KTM 990 Super Duke 2005 Owners manual

OWNER’S MANUAL
MANUALE D’USO
MANUEL D’UTILISATION
MANUAL DE INSTRUCCIONES

ART. NR. 3.211.57

990 SUPER DUKE

BEDIENUNGSANLEITUNG2005

ENGLISH

1

IMPORTANT »

Please insert the serial numbers of your motorcycle in the boxes below

Frame number

Engine number

Key number

Stamp of dealer

All information contained is without obligation. KTM-Sportmotorcycle AG particularly reserves the right
to modify any equipment, technical specifications, prices, colors, shapes, materials, services, service work,
constructions, equipment and the like so as to adapt them to local conditions or to cancel any of the above
items, all without previous announcement and without giving reasons. KTM may stop manufacturing cer­tain models without previous notice. KTM shall not be held liable for any deviations of availability and/or
ability to deliver, illustrations, descriptions, printing and/or other errors. The illustrated models partly con­tain extra equipment, which is not applied to standard models.

© 2004 by KTM-SPORTMOTORCYCLE AG, Mattighofen AUSTRIA; All rights reserved; Reprint, also in
extracts, with written allowance of KTM-SPORTMOTORCYCLE AG, Mattighofen only.

COMSUMER INFORMATION FOR AUSTRALIA ONLY
Tampering with noise control system prohibited

Owners are warned that the law may prohibit:
(a) The removal or rendering inoperative by any person other than for purposes of maintenance, repair or

replacement, of any device or element of design 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; and

(b) the use of the vehicle after such device or element of design has been removed or rendered inopera-

tive by any person.

We strongly suggest that you read this manual carefully and completely before going on your first ride.
It contains a great deal of information and advice which will help you use and handle your bike properly.
In your own interest, please pay particular attention to notices that are marked as follows:

– IGNORING THESE INSTRUCTIONS, CAN ENDANGER YOUR BODY AND YOUR LIFE.

– IGNORING THESE INSTRUCTIONS COULD CAUSE DAMAGE TO PARTS OF YOUR MOTORCYCLE OR THAT

THE MOTOR-CYCLE IS NOT ROAD-SAFE ANYMORE.

ENGLISH

2

INTRODUCTION »

We would like to congratulate you on your purchase of a KTM motorcycle.

You are now the owner of a state-of-the-art sport motorcycle that guarantees to bring you lots of fun and
enjoyment, provided that you clean and maintain it appropriately. Before you go for your first ride, be sure

to read this manual carefully and thoroughly in order to familiarize yourself with how to operate your new
motorcycle and with its characteristics, even if this means that you will have to dedicate some of your
valuable time to this task. Only by doing so will you learn how to tune your motorcycle to your specific
needs and how to protect yourself against injury. Besides, this manual contains important information on
motorcycle maintenance. At the time this manual was typeset, it was up-to-date with the latest state of

this production series. It cannot be completely ruled out, however, that minor discrepancies may exist
resulting from further design upgrades of these motorcycles.This manual is an important part of your motor­cycle and should be passed on to any subsequent owner in case you decide to sell it.

We expressly point out that work marked with an asterisk in the chapter "Maintenance work on the chas­sis and engine" must be performed. If maintenance work should become necessary during a competition
it should be performed by a trained mechanic. KTM strongly recommends that all service work to your
KTM should be performed by a qualified KTM dealer.

For your own safety, use KTM-approved parts and accessories only. KTM is not liable for damage that
arises in connection with the use of other products.

Take special care to follow the recommended run in, inspection, and maintenance intervals. Heeding
these guidelines will significantly increase the life of your motorcycle. To ensure that all work to your KTM
is performed properly and to avoid warranty conflicts, KTM recommends that you always have your KTM
serviced by a recognized and qualified KTM dealer.

Motorcycle driving is a wonderful sport and we hope that you will be able to enjoy it to the full. It may,
however, involve potential problems for the environment or lead to conflicts with others. These problems
or conflicts can be avoided if the motorcycle is used responsibly. To safeguard the future of motorcycle
sports, make sure that you use the motorcycle in accordance with the law, show that you are environmen­tally conscious and respect the rights of others.

We wish you a lot of fun when driving !

KTM-SPORTMOTORCYCLE AG
5230 MATTIGHOFEN, AUSTRIA

ENGLISH

3

IMPORTANT LIMITED WARRANTY AND LIMITED GUARANTEE INFORMATION »

The 990 Super Duke is designed and constructed for normal use on public roads but not for use on race
courses or offroad terrain.

The service, care and operating instructions for the engine and chassis specified in the owner's manual
must be observed to ensure that the bike runs smoothly and to avoid premature wear.

The service work described in the "Lubrication and maintenance chart" must be carried out by an author­ized KTM workshop and confirmed in the service manual, otherwise your warranty will become void.

The fuels and lubricants specified in the owner's manual or those of an equal quality must be used in
accordance with the maintenance schedule.

The warranty or guarantee shall become void for damage and consequential damage caused by manipu­lations or conversions to the motorcycle.

The use of the motorcycle under extreme conditions, e.g. on the race course, can cause above average
wear to components such as the brakes. In this case it may become necessary to service or replace wear
parts before the service limit specified in the maintenance schedule has been reached.

In accordance with the international quality management ISO 9001 standard, KTM uses
quality assurance processes that lead to the highest possible product quality.

ENGLISH

4

INDEX »

Page

SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . .5

Chassis number, Type label . . . . . . . . . . . . . . . . . . . .5

Engine number, engine type . . . . . . . . . . . . . . . . . . . .5

OPERATION INSTRUMENTS . . . . . . . . . . . . . . . . . . . . .5

Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Multi-functional digital speedometer . . . . . . . . . . . . .6

Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Setting options in the display . . . . . . . . . . . . . . . . . . .7

Cooling liquid temperature display . . . . . . . . . . . . . . .8

Indicator lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Ignition lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Combination switch . . . . . . . . . . . . . . . . . . . . . . . . . .9

Emergency OFF tip switch, light switch, starter tip switch

.9

Filler cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Seat lock, removing the seat . . . . . . . . . . . . . . . . . .10

Baggage loops . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Tool set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Helmet lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Holding strap . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Side stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Foot brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Footrests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Compression damping of fork . . . . . . . . . . . . . . . . .12

Rebound damping of fork . . . . . . . . . . . . . . . . . . . . .12

Spring preload of the fork . . . . . . . . . . . . . . . . . . . . .12

Damping action during compression of shock absorber

.13

Rebound damping of shock absorber . . . . . . . . . . . . .13

Spring preload on shock absorber . . . . . . . . . . . . . .13

GENERAL TIPS AND WARNINGS FOR STARTING THE

MOTORCYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Instructions for initial operation . . . . . . . . . . . . . . . .14

Running in the LC8 engine . . . . . . . . . . . . . . . . . . . .14

Accessories and payload . . . . . . . . . . . . . . . . . . . . .14

DRIVING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . .15

Check the following before each start . . . . . . . . . . . .15

Starting the engine . . . . . . . . . . . . . . . . . . . . . . . . .16

Starting off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Shifting/Riding . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Stopping and parking . . . . . . . . . . . . . . . . . . . . . . . .18

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

PERIODIC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . .20

MAINTENANCE WORK ON CHASSIS AND ENGINE . . . .22

Adjusting the fork and shock absorber . . . . . . . . . . .22

Adjusting compression damping of fork . . . . . . . . . . .22

Adjusting rebound damping of fork . . . . . . . . . . . . . .22

Adjusting the spring preload on the fork . . . . . . . . . .23

Compression damping of shock absorber . . . . . . . . . .23

Rebound damping of shock absorber . . . . . . . . . . . . .24

Page

Checking the chain tension . . . . . . . . . . . . . . . . . . .24

Correcting the chain tension . . . . . . . . . . . . . . . . . .24

Chain maintenance . . . . . . . . . . . . . . . . . . . . . . . . .25

Checking the chain for wear . . . . . . . . . . . . . . . . . . .25

General information on KTM disk brakes . . . . . . . . .26

Adjusting the basic position of the hand brake lever . .27

Checking the front brake fluid level . . . . . . . . . . . . .27

Refilling front brake fluid . . . . . . . . . . . . . . . . . . . .27

Checking the front brake pads . . . . . . . . . . . . . . . . .27

Changing the basic position of the foot brake lever . . .28

Checking the rear brake fluid level . . . . . . . . . . . . . .28

Refilling rear brake fluid . . . . . . . . . . . . . . . . . . . . .28

Checking the rear brake pads . . . . . . . . . . . . . . . . . .28

Dismounting and remounting the front wheel . . . . . .29

Dismounting and remounting the rear wheel . . . . . . .30

Tires, air pressure . . . . . . . . . . . . . . . . . . . . . . . . . .31

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Removing and remounting the battery . . . . . . . . . . .32

Charging the battery . . . . . . . . . . . . . . . . . . . . . . . .32

Jump start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

Main fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Fuses for individual power consumers . . . . . . . . . . .33

Replacing the headlight lamp . . . . . . . . . . . . . . . . .34

Adjusting the headlight range . . . . . . . . . . . . . . . . . .34

Replacing the brake light and taillight bulbs . . . . . . .35

Replacing the flasher bulbs . . . . . . . . . . . . . . . . . . .35

Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

Checking the cooling liquid level in the

compensating tank . . . . . . . . . . . . . . . . . . . . . . . . .36

Checking the cooling liquid level in the radiator . . . .37

Bleeding the cooling system . . . . . . . . . . . . . . . . . .37

Changing the basic position of the clutch lever . . . . .38

Checking the oil level of the hydraulic clutch . . . . . . .38

Adjusting the handlebar tilt . . . . . . . . . . . . . . . . . . .38

Checking and adjusting the throttle cable play . . . . . .38

Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Checking the engine oil level . . . . . . . . . . . . . . . . . .39

Refilling engine oil . . . . . . . . . . . . . . . . . . . . . . . . .39

Changing the engine oil and the oil filter, cleaning

the oil screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . .42

CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

CONSERVATION FOR WINTER OPERATION . . . . . . . . . .45

STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

STARTING UP AFTER IMMOBILIZATION . . . . . . . . . .45

TECHNICAL SPECIFICATIONS – CHASSIS . . . . . . . . . .46

TECHNICAL DATA - CHASSIS . . . . . . . . . . . . . . . . . . . .47

TECHNICAL SPECIFICATIONS – ENGINE . . . . . . . . . . .48

HEAD WORD INDEX . . . . . . . . . . . . . . . . . . . . . . . . . .49

ENGLISH

5

SERIAL NUMBER LOCATIONS »

Chassis number, Type label

The chassis number is stamped on the right side of the steering head tube.
Enter this number in the field on page no 1.
The type label is located on the right frame tube under the seat.

Engine number, engine type

The engine number and the engine type are stamped into the left side of the
engine below the engine sprocket. Enter this number on page 1.

Clutch lever

The clutch lever [1] is fitted on the left hand side of the handle bar.
The adjusting screw [A] is used to change the original position of the clutch
lever (see maintenance work on chassis and engine).
The clutch is hydraulically actuated and adjusts itself automatically.

Hand brake lever

The hand brake lever [2] is mounted on the handlebar on the right and actu­ates the front wheel brake.The adjusting screw [B] is used to change the orig­inal position of the hand brake lever (see maintenance work on chassis and
engine).

OPERATION INSTRUMENTS »

1

A

2

B

ENGLISH

6

OPERATION INSTRUMENTS »

Multi-functional digital speedometer

The universal instrument is divided into 3 parts.
Use the MODE and SET [1] button to change the display and the basic set­tings in the display.
Display [2] shows all of the information that may be of interest to you. 5 dis­play modes can be selected with the MODE button.

The indicator lamps [3] provide additional information on the motorcycle's
running condition.

Display

TEST
When you switch on the ignition, all of the display elements will light up for
1 second for the function test.

WS (wheel size)
The display will change and show the diameter of the front wheel in inches
for 1 second (WS = wheel size).
Then the CLOCK mode will be displayed, or the mode that was active when
the ignition was switched off.

CLOCK
You will recognize the CLOCK display by the blinking dots between the hours
and minutes. It displays the speed, temperature of the cooling liquid and the
clock.
To switch to the next display mode, press the MODE button.

ODO
The speed, temperature of the cooling liquid and the total kilometers or miles
traveled are shown in the ODO mode.
To switch to the next display mode, press the MODE button.

TRIP 1
The TRIP 1 mode shows the speed, the temperature of the cooling liquid and
the trip odometer 1.
To switch to the next display mode, press the MODE button.

TRIP 2
The TRIP 2 mode shows the speed, the temperature of the cooling liquid and
the trip odometer 2.
To switch to the next display mode, press the MODE button.

TRIP F
The TRIP F (fuel) mode shows the speed, the temperature of the cooling liq­uid and the distance traveled since reaching the low-fuel mark (the low-fuel
indicator lamp will blink).
To return to the UHR mode, press the MODE button.

TEST

WS

ODO

CLOCK

TRIP 1

TRIP 2

TRIP F

1 2 3

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7

OPERATION INSTRUMENTS »

Setting options in the display

KILOMETERS OR MILES.
You can have the speed and distance shown in kilometers or miles in the dis­play. The display can be adapted to the respective country on long-distance
trips.
To switch from kilometers to miles, switch on the ignition and press the MODE
[1] button for approx. 10 seconds. The km/h display will switch to mph. The
speed and the stored distances will be converted and displayed in miles.
To return to kilometers, proceed as described above.

CLOCK
Switch on the ignition and change to the CLOCK mode.
Simultaneously press MODE [1] and SET [2]. The numbers on the clock will
start to blink. Use the MODE button to set the hours and the SET button to
set the minutes.
The press the MODE and SET buttons simultaneously.

NOTE:
0:00 will be displayed if the clock is not supplied with electricity. This can
be caused by a defective fuse or a fault in the board electric system (see
Troubleshooting).

TRIP 1
The trip meter 1 runs continuously and counts up to 999.9. It can be used
to measure the length of a certain route on a trip or the distance between two
refueling stops.
To return the trip meter 1 to zero, switch on the ignition, change to the TRIP
1 mode and press the SET button.

RESETTING TRIP 2
The trip meter 2 runs continuously and counts up to 999.9. It can be used
similarly to TRIP 1 or together with a switch available as an accessory (see
below) for trips according to a roadbook.
To return the trip meter 2 to zero, switch on the ignition, change to the TRIP
2 mode and press the SET button.

TRIP F
When the fuel level reaches the reserve mark, the display will automatically
switch to TRIP F and begin to count (no matter which display mode was active
before). At the same time, the fuel warning lamp will start to blink. You will
still have enough reserve fuel for at least 30 kilometers.
After refueling, it will take approx. 8 minutes for the fuel warning lamp to
switch off and for TRIP F to automatically reset to 0 and return to the previ­ous display mode.

NOTE:
Press the SET key for 2 seconds to immediately turn off the fuel warning lamp.

1 10 sec

1

2

2

2

ENGLISH

8

OPERATION INSTRUMENTS »

Cooling liquid temperature display

The temperature display [1] is shown in 7 bars. The more bars that light up,
the hotter the cooling liquid. When the lowest bar lights up, the cooling liq­uid has reached a temperature of approx. 40°C (104°F). When the upper bar
lights up 120°C (248°F), all of the bars will start to blink and the red warn­ing lamp [2] will light up.

POSSIBLE CAUSES FOR AN INCREASE IN TEMPERATURE, CAUSING THE RED
WARNING LIGHT FOR THE COOLING LIQUID TEMPERATURE TO LIGHT UP (ALSO
SEE PAGE 36):

– DRIVING TOO SLOWLY AND DRIVING WITH A HEAVY LOAD AT HIGH AIR TEM-

PERATURES
– NOT ENOUGH COOLING LIQUID IN THE SYSTEM
– THE VENTILATOR ON THE LEFT RADIATOR IS NOT RUNNING
– IMPROPER USE OF THE CLUTCH WHEN DRIVING SLOWLY

Indicator lamps

The green indicator lamp will blink in the blinker rhythm when the
blinker is switched on.
NOTE:
The indicator lamp will blink slower when a blinker is broken.

The green indicator lamp will light up when the gearbox is in an
idling position.

The blue indicator lamp will light up when the high beams are
switched on.

The red warning light will light up when the cooling liquid has
reached a temperature of approx. 120°C (248°F).

The orange warning light will start to blink when the fuel level has
reached the reserve mark. At the same time the display will auto­matically change to TRIP F (see TRIP F).

The red warning lamp lights up when the ignition is switched on but
the engine is not running. When the engine is started, the warning
lamp will go out as soon as the oil pressure is high enough.

The orange warning lamp (fuel injection) briefly lights up when the
ignition is switched on. It will go out when the gasoline pressure is
high enough.
If this warning lamp lights up while driving, a component in the
injection system is defective. The error can be identified by means
of a blink code (see Maintenance work).

Tachometer

The tachometer [3] shows the engine speed in revolutions per minute. Do not
run the engine beyond the black mark at 9500 rpm.
The speed limiter will set in at 9600 rpm, drastically reducing the engine
power above this rotational speed.

120°C (248°F)

110°C (230°F)

100°C (212°F)

70°C (158°F)

60°C (140°F)

50°C (122°F)

40°C (104°F)

1

2

3

ENGLISH

9

OPERATION INSTRUMENTS »

Ignition lock

The ignition lock has 3 switching positions.

Ignition off, (engine can't be started)

Ignition on, (engine can be started)

Ignition off, handlebar blocked
To switch the ignition to position turn the ignition key to position

and firmly press it into the lock. Turn the handlebar all the way to

the left, then turn the ignition key to the left.

The ignition key can be withdrawn in position and .

Combination switch

The rocker switch LIGHTS [1] actuates the high beam or low beam.

= High-beam light

= Low-beam light

The light signal (high beam) is actuated with button [2].

The indicator switch [3] returns to central position after actuation. Press
flasher switch towards switch housing to switch off the flasher.

The horn is sounded with button [4].

Emergency OFF tip switch, light switch, starter tip switch

The emergency off switch [5] is provided for emergency situations and should
not be used to switch off the engine.
The engine is ready for operation in position (ignition circuit and starter
circuit are switched on).
The engine cannot be started in position (ignition circuit and starter cir­cuit are interrupted).

The light switch [6] has 3 positions:

= Light off

= Parking light on

= Headlight on

Use the starter tip switch [7] to operate the electric starter.

1

2

4

3

1

5

6

7

ENGLISH

10

OPERATION INSTRUMENTS »

Filler cap

The filler cap [1] can be locked. It is equipped with a tank ventilation system.
To open, insert the ignition key, turn 45° in a clockwise direction and tilt the
filler cap back.
After refueling, pull out the ignition key and press down on the filler cap until
the lock engages.

Seat lock, removing the seat

The seat lock [2] can be locked with the ignition key.
To remove the seat, insert the ignition key and turn 90° in a clockwise direc­tion. Lift the seat in the back while pressing near the holding strap and pull
off towards the back.

To mount the seat, place it on the motorcycle and position the hooks [3] on
the bottom of the seat behind the dollies [4] on the subframe. Press down on
the seat near the holding strap while sliding it forwards. The two tabs [5] must
hook onto the tank. Turn the ignition key in the seat lock 90° in a counter­clockwise direction and pull off. Check whether the seat is mounted correctly.

Baggage loops

4 loops [6] are mounted on the bottom of the seat to which small pieces of
baggage can be fastened. Fold the loops towards the outside to make them
accessible when the seat is mounted.

BAGGAGE WEIGHT: MAX. 5 KG

Tool set

The tool set [7] is located in the storage compartment under the seat.

1

2

3

4

5

6

6

7

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11

OPERATION INSTRUMENTS »

Helmet lock

The steel rope [1] in the tool bag can be used to secure a helmet.
To secure, remove the seat, run the rope through the helmet, attach both ends
to the hook [2] and mount the seat.

THE HELMET LOCK IS PROVIDED TO SECURE THE HELMET TO THE MOTORCYCLE
WHEN PARKED. DO NOT ATTACH THE HELMET OR OTHER OBJECTS TO THE STEEL
ROPE WHILE DRIVING. YOU CAN EASILY LOSE CONTROL OF THE MOTORCYCLE.

Holding strap

The passenger should hold on to the holding strap [3] or the driver while
riding.

Shift lever

The shift lever is mounted on the left side of the engine. The position of the
gears is shown in the illustration. Neutral, or the idle speed, is located between
first and second gear.
The basic position of the shift lever can be adjusted according to your seat­ing position (see Maintenance work).

Side stand

Fold the side stand [4] forward to the stop with your foot and put the weight
of the motorcycle on the stand. Make sure it is standing securely on a firm
surface. The side stand is linked to the safety start system; follow the driving
instructions.

Foot brake pedal

The foot brake pedal [5] is located in front of the right footrest. Its basic
position can be adjusted to your seat position (see maintenance work).

1

N

2,3,4,5,6

3

1

2

4

5

ENGLISH

12

OPERATION INSTRUMENTS »

Footrests

The passenger footrests [1] fold up.

Compression damping of fork

The fork's damping action during compression travel (compression damping)
can be adjusted. This allows you adjust the damping behavior to match your
driving style and the payload.
The adjusting screws [2] are located on the fork leg axle passage.
More information is provided in the chapter "Adjusting the fork and shock
absorber.“

Rebound damping of fork

The fork's damping action during rebound travel (rebound damping) can also
be adjusted. This allows you adjust the damping behavior to match your driv­ing style and the payload.
The adjusting screws [3] are located on the upper end of the fork legs.
More information is provided in the chapter "Adjusting the fork and shock
absorber.“

Spring preload of the fork

The fork's preload can be adjusted by means of the adjusting screws [4].
More information is provided in the chapter "Adjusting the fork and shock
absorber.“

1

2

3

4

ENGLISH

13

OPERATION INSTRUMENTS »

Damping action during compression of shock absorber

The shock absorber's damping action during compression travel (compression
damping) can be adjusted. This allows you adjust the shock absorber's damp­ing behavior to match your driving style and the payload.
The damping rate can be adjusted in the low and high-speed range (Dual
Compression Control). The designation low and high-speed refers to the move­ment of the shock absorber and not to the motorcycle's driving speed.

The adjusting screw [1] for the low-speed range can be adjusted with a
screwdriver.

The adjusting screw [2] for the high-speed range can be adjusted with a
17 mm socket wrench.

More information is provided in the chapter "Adjusting the fork and shock
absorber.“

Rebound damping of shock absorber

The shock absorber's damping action during rebound travel (rebound damp­ing) can also be adjusted. This allows you adjust the damping behavior to
match your driving style and the payload.
The adjusting screw [3] is located on the bottom of the shock absorber.
More information is provided in the chapter "Adjusting the fork and shock
absorber.“

Spring preload on shock absorber

The spring preload on the shock absorber can be adjusted by turning the adjust­ing ring [4].
More information is provided in the chapter "Adjusting the fork and shock
absorber.“

1

2

3

4

– NEW WHEELS HAVE A SMOOTH SURFACE, WHICH MEANS THAT

THEY MUST BE RUN IN TO ACHIEVE FULL GRIP. FOR THIS PUR­POSE, RIDE THE MOTORCYCLE CAREFULLY AT MODERATE SPEED
DURING THE FIRST 200 KILOMETERS WITH NEW TIRES, TILTING
THE VEHICLE AT DIFFERENT ANGLES SO THAT ALL SECTIONS ARE
PROPERLY ROUGHENED. TIRES WILL NOT DISPLAY THEIR FULL
GRIP CHARACTERISTICS UNTIL THEY ARE PROPERLY RUN IN.

– WHEELS WITH A DIFFERENT RIM DIAMETER OR OTHER RIM WIDTH

MAY NOT BE MOUNTED OTHERWISE THE VEHICLE HANDLING
WILL NO LONGER BE SAFE.

– OBSERVE THE TRAFFIC REGULATIONS, DRIVE DEFENSIVELY AND

TRYING TO LOOK AHEAD AS FAR AS POSSIBLE SO THAT ANY HAZ­ARDS CAN BE RECOGNIZED AS EARLY AS POSSIBLE.

– THE FASTER YOU DRIVE, THE MORE SENSITIVE YOUR MOTORCY-

CLE WILL BE TO CROSSWIND AND CHANGING ROAD CONDITIONS.
YOUR MOTORCYCLE CAN EASILY GO OUT OF CONTROL AT HIGH
SPEEDS.

– CHOOSE YOUR DRIVING SPEED ACCORDING TO THE CONDITIONS

AND YOUR DRIVING SKILLS.

– DRIVE CAREFULLY ON UNKNOWN ROADS OR ON UNFAMILIAR

TRIALS.

– RENEW THE VIZOR ON YOUR HELMET OR THE GLASS OF YOUR

GOGGLES ON TIME SO AS TO ENSURE OPTIMUM VISION IN ANY
SITUATION. WHEN LIGHT SHINES DIRECTLY ON SCRATCHED VISOR
OR GOGGLES, THE OPERATOR WILL BE BLINDED.

– NEVER LEAVE YOUR MOTORCYCLE WITHOUT SUPERVISION IF THE

ENGINE IS RUNNING.

Accessories and payload

Accessory parts and baggage can significantly decrease a motor­cycle's driving stability. Please observe the following warnings.

– NEVER DRIVE FASTER THAN 130 KPH (80 MPH) IF YOU HAVE

MOUNTED ACCESSORY PARTS ON YOUR MOTORCYCLE. ACCESSORY
PARTS CAN SIGNIFICANTLY IMPAIR THE MOTORCYCLE'S HAN­DLING, ESPECIALLY IN THE MAXIMUM SPEED RANGE.

– NEVER DRIVE FASTER THAN 130 KPH (80 MPH) IF YOUR MOTOR-

CYCLE IS LOADED WITH CASES OR OTHER BAGGAGE. THEY WILL
IMPAIR THE MOTORCYCLE'S HANDLING AT HIGHER SPEEDS AND
CAN EASILY CAUSE IT TO GO OUT OF CONTROL

– IF YOU HAVE CASES MOUNTED, DO NOT EXCEED THE MANUFAC-

TURER'S RECOMMENDED MAXIMUM PAYLOAD.

– FASTEN THE BAGGAGE CLOSE TO THE CENTER OF THE MOTOR-

CYCLE AND DISTRIBUTE THE WEIGHT EVENLY ON THE FRONT AND
REAR WHEELS AND ON THE LEFT AND RIGHT.

– BAGGAGE MUST BE SECURELY AND ADEQUATELY FASTENEND;

LOOSE BAGGAGE WILL SIGNIFICANTLY IMPAIR DRIVING SAFETY.

– A HIGH PAYLOAD WILL CHANGE THE MOTORCYCLE'S HANDLING

AND CONSIDERABLY INCREASE THE BRAKING DISTANCE; ADAPT
YOUR DRIVING SPEED ACCORDINGLY.

– NEVER EXCEED THE MAXIMUM PERMISSIBLE LADEN WEIGHT

AND THE AXLE WEIGHTS. THE MAXIMUM PERMISSIBLE LADEN
WEIGHT IS MADE UP OF THE FOLLOWING COMPONENTS:
– MOTORCYCLE READY FOR OPERATION AND TANK FULL
– LUGGAGE
–

DRIVER AND PASSENGER WITH PROTECTIVE CLOTHING AND HELMET

ENGLISH

14

GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE »

Instructions for initial operation

– Make sure the work for the "pre-delivery inspection" was per-

formed by your authorized KTM workshop. The DELIVERY
CERTIFICATE and SERVICE MANUAL will be handed over

when you pick up your vehicle.
– Read these operating instructions carefully before your first ride.
– Enter the chassis, engine and key numbers on page 1.
– Familiarize yourself with the operating elements.
– Adjust the clutch lever, the hand brake lever, the foot brake

lever and the shift lever in the position that is most convenient

for you.
– This motorcycle is equipped with a three-way catalytic conver-

ter. Leaded fuel will destroy the converter. Always use unlea-

ded fuel.
– Get used to handling the motorcycle on an empty parking lot,

before starting on a longer drive. Also try to drive as slowly as

possible and in standing position, to improve your feeling for

the vehicle.
– Do not drive along off-road tracks which go beyond your abitily

and experience.
– Hold the handlebars with both hands and leave your feet on

the foot rests while driving.
– Remove your foot from the foot brake lever when you are not

braking. If the foot brake lever is not released the brake pads

rub continuously and the braking system is overheated.
– Do not make any alterations to the motorcycle and always use

ORIGINAL KTM SPARE PARTS. Spare parts from other man-

ufacturers can impair the safety of the motorcycle.
– Motorcycles are sensitive to changes in the weight distribu-

tion. Read the section on "Accessories and payload“ when car-

rying luggage.
– Pay attention to running-in procedure.

Running in the LC8 engine

Even finely machined surfaces of engine parts have rougher sur­faces than parts that slide on each other for a long time. Therefore,
every engine must be run in. For this reason, do not demand max­imum performance from the engine for the first 1000 kilometers
(620 miles). The vehicle must be run in at low, changing perform­ance level for the first 1000 km (620 miles). The maximum num­ber of revolutions per minute must not go exceed 6500 rpm. Once
you have run your engine in for 1000 km, you may push it to its
9500 rpm limit , i.e. up to the black zone indicated in the tachome­ter. Exceeding the above listed rotations as well as pushing high
rpm when the engine is cold will have an adverse effect on the life
of your engine.

– WEAR SUITABLE CLOTHING WHEN DRIVING A MOTORCYCLE.

CLEVER KTM DRIVERS ALWAYS WEAR A HELMET, BOOTS, GLOVES

AND A JACKET, REGARDLESS OF WHETHER DRIVING ALL DAY OR

JUST FOR A SHORT TRIP. THE PROTECTIVE CLOTHING SHOULD

BE BRIGHTLY COLORED SO THAT OTHER VEHICLE CAN SEE YOU

AS EARLY AS POSSIBLE. YOUR PASSENGER WILL ALSO NEED

SUITABLE PROTECTIVE CLOTHING.
– DO NOT DRIVE AFTER HAVING CONSUMED ALCOHOL.
– ALWAYS TURN ON THE LIGHT TO MAKE SURE THAT OTHER DRIV-

ERS BECOME AWARE OF YOU AS EARLY AS POSSIBLE.
– DRIVE AT A MODERATE SPEED FOR THE FIRST FEW KILOMETERS

OF EACH TRIP TO ALLOW THE TIRES TO REACH THE NECESSARY

OPERATING TEMPERATURE. MAXIMUM ROAD GRIP IS ASSURED

WHEN THE TIRES ARE WARM.
– THE FRONT AND REAR WHEEL ARE ALLOWED TO BE FITTED ONLY

WITH TIRES THAT HAVE THE SAME PROFILE TYPE.
– THE TIRES MUST BE DESIGNED FOR A SPEED OF OVER 240 KPH

(SPEED SYMBOL ZR) AND MUST BE RELEASED BY KTM.
– DO NOT EXCEED THE RESPECTIVE MAXIMUM SPEED FOR TIRES

DESIGNED WITH A SPEED INDEX OF LESS THAN "V“ (240 KPH).

A STICKER SHOWING THE MAXIMUM SPEED MUST BE AFFIXED

TO THE MOTORCYCLE WITHIN THE DRIVER'S FIELD OF VISION.

ENGLISH

15

DRIVING INSTRUCTIONS »

Check the following before each start

When you start, the motorcycle must be in perfect mechanical condition. For
safety reasons, you should make a habit of performing an overall check of
your motorcycle before each start.

The following checks should be performed:

1 FUEL

Check the fuel quantity in the tanks.

2 CHAIN

Check the tension and condition of the chain.
A loose chain can fall off the sprockets and a worn-out chain can tear. In
both cases this can damage other motorcycle components and cause the
motorcycle to go out of control. A chain that is too tight or not greased
will cause unnecessary wear to the chain and sprockets.

3 TIRES

Check for damaged tires. Tires showing cuts or dents must be replaced.
The tread depth must comply with the legal regulations. Also check the
air pressure. Insufficient tread and incorrect air pressure deteriorate the
driving performance.

4 BRAKES

Check correct functioning of the braking system. Check for sufficient
brake fluid in the reservoir. The reservoirs have been designed in such a
way that brake fluid does not need to be refilled even when the brake pads
are worn. If the level of brake fluid falls below the minimum value, this
indicates a leak in the braking system or completely worn out brake pads.
Arrange for the braking system to be checked by a KTM specialist, as com­plete failure of the braking system can be avoided.
Also check the state of the brake hose and the thickness of the brake
linings.
Check free travel at hand brake lever and foot brake lever.

5 CABLES

Check the throttle cable for correct adjustment and smooth operation.

6 COOLING FLUID

Check the level of cooling fluid when the engine is cold.

7 ELECTRICAL SYSTEM

Start the engine and check the headlight, tail lamp, brake light, turn sig­nals, indicator lamps, horn and emergency-off switch for proper
functioning.

8 CHECK OIL LEVEL

Insufficient oil results in premature wear and consequently to engine
damage.

9 BAGGAGE, PAYLOAD

Never exceed the maximum total weight (380 kg, 838 lbs) and the motor­cycle's wheel loads. The maximum total weight is comprised of:
– the motorcycle in a running condition and refueled (195 kg, 430 lbs)
– the baggage and accessories
– the driver and passenger with protective gear and helmet
Adjust the tire inflation pressure as well as the preload and damping prop­erties of the fork and shock absorber to the total weight.

10 REAR MIRROR

Sit on the motorcycle and check the adjustment of the rear mirror.