KTM 990 SUPER DUKE R User Manual
OWNER'S MANUAL 2013
990 Super Duke R EU
990 Super Duke R AUS/UK
990 Super Duke R FR
Art. no. 3211960en
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 Dealer's stamp
Engine number ( p. 21)
Key number ( p. 21)
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 belong to the regular scope of supply.
© 2012 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
1 MEANS OF REPRESENTATION ........................................ 7
1.1 Symbols used ...................................................... 7
1.2 Formats used....................................................... 7
2 SAFETY ADVICE.............................................................. 8
2.1 Use definition - intended use ................................ 8
2.2 Safety advice ....................................................... 8
2.3 Degrees of risk and symbols.................................. 9
2.4 Tampering warning............................................... 9
2.5 Safe operation ................................................... 10
2.6 Protective clothing ............................................. 11
2.7 Work rules ......................................................... 11
2.8 Environment...................................................... 11
2.9 Owner's Manual ................................................. 12
3 IMPORTANT NOTES...................................................... 13
3.1 Guarantee, warranty ........................................... 13
3.2 Operating and auxiliary substances ...................... 13
3.3 Spare parts, accessories ..................................... 13
3.4 Service ............................................................. 13
3.5 Figures ............................................................. 14
3.6 Customer service................................................ 14
4 VIEW OF VEHICLE ........................................................ 16
4.1 View of vehicle, front left side (example) .............. 16
4.2 View of vehicle, rear right side (example).............. 18
5 SERIAL NUMBERS ....................................................... 20
5.1 Chassis number ................................................. 20
5.2 Type label ......................................................... 20
5.3 Key number....................................................... 21
5.4 Engine number .................................................. 21
5.5 Fork part number ............................................... 22
5.6 Shock absorber part number ............................... 22
6 CONTROLS................................................................... 23
6.1 Clutch lever ....................................................... 23
6.2 Hand brake lever................................................ 23
6.3 Throttle grip ...................................................... 24
6.4 Horn button....................................................... 24
6.5 Light switch ...................................................... 25
6.6 Headlight flasher switch ..................................... 25
6.7 Turn signal switch.............................................. 26
6.8 Emergency OFF switch ....................................... 26
6.9 Electric starter button......................................... 27
6.10 Ignition/steering lock.......................................... 27
6.11 Combination instrument ..................................... 28
6.11.1 Overview ....................................................... 28
6.11.2 Function buttons ........................................... 28
6.11.3 Tachometer................................................... 29
6.11.4 Indicator lamps ............................................. 29
6.11.5 Display ......................................................... 30
6.11.6 Speed display................................................ 31
6.11.7 Setting kilometers or miles ............................. 31
6.11.8 Time............................................................. 32
6.11.9 Setting the clock ........................................... 32
6.11.10 ODO display .................................................. 33
6.11.11 Setting/resetting display TRIP 1 ...................... 33
6.11.12 Setting/resetting display TRIP 2 ...................... 34
6.11.13 TRIP F display............................................... 35
6.11.14 Ambient temperature indicator........................ 35
6.11.15 Setting the temperature units.......................... 35
6.11.16 Warning of icy roads....................................... 36
TABLE OF CONTENTS 4
6.11.17 Coolant temperature indicator ......................... 37
6.12 Opening the filler cap......................................... 37
6.13 Closing the filler cap .......................................... 39
6.14 Seat lock........................................................... 40
6.15 Baggage lugs ..................................................... 40
6.16 Tool set............................................................. 41
6.17 Supporting strap ................................................ 41
6.18 Helmet lock....................................................... 42
6.19 Passenger footrests ............................................ 42
6.20 Shift lever ......................................................... 43
6.21 Foot brake lever ................................................. 44
6.22 Side stand......................................................... 44
7 PREPARING FOR USE................................................... 45
7.1 Information on first use ...................................... 45
7.2 Running in the engine ........................................ 46
7.3 Loading the vehicle............................................ 46
8 RIDING INSTRUCTIONS................................................ 49
8.1 Checks and maintenance measures when
preparing for use................................................ 49
8.2 Starting............................................................. 50
8.3 Starting off........................................................ 51
8.4 Shifting, riding .................................................. 52
8.5 Braking............................................................. 55
8.6 Stopping, parking............................................... 56
8.7 Transport .......................................................... 58
8.8 Refueling .......................................................... 59
9 SERVICE SCHEDULE .................................................... 61
9.1 Service schedule................................................ 61
10 TUNING THE CHASSIS ................................................. 64
10.1 Fork/shock absorber ........................................... 64
10.2 Adjusting the compression damping of the fork..... 64
10.3 Adjusting the rebound damping of the fork........... 65
10.4 Adjusting the spring preload of the fork................ 66
10.5 Compression damping of the shock absorber......... 68
10.6 Adjusting the low-speed compression damping of
the shock absorber............................................. 68
10.7 Adjusting the high-speed compression damping
of the shock absorber ......................................... 69
10.8 Adjusting the rebound damping of the shock
absorber............................................................ 70
10.9 Adjusting the spring preload of the shock
absorber x....................................................... 71
10.10 Handlebar position............................................. 73
10.11 Adjusting the handlebar position x .................... 73
10.12 Steering damper ................................................ 74
10.13 Adjusting the steering damper............................. 75
11 SERVICE WORK ON THE CHASSIS................................. 76
11.1 Raising the motorcycle with the rear wheel
stand ................................................................ 76
11.2 Taking the motorcycle off of the rear wheel
stand ................................................................ 76
11.3 Raising the motorcycle with the front wheel
stand ................................................................ 77
11.4 Taking the motorcycle off of the front wheel
stand ................................................................ 77
11.5 Bleeding the fork legs......................................... 78
11.6 Removing the spoiler.......................................... 78
11.7 Installing the spoiler........................................... 79
TABLE OF CONTENTS 5
11.8 Removing the front spoiler .................................. 81
11.9 Installing the front spoiler................................... 81
11.10 Removing the seat ............................................. 82
11.11 Mounting the seat .............................................. 82
11.12 Mounting the helmet lock on the vehicle .............. 83
11.13 Checking the chain for dirt.................................. 83
11.14 Cleaning the chain ............................................. 84
11.15 Checking the chain tension ................................. 85
11.16 Adjusting the chain tension................................. 86
11.17 Checking the chain, rear sprocket, engine
sprocket and chain guide .................................... 88
11.18 Adjusting the basic position of the clutch lever ..... 91
11.19 Checking/correcting the fluid level of the
hydraulic clutch................................................. 91
12 BRAKE SYSTEM ........................................................... 93
12.1 Adjusting the basic position of the hand brake
lever ................................................................. 93
12.2 Checking the front brake discs ............................ 93
12.3 Checking the front brake fluid level ..................... 94
12.4 Adding front brake fluid x................................. 95
12.5 Checking the front brake linings .......................... 96
12.6 Adjusting the basic position of the foot brake
lever x ............................................................ 98
12.7 Checking the rear brake disc ............................... 98
12.8 Checking the rear brake fluid level....................... 99
12.9 Adding rear brake fluid x................................ 100
12.10 Checking the rear brake linings ......................... 101
13 WHEELS, TIRES ......................................................... 103
13.1 Removing the front wheel x ............................ 103
13.2 Installing the front wheel x............................. 104
13.3 Removing the rear wheel x.............................. 106
13.4 Installing the rear wheel x .............................. 107
13.5 Checking the rear hub rubber dampers x.......... 109
13.6 Checking the tire condition ............................... 110
13.7 Checking the tire air pressure............................ 111
14 ELECTRICAL SYSTEM ................................................. 113
14.1 Removing the battery x .................................. 113
14.2 Installing the battery x ................................... 115
14.3 Recharging the battery x ................................ 116
14.4 Changing the main fuse .................................... 119
14.5 Changing the fuses of individual power
consumers....................................................... 121
14.6 Changing the low beam bulb ............................. 123
14.7 Changing the high beam bulb............................ 125
14.8 Changing the parking light bulb......................... 128
14.9 Changing the turn signal bulb ........................... 129
14.10 Changing the brake light bulb ........................... 130
14.11 Changing the tail light bulbs ............................. 132
14.12 Changing the license plate lamp........................ 133
14.13 Checking the headlight setting .......................... 134
14.14 Adjusting the headlight range............................ 135
15 COOLING SYSTEM ...................................................... 136
15.1 Cooling system ................................................ 136
15.2 Checking the antifreeze and coolant level ........... 136
15.3 Checking the coolant level in the compensating
tank................................................................ 139
15.4 Draining the coolant x.................................... 140
15.5 Filling/bleeding the cooling system x ............... 141
TABLE OF CONTENTS 6
16 TUNING THE ENGINE................................................. 144
16.1 Checking the play in the throttle cable............... 144
16.2 Adjusting the play in the throttle cable x.......... 145
16.3 Checking the basic position of the shift lever ...... 145
16.4 Adjusting the basic position of the shift
lever x .......................................................... 146
17 SERVICE WORK ON THE ENGINE ................................ 147
17.1 Checking the engine oil level............................. 147
17.2 Changing the engine oil and filter, cleaning the
oil screens x.................................................. 148
17.3 Draining the engine oil and filter, cleaning the
oil screens x.................................................. 148
17.4 Filling up with engine oil x ............................. 152
17.5 Adding engine oil............................................. 154
18 CLEANING, CARE ....................................................... 156
18.1 Cleaning motorcycle ......................................... 156
18.2 Checks and maintenance measures for winter
operation......................................................... 158
19 STORAGE................................................................... 160
19.1 Storage ........................................................... 160
19.2 Preparing for use after storage........................... 162
20 TROUBLESHOOTING .................................................. 163
21 BLINK CODE .............................................................. 166
22 TECHNICAL DATA....................................................... 172
22.1 Engine............................................................ 172
22.2 engine tightening torques ................................. 173
22.3 Capacities ....................................................... 176
22.3.1 Engine oil ................................................... 176
22.3.2 Coolant....................................................... 177
22.3.3 Fuel ........................................................... 177
22.4 Chassis ........................................................... 177
22.5 Electrical system.............................................. 179
22.6 tires................................................................ 180
22.7 Fork................................................................ 180
22.8 shock absorber ................................................ 181
22.9 Chassis tightening torques ................................ 182
23 SUBSTANCES ............................................................ 186
24 AUXILIARY SUBSTANCES ........................................... 190
25 STANDARDS .............................................................. 193
INDEX ............................................................................... 194
1 MEANS OF REPRESENTATION 7
1.1 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 optimally
cared for by specially trained experts using the specialist tools required.
Indicates a page reference (more information is provided on the specified page).
1.2 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.
2 SAFETY ADVICE 8
2.1 Use definition - intended use
KTM sport motorcycles are designed and constructed to meet the normal demands of regular road operation and also for use on race
courses, but not for offroad use.
Info
The motorcycle is only authorized for operation on public roads in the homologated version.
2.2 Safety advice
A number of safety instructions need to be followed to operate the vehicle safely. Therefore, read this manual carefully. The safety instructions are highlighted in the text and are referred to at the relevant passages.
Info
The vehicle has various information and warning labels at prominent locations. Do not remove information/warning labels. If they
are missing, you or others may not recognize dangers and may therefore be injured.
2 SAFETY ADVICE 9
2.3 Degrees of risk and symbols
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.
2.4 Tampering warning
Tampering with the noise control system is prohibited. Federal law prohibits the following acts or the causing thereof:
1 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, or
2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.
Among those acts presumed to constitute tampering are the acts listed below:
2 SAFETY ADVICE 10
1 Removal or puncturing of the main silencer, baffles, header pipes or any other components which conduct exhaust gases.
2 Removal or puncturing of any part of the intake system.
3 Lack of proper maintenance.
4 Replacing any moving part of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by the manu-
facturer.
2.5 Safe operation
Danger
Danger of accidents Danger arising from the rider's judgement being impaired.
– Do not operate the vehicle while under the influence of alcohol, drugs and certain medications or physically or mentally
impaired.
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death.
– When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed
space without an effective exhaust extraction system.
Warning
Danger of burns Some vehicle components become very hot when the vehicle is operated.
– Do not touch hot components such as exhaust system, radiator, engine, shock absorber, and the brake system. Allow these
components to cool down before starting work on them.
Only operate the vehicle when it is in perfect technical condition, in accordance with its intended use, and in a safe and environmentally
compatible manner.
The vehicle should only be used by trained persons. An appropriate driver's license is needed to ride the vehicle on public roads.
Have malfunctions that impair safety promptly eliminated by an authorized KTM workshop.
Adhere to the information and warning labels on the vehicle.
2 SAFETY ADVICE 11
2.6 Protective clothing
Warning
Risk of injury Missing or poor protective clothing presents an increased safety risk.
– Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle. Always wear
protective clothing that is in good condition and meets the legal requirements.
In the interest of your own safety, KTM recommends that you only operate the vehicle while wearing protective clothing.
2.7 Work rules
Special tools are necessary for certain tasks. The tools are not contained in the vehicle but can be ordered under the number in parentheses. E.g.: bearing puller (15112017000)
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.
In some instances, a thread locker (e.g. Loctite®) is required. The manufacturer instructions for use must be followed.
After disassembly, clean the parts that are to be reused and check them for damage and wear. Change damaged or worn parts.
After you complete the repair or service work, check the operating safety of the vehicle.
2.8 Environment
If you use your motorcycle responsibly, you can ensure that problems and conflicts do not occur. To protect the future of the motorcycle
sport, make sure that you use your motorcycle legally, display environmental consciousness, and respect the rights of others.
When disposing of used oil, other operating and auxiliary fluids, and used components, comply with the laws and regulations of the
respective country.
Because motorcycles are not subject to the EU regulations governing the disposal of used vehicles, there are no legal regulations that pertain to the disposal of an end-of-life motorcycle. Your authorized KTM dealer will be glad to advise you.
2 SAFETY ADVICE 12
2.9 Owner's Manual
It is important that you read this Owner's Manual carefully and completely before making your first trip. The Owner's Manual contains useful information and many tips on how to operate, handle, and maintain your motorcycle. Only then will you find out how to customize the
vehicle ideally for your own use and how you can protect yourself from injury.
Keep the Owner's Manual in an accessible place to enable you to refer to it as needed.
If you would like to know more about the vehicle or have questions on the material you read, please contact an authorized KTM dealer.
The Owner's Manual is an important component of the vehicle and should be handed over to the new owner if the vehicle is sold.
3 IMPORTANT NOTES 13
3.1 Guarantee, 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.
Additional information on the guarantee or warranty and the procedures involved can be found in the service record.
3.2 Operating and auxiliary substances
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to get into the ground water, the ground, or the sewage system.
Use operating and auxiliary substances (such as fuel and lubricants) as specified in the Owner's Manual.
3.3 Spare parts, accessories
For your own safety, only use spare parts and accessory products that are 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 or loss.
Certain spare parts and accessory products are specified in parentheses in the descriptions. Your KTM dealer will be glad to advise you.
The current KTM PowerParts for your vehicle can be found on the KTM website.
International KTM Website: http://www.ktm.com
3.4 Service
A prerequisite for perfect operation and prevention of premature wear is that the service, care, and tuning work on the engine and chassis
is properly carried out as described in the Owner's Manual. Incorrect adjustment and tuning of the engine and chassis can lead to damage
and breakage of components.
Use of the vehicle under difficult conditions, such in rain, high heat or with a heavy load, can lead to considerably more rapid wear of
components such as the drive train, brake system, or suspension components. For this reason, it may be necessary to inspect or replace
parts before the next scheduled service.
3 IMPORTANT NOTES 14
It is imperative that you adhere to the stipulated run-in times and service intervals. If you observe these exactly, you will ensure a much
longer service life for your motorcycle.
3.5 Figures
The figures contained in the manual may depict special equipment.
In the interest of clarity, some components may be shown disassembled or may not be shown at all. It is not always necessary to disassemble the component to perform the activity in question. Please follow the instructions in the text.
3.6 Customer service
Your authorized KTM dealer will be happy to answer any questions you may have on your vehicle and KTM.
A list of authorized KTM dealers can be found on the KTM website.
International KTM Website: http://www.ktm.com
15
4 VIEW OF VEHICLE 16
4.1 View of vehicle, front left side (example)
L00403-10
4 VIEW OF VEHICLE 17
1 Function buttons ( p. 28)
1 Indicator lamps ( p. 29)
2 Clutch lever ( p. 23)
3 Filler cap
4 Seat lock ( p. 40)
5 Engine number ( p. 21)
6 Side stand ( p. 44)
7 Shift lever ( p. 43)
8 Shock absorber, spring preload setting
9 Compression damping of the shock absorber ( p. 68)
10 Passenger footrests ( p. 42)
4 VIEW OF VEHICLE 18
4.2 View of vehicle, rear right side (example)
L00402-10
4 VIEW OF VEHICLE 19
1 Light switch ( p. 25)
1 Headlight flasher switch ( p. 25)
1 Turn signal switch ( p. 26)
1 Horn button ( p. 24)
2 Emergency OFF switch ( p. 26)
2 Electric starter button ( p. 27)
3 Throttle grip ( p. 24)
4 Fork rebound setting and spring preload setting
5 Chassis number/type label
6 Shock absorber rebound adjustment
7 Brake fluid reservoir
8 Foot brake lever ( p. 44)
9 Chassis number/type label
10 Fork compression adjustment
5 SERIAL NUMBERS 20
5.1 Chassis number
Chassis number 1 is embossed in the steering head at the right.
L00400-10
5.2 Type label
Type label 1 is located on the upper frame tube on the right.
L00401-10
5 SERIAL NUMBERS 21
5.3 Key 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
5.4 Engine number
The engine number 1 is stamped on the left side of the engine under the engine sprocket.
L00404-10
5 SERIAL NUMBERS 22
5.5 Fork part number
The fork part number 1 is stamped on the inner side of the fork stub.
L00405-10
5.6 Shock 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.
L00406-10
6 CONTROLS 23
6.1 Clutch lever
The clutch lever 1 is fitted on the left side of the handlebar.
The clutch is hydraulically operated and self-adjusting.
B00157-10
6.2 Hand 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
6 CONTROLS 24
6.3 Throttle grip
The throttle grip 1 is fitted on the right side of the handlebar.
101182-10
6.4 Horn 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
6 CONTROLS 25
6.5 Light switch
The light switch 1 is fitted on the left side of the handlebar.
Possible states
Low beam on – The light switch is turned downward. 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
6.6 Headlight 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.
L00407-10
6 CONTROLS 26
6.7 Turn 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
6.8 Emergency OFF switch
B00161-10
To switch off the turn signal, press the turn signal switch towards the switch case.
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.
6 CONTROLS 27
6.9 Electric 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
6.10 Ignition/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.
6 CONTROLS 28
6.11 Combination instrument
6.11.1 Overview
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
6.11.2 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
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