KTM 990 Adventure 2012 Owner's manual
OWNER'S MANUAL 2012
990 Adventure EU
990 Adventure AUS/UK
990 Adventure FR
990 Adventure R EU
990 Adventure R AUS/UK
Art. no. 3211791en
DEAR KTM CUSTOMER 1
DEARKTM CUSTOMER
Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will
give you enormous pleasure if you service and maintain it accordingly.
We wish you a lot of enjoyment in riding this vehicle.
Please enter the serial numbers of your vehicle below.
Chassis number ( p. 16) Dealer's stamp
Engine number ( p. 17)
Key number ( p. 17)
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.
© 2011 KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright owner.
DEAR KTM CUSTOMER 2
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 3
TABLEOF CONTENTS
MEANS OF REPRESENTATION ............................................... 7
IMPORTANT INFORMATION ................................................... 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
SERIAL NUMBERS............................................................... 16
Chassis number................................................................ 16
Type label........................................................................ 16
Engine number................................................................. 17
Key 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
Emergency OFF switch ...................................................... 22
Electric starter button ....................................................... 22
Ignition/steering lock ........................................................ 23
Immobilizer ..................................................................... 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 - ODO display ............................... 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
Hazard warning flasher switch/hazard warning flasher .......... 34
Socket for electrical accessories......................................... 34
Opening the filler caps ...................................................... 35
Closing the filler caps ....................................................... 36
Unlocking the storage compartment ................................... 37
Locking the storage compartment....................................... 37
Opening the storage compartment ...................................... 38
Closing the storage compartment ....................................... 38
Seat lock ......................................................................... 39
Tool set ........................................................................... 39
Passenger footrests........................................................... 40
Fuel taps ......................................................................... 40
Handrails......................................................................... 41
Luggage rack plate ........................................................... 41
Shift lever........................................................................ 42
Foot brake lever................................................................ 43
TABLE OF CONTENTS 4
Side stand ....................................................................... 43
Center stand .................................................................... 44
PREPARING FOR USE .......................................................... 45
Information on first use ..................................................... 45
Running in the engine....................................................... 46
Loading the vehicle .......................................................... 47
RIDING INSTRUCTIONS ....................................................... 49
Checks and maintenance measures when preparing for
use ................................................................................. 49
Starting ........................................................................... 50
Starting off ...................................................................... 52
Shifting, riding................................................................. 52
Braking ........................................................................... 56
Stopping, parking ............................................................. 58
Refueling......................................................................... 60
SERVICE SCHEDULE............................................................ 63
Service schedule .............................................................. 63
TUNING THE CHASSIS......................................................... 66
Fork/shock absorber.......................................................... 66
Adjusting the compression damping of the fork ................... 66
Adjusting the rebound damping of the fork.......................... 67
Adjusting the spring preload of the fork .............................. 69
Compression damping of the shock absorber ....................... 70
Adjusting the low-speed compression damping of the shock
absorber .......................................................................... 70
Adjusting the high-speed compression damping of the
shock absorber................................................................. 72
Adjusting the rebound damping of the shock absorber.......... 73
Adjusting the spring preload of the shock absorber .............. 74
SERVICE WORK ON THE CHASSIS ........................................ 76
Raising the vehicle using the center stand .......................... 76
Raising the vehicle off of the center stand .......................... 77
Bleeding the fork legs ....................................................... 77
Cleaning the dust boots of the fork legs .............................. 78
Checking the steering head bearing play ............................. 79
Removing the front side cover............................................ 80
Installing the front side cover ............................................ 80
Removing the radiator guard .............................................. 81
Installing the radiator guard............................................... 82
Removing the seat............................................................ 83
Mounting the seat ............................................................ 83
Removing the crash bar x (990 Adventure) ....................... 84
Installing the crash bar x (990 Adventure)........................ 85
Removing the storage compartment and hanging it to one
side x............................................................................ 86
Installing the storage compartment x ............................... 86
Removing the left fuel tank x .......................................... 87
Installing the left fuel tank x ........................................... 88
Checking for chain dirt...................................................... 90
Cleaning the chain............................................................ 91
Checking the chain tension ............................................... 92
Adjusting the chain tension ............................................... 93
Checking the chain, rear sprocket and engine sprocket......... 95
Adjusting the basic setting of the clutch lever ..................... 98
Checking/rectifying the fluid level of the hydraulic clutch ..... 98
Removing the right underride guard.................................... 99
Installing the right underride guard .................................... 99
Removing the underride guard x .................................... 100
TABLE OF CONTENTS 5
Installing the underride guard x..................................... 100
BRAKES............................................................................ 101
ABS/antilock brake system (990 Adventure)...................... 101
Checking the free travel of the hand brake lever ................ 102
Adjusting the free travel of the hand brake lever ................ 103
Checking the brake discs................................................. 103
Checking the front brake fluid level .................................. 104
Adding front brake fluid x ............................................. 105
Checking the front brake linings....................................... 107
Checking the free travel of the foot brake lever .................. 107
Checking the rear brake fluid level ................................... 108
Adding rear brake fluid x .............................................. 109
Checking the rear brake linings ........................................ 111
WHEELS, TIRES ................................................................ 113
Removing the front wheel x........................................... 113
Installing the front wheel x............................................ 115
Removing the rear wheel x ............................................ 116
Installing the rear wheel x............................................. 118
Checking the rear hub rubber dampers x ........................ 120
Checking the tire condition.............................................. 121
Checking the tire air pressure .......................................... 122
Checking spoke tension................................................... 123
ELECTRICAL SYSTEM ........................................................ 125
Removing the battery x................................................. 125
Installing the battery x.................................................. 126
Recharging the battery x............................................... 127
Changing the main fuse .................................................. 129
Changing the ABS fuses (990 Adventure) ......................... 131
Changing the fuses in the fuse box ................................... 133
Removing the headlight mask with the headlight ............... 136
Installing the headlight mask with the headlight ................ 137
Changing the low beam bulb............................................ 137
Changing the high beam bulb .......................................... 139
Changing the parking light bulb in the headlight................ 140
Changing the turn signal bulb .......................................... 141
Changing the tail light bulb ............................................. 142
Changing the brake light bulb .......................................... 143
Checking the headlight setting......................................... 145
Adjusting the headlight range .......................................... 145
Activating/deactivating the ignition key ............................. 146
COOLING SYSTEM ............................................................. 151
Cooling system............................................................... 151
Checking the antifreeze and coolant level ......................... 152
Checking the coolant level in the compensating tank ......... 155
Draining the coolant x .................................................. 156
Filling/bleeding the cooling system x.............................. 158
TUNING THE ENGINE ........................................................ 161
Checking the play in the throttle cable.............................. 161
Adjusting the play in the throttle cable x ........................ 162
Ignition curve plug-in connector....................................... 162
Adjusting the ignition curve to the fuel quality................... 163
SERVICE WORK ON THE ENGINE ....................................... 164
Checking the engine oil level ........................................... 164
Changing the engine oil and filter, cleaning the oil
screens x..................................................................... 165
Draining engine oil, cleaning oil screens x ...................... 165
Removing the oil filter x................................................ 169
TABLE OF CONTENTS 6
Installing the oil filter x ................................................ 170
Filling up with engine oil x............................................ 170
Adding engine oil ........................................................... 172
CLEANING, CARE .............................................................. 174
Cleaning motorcycle ....................................................... 174
Checks and maintenance steps for winter operation ........... 176
STORAGE .......................................................................... 177
Storage.......................................................................... 177
Preparing for use after storage ......................................... 178
TROUBLESHOOTING.......................................................... 179
IMMOBILIZER BLINK CODE................................................ 182
ENGINE CONTROL BLINK CODE ......................................... 184
TECHNICAL DATA - ENGINE ............................................... 190
Capacity - engine oil ....................................................... 191
Capacity - coolant........................................................... 191
TECHNICAL DATA - ENGINE TIGHTENING TORQUES........... 192
TECHNICAL DATA - CHASSIS ............................................. 195
Lighting equipment ........................................................ 197
Tires ............................................................................. 198
Capacity - fuel................................................................ 198
TECHNICAL DATA - FORK................................................... 199
990 Adventure............................................................... 199
990 Adventure R ............................................................ 200
TECHNICAL DATA - SHOCK ABSORBER .............................. 202
990 Adventure............................................................... 202
990 Adventure R ............................................................ 203
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ......... 205
SUBSTANCES.................................................................... 208
AUXILIARY SUBSTANCES................................................... 212
STANDARDS...................................................................... 214
INDEX ............................................................................... 215
MEANS OF REPRESENTATION 7
Symbols used
The meaning of specific symbols is described below.
Indicates an expected reaction (e.g. of a work step or a function).
Indicates an unexpected reaction (e.g. of a work step or a function).
All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your
own safety, have these jobs performed by an authorized KTM workshop! There, your motorcycle will be serviced optimally by specially trained experts using the specialist tools required.
Indicates 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
Brand™ Identifies a brand available on the open market.
Identifies a protected name.
IMPORTANT INFORMATION 8
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.
Service
A prerequisite for perfect operation and prevention of premature wear is that the service, care and tuning work on the engine and chassis
are properly carried out as 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 service intervals. Close adherence to these periods will significantly lengthen
the service life of your motorcycle.
Warranty
The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's
service record and in the KTM dealer.net; otherwise, all warranty claims will be void. No warranty claims can be considered for damage
resulting from manipulations and/or alterations to the vehicle.
Materials
The fuels and lubricants named in the owner's manual must be used according to specifications.
IMPORTANT INFORMATION 9
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.
Where thread lockers are used on screw connections (e.g., Loctite®), follow the instructions for use from the manufacturer.
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 10
– 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.
Notes/warnings
Pay close attention to the notes/warnings.
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.
IMPORTANT INFORMATION 11
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.
VIEW OF VEHICLE 12
3.1View of vehicle, front left side (vehicle differs slightly from photo)
B00889-10
VIEW OF VEHICLE 13
1 Clutch lever ( p. 19)
2 Tool set ( p. 39)
3 Seat lock ( p. 39)
4 Luggage rack plate ( p. 41)
5 Handrails ( p. 41)
6 Fork compression adjustment
7 Fuel taps ( p. 40)
8 Side stand ( p. 43)
9 Shift lever ( p. 42)
10 Footrest
11 Center stand ( p. 44)
12 Passenger footrests ( p. 40)
VIEW OF VEHICLE 14
3.2View of vehicle, rear right side (vehicle differs slightly from photo)
B00890-10
VIEW OF VEHICLE 15
1 Storage compartment
2 Light switch ( p. 20)
2 Turn signal switch ( p. 21)
2 Horn button ( p. 21)
2 Headlight flasher switch ( p. 20)
3 Hazard warning flasher switch/hazard warning flasher ( p. 34)
4 Socket for electrical accessories ( p. 34)
5 Emergency OFF switch ( p. 22)
5 Electric starter button ( p. 22)
6 Hand brake lever ( p. 19)
7 Filler cap
8 Shock absorber rebound adjustment
9 Foot brake lever ( p. 43)
10 Oil dipstick
11 Cooling system compensating tank
SERIAL NUMBERS 16
4.1Chassis number
The chassis number 1 is stamped on the right side of the steering head.
The chassis number is also found on the type label.
100542-10
4.2Type label
The type label 1 is located on the right frame tube in the vicinity of the oil tank.
B00891-10
SERIAL NUMBERS 17
4.3Engine number
The engine number 1 is stamped on the left side of the engine under the engine sprocket.
100544-10
4.4Key number
The key number Code number 1 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
SERIAL NUMBERS 18
4.5Fork part number
The fork part number 1 is stamped on the inner side of the fork stub.
100545-10
4.6Shock absorber part number
The shock absorber part number 1 is stamped on the upper part of the shock absorber.
100546-10
CONTROLS 19
5.1Clutch lever
The clutch lever 1 is fitted on the left side of the handlebar.
The clutch is hydraulically operated and self-adjusting.
100505-10
5.2Hand brake lever
The hand brake lever 1 is fitted on the right side of the handlebar.
The front brake is engaged using the hand brake lever.
100506-10
CONTROLS 20
5.3Light switch
The light switch 1 is fitted on the left side of the handlebar.
Possible states
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.
100507-10
5.4Headlight flasher switch
The headlight flasher switch 1 is fitted on the left side of the handlebar.
Possible states
• Headlight flasher switch in neutral position
• Headlight flasher switch pressed – The headlight flasher switch (high beam) is operated in this position.
100508-10
CONTROLS 21
5.5Turn signal switch
The turn signal switch 1 is fitted on the left side of the handlebar.
Possible states
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.
5.6Horn button
100509-10
100510-10
To switch off the turn signal, press the turn signal switch towards the switch case.
The horn button 1 is fitted on the left side of the handlebar.
Possible states
• Horn button in neutral position
• Horn button pressed – The horn is operated in this position.
CONTROLS 22
5.7Emergency OFF switch
The emergency OFF switch 1 is fitted on the right side of the handlebar.
Possible states
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.
100547-10
5.8Electric starter button
The electric starter button 1 is fitted on the right side of the handlebar.
Possible states
• Electric starter button in basic position
• Electric starter button is pressed – The electric starter is actuated in this position.
100548-10
CONTROLS 23
5.9Ignition/steering lock
The ignition/steering lock 1 is in front of the upper triple clamp.
Info
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.
Possible states
Ignition OFF – In this position, the ignition circuit is interrupted, a running
engine stops, and a non-running engine will not start. The black ignition
100511-10
5.10Immobilizer
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.
key can be removed.
Ignition ON – 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.
400915-01
Info
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.
CONTROLS 24
The second black ignition key is activated when the vehicle is shipped.
Two additional spare ignition keys (key number on the KEYCODECARD) can be ordered from
an authorized KTM workshop, but they must be activated before use.
5.11Combination instrument
The combination instrument is installed in front of the handlebar.
The combination instrument is divided into 4 function areas.
1 Function buttons
2 Tachometer
3 Indicator lamps
4 Display
400913-10
5.12Combination instrument - function buttons
You can change the display mode with the MODE button 1.
Possible display modes are the distance traveled (ODO), trip master 1 (TRIP 1), trip master 2 (TRIP 2) and the ambient temperature.
Press the SET button 2 to reset the trip master 1 function (TRIP 1) and trip master 2 function (TRIP 2) to 0.0.
(990 Adventure)
Button 3 is used to switch off the ABS.
(990 Adventure R)
Button 3 has no function.
400914-10
CONTROLS 25
5.13Combination instrument - tachometer
The tachometer 1 shows the engine speed in revolutions per minute.
The red marking 2 shows the overspeed range of the engine.
400916-10
5.14Combination instrument - indicator lamps
The indicator lamps offer additional information about the operating state of the motorcycle.
Possible states
The turn signal indicator lamp flashes green simultaneously with the turn
signal – The turn signal is switched on.
The idle speed indicator lamp lights up green – The transmission is
switched to idle.
400917-01
The high beam indicator lamp lights up blue – The high beam is switched
on.
The temperature warning lamp lights up red – The coolant temperature has
reached a critical value.
The fuel level warning lamp lights up orange – The fuel level has reached
the reserve mark. The display switches to TRIP F.
CONTROLS 26
The oil pressure warning lamp lights up red – The oil pressure is too low.
FI warning lamp (MIL) lights up/flashes orange – The OBD (on-board diagno-
sis) has detected an emission- or safety-critical error.
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 the vehicle system
is too low.
(990 Adventure)
The ABS warning lamp lights up/flashes red – Status or error messages
relating to ABS (antilock brake system).
5.15Combination instrument - display
When you switch on the ignition, all display segments light up for one second as a function
test.
400892-01
CONTROLS 27
LEnGth
Following the display function test, the wheel circumference LEnGth is shown for one second.
Info
2205 mm equals the circumference of the 21" front wheel with a series production
tire.
The display then changes to the last selected mode.
400837-01
5.16Combination instrument - speedometer
The speed 1 is shown in kilometers per hour km/h or in miles per hour mph.
400838-10
5.17Setting kilometers or miles
Info
If you change the unit, the value ODO is retained and converted accordingly.
Making the setting according to the country.
CONTROLS 28
Condition
The motorcycle is standing.
– Switch on the ignition by turning the black ignition key to the position ON .
– Press the MODE button repeatedly until the ODO mode is active.
– Keep the MODE button pressed until the display mode changes from km/h to mph or
from mph to km/h.
400893-10
5.18Combination instrument - time
The time is shown in area 1 of the display.
Info
After reconnecting the battery or changing the fuse, the time must be reset.
400893-11
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