KTM 990 Super Duke 2012 Owner's manual
OWNER'S MANUAL 2012
990 Super Duke FR
990 Super Duke R EU
990 Super Duke R AUS/UK
990 Super Duke R FR
Art. no. 3211796en
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/type label ( 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. However, it is never possible to exclude
small deviations arising from further development in design and construction.
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 printing and other errors. The models portrayed partly contain special equipment that
does not belong to the regular scope of delivery.
DEAR KTM CUSTOMER 2
© 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.
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/type label ................................................. 16
Key number ..................................................................... 17
Engine number................................................................. 17
Fork part number.............................................................. 18
Shock absorber part number .............................................. 18
CONTROLS.......................................................................... 19
Clutch lever ..................................................................... 19
Hand brake lever .............................................................. 19
Throttle grip..................................................................... 20
Light switch..................................................................... 20
Headlight flasher switch .................................................... 21
Turn signal switch ............................................................ 21
Horn button ..................................................................... 22
Ignition/steering lock ........................................................ 22
Emergency OFF switch ...................................................... 23
Electric starter button ....................................................... 23
Combination instrument .................................................... 24
Combination instrument - function buttons ......................... 24
Combination instrument - tachometer................................. 25
Combination instrument - indicator lamps........................... 25
Combination instrument - display....................................... 26
Combination instrument - speedometer............................... 27
Setting kilometers or miles ................................................ 27
Combination instrument - time .......................................... 28
Setting the clock .............................................................. 28
Combination instrument - ODO display ............................... 29
Combination instrument - setting/resetting TRIP 1............... 29
Combination instrument - setting/resetting TRIP 2............... 30
Combination instrument - TRIP F display............................ 31
Combination instrument - ambient temperature display........ 31
Setting the temperature units ............................................ 32
Combination instrument - warning of slippery roads ............. 32
Combination instrument - coolant temperature indicator ...... 33
Opening the filler cap ....................................................... 33
Closing the filler cap ......................................................... 35
Seat lock ......................................................................... 36
Supporting strap............................................................... 36
Baggage lugs.................................................................... 37
Tool set ........................................................................... 37
Helmet lock ..................................................................... 38
Passenger footrests........................................................... 38
Shift lever........................................................................ 39
Foot brake lever................................................................ 40
Side stand ....................................................................... 40
PREPARING FOR USE .......................................................... 41
Information on first use ..................................................... 41
Running in the engine....................................................... 42
Loading the vehicle .......................................................... 42
TABLE OF CONTENTS 4
RIDING INSTRUCTIONS ....................................................... 45
Checks and maintenance measures when preparing for
use ................................................................................. 45
Starting ........................................................................... 46
Starting off ...................................................................... 47
Shifting, riding................................................................. 48
Braking ........................................................................... 51
Stopping, parking ............................................................. 52
Refueling......................................................................... 54
SERVICE SCHEDULE............................................................ 56
Service schedule .............................................................. 56
TUNING THE CHASSIS......................................................... 59
Fork/shock absorber.......................................................... 59
Adjusting the compression damping of the fork ................... 59
Adjusting the rebound damping of the fork.......................... 61
Adjusting the spring preload of the fork .............................. 62
Compression damping of the shock absorber ....................... 63
Adjusting the low-speed compression damping of the shock
absorber .......................................................................... 64
Adjusting the high-speed compression damping of the
shock absorber................................................................. 65
Adjusting the rebound damping of the shock absorber.......... 67
Adjusting the spring preload of the shock absorber x ......... 68
Handlebar position (Super Duke R) .................................... 69
Adjusting the handlebar position x (Super Duke R)............ 70
Steering damper (Super Duke R)........................................ 71
Adjusting the steering damper (Super Duke R) .................... 71
SERVICE WORK ON THE CHASSIS ........................................ 73
Raising the motorcycle with the front wheel stand ............... 73
Taking the motorcycle off of the front wheel stand ............... 73
Raising the motorcycle with the rear wheel stand................. 74
Taking the motorcycle off of the rear wheel stand ................ 74
Bleeding the fork legs ....................................................... 75
Removing the spoiler ........................................................ 75
Installing the spoiler ......................................................... 76
Removing the front spoiler................................................. 78
Installing the front spoiler ................................................. 78
Removing the seat............................................................ 79
Mounting the seat ............................................................ 79
Mounting the helmet lock on the vehicle............................. 80
Checking the chain for dirt ................................................ 80
Cleaning the chain............................................................ 81
Checking the chain tension ............................................... 82
Adjusting the chain tension ............................................... 83
Checking the chain, rear sprocket, engine sprocket and
chain guide...................................................................... 85
Adjusting the basic position of the clutch lever.................... 88
Checking/correcting the fluid level of the hydraulic clutch .... 88
BRAKES.............................................................................. 90
Adjusting the basic position of the hand brake lever............. 90
Checking the front brake discs ........................................... 90
Checking the front brake fluid level .................................... 91
Adding front brake fluid x ............................................... 92
Checking the front brake linings......................................... 93
Adjusting the basic position of the foot brake lever x ......... 95
Checking the rear brake disc.............................................. 95
Checking the rear brake fluid level ..................................... 96
Adding rear brake fluid x ................................................ 97
TABLE OF CONTENTS 5
Checking the rear brake linings .......................................... 98
WHEELS, TIRES ................................................................ 100
Removing the front wheel x........................................... 100
Installing the front wheel x............................................ 101
Removing the rear wheel x ............................................ 103
Installing the rear wheel x............................................. 104
Checking rear hub shock absorbers x ............................. 106
Checking the tire condition.............................................. 107
Checking the tire air pressure .......................................... 108
ELECTRICAL SYSTEM ........................................................ 110
Removing the battery x................................................. 110
Installing the battery x.................................................. 112
Recharging the battery x............................................... 113
Changing the main fuse .................................................. 116
Changing the fuses of individual power consumers............. 118
Changing the low beam bulb............................................ 120
Changing the high beam bulb .......................................... 122
Changing the parking light bulb ....................................... 125
Changing the turn signal bulb .......................................... 126
Changing the brake light bulb .......................................... 127
Changing the tail light bulbs............................................ 129
Changing the license plate lamp ...................................... 130
Checking the headlight setting......................................... 131
Adjusting the headlight range .......................................... 132
COOLING SYSTEM ............................................................. 133
Cooling system............................................................... 133
Checking the antifreeze and coolant level ......................... 133
Checking the coolant level in the compensating tank ......... 136
Draining the coolant x .................................................. 137
Filling/bleeding the cooling system x.............................. 139
TUNING THE ENGINE ........................................................ 142
Checking the play in the throttle cable.............................. 142
Adjusting the play in the throttle cable x ........................ 143
Adjusting the basic position of the shift lever x ............... 144
SERVICE WORK ON THE ENGINE ....................................... 145
Checking the engine oil level ........................................... 145
Changing the engine oil and filter, cleaning the oil
screens x..................................................................... 146
Draining the engine oil and filter, cleaning the oil
screens x..................................................................... 146
Filling up with engine oil x............................................ 150
Adding engine oil ........................................................... 152
CLEANING, CARE .............................................................. 154
Cleaning motorcycle ....................................................... 154
Checks and maintenance measures for winter operation ..... 156
STORAGE .......................................................................... 157
Storage.......................................................................... 157
Preparing for use after storage ......................................... 158
TROUBLESHOOTING.......................................................... 159
ENGINE CONTROL BLINK CODE ......................................... 162
TECHNICAL DATA - ENGINE ............................................... 168
Capacity - engine oil ....................................................... 169
Capacity - coolant........................................................... 169
TECHNICAL DATA - ENGINE TIGHTENING TORQUES........... 170
TECHNICAL DATA - CHASSIS ............................................. 173
Lighting equipment ........................................................ 174
Tires ............................................................................. 175
Capacity - fuel................................................................ 175
TABLE OF CONTENTS 6
TECHNICAL DATA - FORK................................................... 176
Super Duke.................................................................... 176
Super Duke R ................................................................ 177
TECHNICAL DATA - SHOCK ABSORBER .............................. 179
Super Duke.................................................................... 179
Super Duke R ................................................................ 180
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ......... 182
SUBSTANCES.................................................................... 185
AUXILIARY SUBSTANCES................................................... 189
STANDARDS...................................................................... 191
INDEX ............................................................................... 192
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
(Super Duke)
KTM sport motorcycles are designed and constructed to meet the normal demands of regular road operation but not for use on race
courses or offroad.
Info
The motorcycle is authorized for public road traffic in the homologous version only.
(Super Duke R)
KTM sport motorcycles are designed and constructed to meet the normal demands of regular road and race track operation, but not for
use on dirt roads.
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 claim can be honored for damage resulting from manipulation and/or other changes to the vehicle.
IMPORTANT INFORMATION 9
Fuels, oils, etc.
The fuels and lubricants named in the owner's manual must be used according to specifications.
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.
IMPORTANT INFORMATION 10
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.
– 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)
101612-10
VIEW OF VEHICLE 13
1 Combination instrument ( p. 24)
2 Rear mirror
3 Clutch lever ( p. 19)
4 Seat
5 Seat lock ( p. 36)
6 Engine number ( p. 17)
7 Shift lever ( p. 39)
8 Shock absorber, spring preload setting
9 Compression damping of the shock absorber ( p. 63)
VIEW OF VEHICLE 14
3.2View of vehicle, rear right side (vehicle differs slightly from photo)
101613-10
VIEW OF VEHICLE 15
1 Light switch ( p. 20)
1 Headlight flasher switch ( p. 21)
1 Turn signal switch ( p. 21)
1 Horn button ( p. 22)
2 Emergency OFF switch ( p. 23)
2 Electric starter button ( p. 23)
3 Throttle grip ( p. 20)
4 Hand brake lever ( p. 19)
5 Fork rebound setting and spring preload setting
6 Chassis number/type label ( p. 16)
7 Shock absorber rebound adjustment
8 Brake fluid reservoir
9 Foot brake lever ( p. 40)
10 Chassis number/type label ( p. 16)
11 Fork compression adjustment
SERIAL NUMBERS 16
4.1Chassis number/type label
Chassis number 1 is embossed in the steering head at the right.
Type label 2 is located on the upper frame tube on the right.
B00153-10
SERIAL NUMBERS 17
4.2Key number
Key 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.
100179-10
4.3Engine number
The engine number 1 is stamped on the left side of the engine under the engine sprocket.
B00154-10
SERIAL NUMBERS 18
4.4Fork part number
The fork part number 1 is stamped on the inner side of the fork stub.
B00155-10
4.5Shock absorber part number
The shock absorber part number 1 is stamped on the top of the shock absorber above the
adjusting ring on the engine side.
B00156-10
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.
B00157-10
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.
B00158-10
CONTROLS 20
5.3Throttle grip
The throttle grip 1 is fitted on the right side of the handlebar.
101182-10
5.4Light 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.
B00159-10
CONTROLS 21
5.5Headlight flasher switch
The headlight flasher switch 1 is fitted on the left side of the handlebar.
Possible states
• Headlight flasher switch in basic position
• Headlight flasher switch pressed – The headlight flasher switch (high beam) is operated in this position.
B00160-10
5.6Turn signal switch
The turn signal switch 1 is fitted on the left side of the handlebar.
Possible states
Turn signal off
Left turn signal on – The turn signal switch is pressed to the left. The turn
signal switch automatically returns to the central position after use.
Right turn signal on – The turn signal switch is pressed to the right. The
turn signal switch automatically returns to the central position after use.
B00159-11
To switch off the turn signal, press the turn signal switch towards the switch case.
CONTROLS 22
5.7Horn button
The horn button 1 is fitted on the left side of the handlebar.
Possible states
• Horn button in basic position
• Horn button pressed – The horn is operated in this position.
B00159-12
5.8Ignition/steering lock
The ignition/steering lock is in front of the upper triple clamp.
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 ignition 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
600825-01
steering locked. The ignition key can be removed.
CONTROLS 23
5.9Emergency OFF switch
The emergency OFF switch 1 is fitted on the right side of the handlebar.
Possible states
Emergency OFF switch on – This position is necessary for operation as it
closes the ignition circuit.
Emergency OFF switch off – In this position, the ignition circuit is interrupted, a running engine stops, and the engine cannot be started.
B00161-10
5.10Electric 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 pressed – The electric starter is actuated in this position.
700552-11
CONTROLS 24
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 lights
4 Display
400972-10
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.
Button 3 has no function.
400973-10
CONTROLS 25
5.13Combination instrument - tachometer
The tachometer 1 shows the engine speed in revolutions per minute.
The red marking 2 shows the excess speed range of the engine.
400974-10
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 shifted
to idle.
400975-01
The high beam indicator lamp lights up blue – The high beam is switched
on.
The temperature warning lamp lights up red – The coolant 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.
Warning lamp FI (MIL) lights up/flashes orange – The OBD (on-board diagnosis) has detected an emission- or safety-critical error.
The battery warning lamp lights up red – The voltage in the vehicle system
is too low.
5.15Combination instrument - display
When you switch on the ignition, all display segments light up for one second as a function
test.
400892-01
LEnGth
Following the display function test, the LEnGth wheel circumference is shown for one second.
400881-01
Info
1870 mm corresponds to the circumference of the 17" front wheel with a series production tire.
The display then changes to the last selected mode.
CONTROLS 27
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.
Condition
The motorcycle is stationary.
CONTROLS 28
– Switch on the ignition by turning the ignition key to the ON position.
– 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
5.19Setting the clock
Condition
The motorcycle is stationary.
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