL DATA - ENGINE...............................................	191
Capacityengine oil ........................................................	192
Capacity - coolant...........................................................	192
TECHNICAL DATA - ENGINE TIGHTENING TORQUES...........	193
TECHNICAL DATA - CHASSIS .............................................	197
Lighting equipment ........................................................	199
Tires .............................................................................	199
Capacity - fuel................................................................	200
TECHNICAL DATA - FORK...................................................	201
990 Adventure USA........................................................	201
990 Adventure R USA ....................................................	202
TECHNICAL DATA - SHOCK ABSORBER ..............................	204
990 Adventure USA........................................................	204
990 Adventure R USA ....................................................	205
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES .........	207
SUBSTANCES....................................................................	210
AUXILIARY SUBSTANCES...................................................	214
STANDARDS......................................................................	216
INDEX ...............................................................................	217

MEANS OF REPRESENTATION

Symbols used

The meaning of specific symbols is described below.

Indicates an expected reaction (e.g. of a work step or a function).

Indicates an unexpected reaction (e.g. of a work step or a function).

All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own safety, have these jobs performed 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).

Formats used

The typographical formats used in this document are explained below.

Specific name	Identifies a proprietary name.
Name®	Identifies a protected name.
Brand™	Identifies a trademark.

IMPORTANT INFORMATION

Use definition

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.

Info

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

Maintenance

A prerequisite for fault-free operation and avoiding premature wear is compliance with the 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.

Warranty

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.

Materials

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

IMPORTANT INFORMATION

Spare parts, accessories

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 KTM PowerParts for your vehicle on the KTM website.

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

Work rules

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. Loctite®) 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.

Transport

Note

Danger of damage The parked vehicle may roll away or fall over.

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

Note

Fire hazard Some vehicle components become very hot when the vehicle is operated.

–Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from being run. Always let the vehicle cool first.

IMPORTANT INFORMATION

–Switch off the engine and remove the ignition key.

–Secure the motorcycle against falling over or rolling away using straps or other suitable devices.

Environment

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.

IMPORTANT INFORMATION

IMPORTANT INFORMATION

Overview of labels

100643-10

IMPORTANT INFORMATION

1Information on starting up

2Information on emission control

3USA type label

4Information on the evaporative emission control system

5Information on suspension tuning

6Information on refueling

7Information on chain tension

8Canada type label

9Information on noise emission

Information on starting up

700210-01

IMPORTANT INFORMATION

B00108-01

Information on emission control

400635-01

USA type label

IMPORTANT INFORMATION		15
	Information on the evaporative emission control system
	Information on the evaporative emission control system

B00109-01

100644-01

Information on suspension tuning

IMPORTANT INFORMATION		16
	Information on refueling
	Information on refueling

400630-01

400628-01

Information on chain tension

IMPORTANT INFORMATION

400636-01

Canada type label

B00110-01

Information on noise emission

Notes/warnings

Pay close attention to the notes/warnings.

IMPORTANT INFORMATION

Info

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 potential hazards and may therefore be injured.

Grades of risks

Danger

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

Warning

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

Caution

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

Note

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

Warning

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

Owner's manual

–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.

IMPORTANT INFORMATION

Reporting safety defects

If you believe that your vehicle has a defect which could cause an accident resulting in injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying KTM North America, Inc.

If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in individual problems between you, your dealer, or KTM North America, Inc.

To contact NHTSA, you may either call the Vehicle Safety Hotline toll-free at 1–888–327–4236 or visit the website www.nhtsa.dot.gov, or write to: NHTSA Headquarters, 1200 New Jersey Avenue, SE, West Building, Washington, DC 20590. You can also obtain other information about motor vehicle safety from the Hotline.

Noise emission warranty

KTM Sportmotorcycle AG warrants that this exhaust system, at the time of sale, meets all applicable U.S. EPA federal noise standards. This warranty extends to the first person who buys this exhaust system for purposes other than resale, and to all subsequent buyers. Warranty claims should be directed to:

KTM North America, Inc., Customer Support, 1119 Milan Ave., Amherst, OH 44001, USA Phone: (440) 985–3553

www.ktmusa.com

KTM Canada, Inc., Customer Support, 1375-1 Marie-Victorin, Saint-Bruno, QC J3V 6B7 Phone: (450) 441–4451 x 4250

www.ktmcanada.com

Tampering warning

Tampering with noise control system prohibited. Federal law prohibits the following acts or the causing thereof:

1The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated 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, or

2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. Among those acts presumed to constitute tampering are the acts listed below.

IMPORTANT INFORMATION

1 Removal of, or puncturing the muffler, baffles, header pipes or any other components which conducts exhaust gases. 2 Removal or puncturing of any part of the intake system.

3Lack of proper maintenance.

4Replacing any moving part of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by the manufacturer.

Operating noise warning

This product should be checked for necessary repairs or replacement parts if motorcycle noise has increased significantly through use. Otherwise, the owner may become subject to penalties depending on local laws.

Consumer rights

Warranty claims should be directed to an authorized KTM workshop. If you are not satisfied, please contact:

KTM North America, Inc., Customer Support, 1119 Milan Ave., Amherst, OH 44001, USA

Phone: (440) 985–3553

www.ktmusa.com

KTM Canada, Inc., Customer Support, 1375-1 Marie-Victorin, Saint-Bruno, QC J3V 6B7

Phone: (450) 441–4451 x 4250

www.ktmcanada.com

Your rights may vary depending on national and regional laws.

VIEW OF VEHICLE

View of vehicle, front left side (vehicle differs slightly from photo)

100645-10

VIEW OF VEHICLE

1Clutch lever

2Seat

3Seat lock

4Luggage rack plate

5Handrail

6Front brake caliper

7Underride guard

8Side stand

9Shift lever

10Footrest

11Center stand

12Passenger footrest

VIEW OF VEHICLE

View of vehicle, rear right side (vehicle differs slightly from photo)

100646-10

	VIEW OF VEHICLE		25

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

LOCATION OF SERIAL NUMBERS

Chassis number

The chassis number is stamped on the right side of the steering head.

The chassis number is also found on the type label.

100542-10

Type label

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

100543-10

LOCATION OF SERIAL NUMBERS

Key number

The key number Code number can be found on the KEYCODECARD.

Info

You need the key number to order a spare key. Keep the KEYCODECARD 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.

700222-01

Engine number

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

100544-10

LOCATION OF SERIAL NUMBERS

Fork part number

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

100545-10

Shock absorber part number

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

100546-10

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