KTM 990 Supermoto 2011 Owner's manual
OWNER'S MANUAL 2011
990 Supermoto T USA
Art. no. 3211663en
DEAR KTM CUSTOMER 1
DEARKTM CUSTOMER
We would like to congratulate you on deciding to purchase a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will give you enormous pleasure if you service and maintain it accordingly.
We wish you a lot of enjoyment in riding this vehicle.
Please enter the serial numbers of your vehicle below.
Chassis number/type label ( p. 26) Dealer's stamp
Engine number ( p. 28)
Key number ( p. 27)
The owner's manual contained the latest information for this model at the time of going to print. Minor differences due to developments in
design cannot be ruled out completely.
All specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifications,
prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt these
to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery options,
deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain special equipment
that does not form part of the regular scope of delivery.
© 2011 KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright owner.
DEAR KTM CUSTOMER 2
ISO 9001(12 100 6061)
According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead to
the maximum possible quality of the products.
Issued by: TÜV Management Service
KTM-Sportmotorcycle AG
5230 Mattighofen, Austria
TABLE OF CONTENTS 3
TABLEOF CONTENTS
MEANS OF REPRESENTATION ............................................... 7
IMPORTANT INFORMATION ................................................... 8
Overview of labels............................................................. 12
VIEW OF VEHICLE................................................................ 22
View of vehicle, front left side (vehicle differs slightly from
photo) ............................................................................. 22
View of vehicle, rear right side (vehicle differs slightly from
photo) ............................................................................. 24
SERIAL NUMBERS............................................................... 26
Chassis number/type label ................................................. 26
Key number ..................................................................... 27
Engine number................................................................. 28
Fork part number.............................................................. 28
Shock absorber part number .............................................. 29
CONTROLS.......................................................................... 30
Clutch lever ..................................................................... 30
Hand brake lever .............................................................. 30
Throttle grip..................................................................... 31
Light switch..................................................................... 31
Headlight flasher switch .................................................... 32
Turn signal switch ............................................................ 32
Horn button ..................................................................... 33
Ignition/steering lock ........................................................ 33
Immobilizer ..................................................................... 34
Emergency OFF switch ...................................................... 34
Electric starter button ....................................................... 35
Combination instrument .................................................... 35
Combination instrument - function buttons ......................... 36
Combination instrument - tachometer................................. 36
Combination instrument - indicator lamps........................... 37
Combination instrument - display....................................... 38
Combination instrument - speedometer............................... 39
Setting kilometers or miles ................................................ 39
Combination instrument - time .......................................... 40
Setting the clock .............................................................. 40
Combination instrument - ODO display ............................... 41
Combination instrument - setting/resetting TRIP 1............... 41
Combination instrument - setting/resetting TRIP 2............... 42
Combination instrument - TRIP F display............................ 43
Combination instrument - ambient temperature display........ 43
Setting the temperature units ............................................ 44
Combination instrument - warning of slippery roads ............. 44
Combination instrument - coolant temperature indicator ...... 45
Hazard warning flasher switch/hazard warning flasher .......... 45
Socket for electrical accessories......................................... 46
Opening the filler cap ....................................................... 46
Closing the filler cap ......................................................... 47
Handrails......................................................................... 48
Luggage rack plate ........................................................... 48
Seat lock ......................................................................... 49
Tool set ........................................................................... 49
Helmet lock ..................................................................... 50
Passenger footrests........................................................... 50
Shift lever........................................................................ 51
Foot brake lever................................................................ 52
Side stand ....................................................................... 52
PREPARING FOR USE .......................................................... 53
Information on first use ..................................................... 53
TABLE OF CONTENTS 4
Running in the engine....................................................... 54
Loading the vehicle .......................................................... 54
RIDING INSTRUCTIONS ....................................................... 57
Checks and maintenance measures when preparing for
use ................................................................................. 57
Starting ........................................................................... 58
Starting off ...................................................................... 60
Shifting, riding................................................................. 60
Braking ........................................................................... 63
Stopping, parking ............................................................. 65
Refueling......................................................................... 66
SERVICE SCHEDULE............................................................ 69
Service schedule .............................................................. 69
TUNING THE CHASSIS......................................................... 72
Fork/shock absorber.......................................................... 72
Adjusting the compression damping of the fork ................... 72
Adjusting the rebound damping of the fork.......................... 73
Adjusting the spring preload of the fork .............................. 74
Compression damping of the shock absorber ....................... 76
Adjusting the low-speed compression damping of the shock
absorber .......................................................................... 76
Adjusting the high-speed compression damping of the
shock absorber................................................................. 77
Adjusting the rebound damping of the shock absorber.......... 78
Adjusting the spring preload of the shock absorber x ......... 79
SERVICE WORK ON THE CHASSIS ........................................ 81
Raising the motorcycle with the front wheel stand ............... 81
Taking the motorcycle off of the front wheel stand ............... 81
Raising the motorcycle with the rear wheel stand................. 82
Taking the motorcycle off of the rear wheel stand ................ 82
Bleeding the fork legs ....................................................... 83
Removing the seat............................................................ 83
Mounting the seat ............................................................ 84
Mounting the helmet lock on the vehicle............................. 84
Reinstalling the fuel tank .................................................. 85
Positioning the fuel tank ................................................... 86
Removing the mask spoiler ................................................ 87
Installing the mask spoiler................................................. 88
Checking the chain for dirt ................................................ 90
Cleaning the chain............................................................ 90
Checking the chain tension ............................................... 91
Adjusting the chain tension ............................................... 92
Checking the chain, rear sprocket, engine sprocket and
chain guide...................................................................... 94
Adjusting the basic position of the clutch lever.................... 97
Checking/rectifying the fluid level of the hydraulic clutch ..... 97
BRAKES.............................................................................. 99
ABS/antilock brake system ................................................ 99
Adjusting the basic position of the hand brake lever........... 100
Checking the front brake discs ......................................... 100
Checking the front brake fluid level .................................. 101
Adding front brake fluid x ............................................. 102
Checking the front brake linings....................................... 103
Checking the free travel of the foot brake lever .................. 104
Adjusting the basic position of the foot brake lever ............ 105
Checking the rear brake disc............................................ 106
Checking the rear brake fluid level ................................... 106
Adding rear brake fluid x .............................................. 107
TABLE OF CONTENTS 5
Checking the rear brake linings ........................................ 109
WHEELS, TIRES ................................................................ 111
Removing the front wheel x........................................... 111
Installing the front wheel x............................................ 112
Removing the rear wheel x ............................................ 114
Installing the rear wheel x............................................. 116
Checking rear hub shock absorbers x ............................. 119
Checking the tire condition.............................................. 119
Checking the tire air pressure .......................................... 121
ELECTRICAL SYSTEM ........................................................ 123
Removing the battery x................................................. 123
Installing the battery x.................................................. 124
Recharging the battery x............................................... 125
Changing the main fuse .................................................. 127
Changing the ABS fuses .................................................. 129
Changing the fuses of individual power consumers............. 130
Changing the headlight bulb ............................................ 132
Changing the parking light bulb ....................................... 134
Changing the turn signal bulb .......................................... 136
Changing the brake light bulb .......................................... 136
Changing the tail light bulbs............................................ 141
Changing the license plate lamp ...................................... 145
Checking the headlight setting......................................... 147
Adjusting headlight range................................................ 147
Activating/deactivating the ignition key ............................. 148
COOLING SYSTEM ............................................................. 153
Cooling system............................................................... 153
Checking the antifreeze and coolant level ......................... 153
Checking the coolant level in the compensating tank ......... 155
Draining the coolant x .................................................. 157
Filling/bleeding the cooling system x.............................. 158
TUNING THE ENGINE ........................................................ 161
Checking the play in the throttle cable.............................. 161
Adjusting the play in the throttle cable x ........................ 162
Ignition curve plug-in connector....................................... 162
Adjusting the ignition curve to the fuel quality................... 163
Checking the basic position of the shift lever..................... 163
Adjusting the basic position of the shift lever x ............... 164
SERVICE WORK ON THE ENGINE ....................................... 165
Checking the engine oil level ........................................... 165
Changing the engine oil and filter, cleaning the oil
screens x..................................................................... 166
Draining the engine oil and filter, cleaning the oil
screens x..................................................................... 166
Filling up with engine oil x............................................ 171
Adding engine oil ........................................................... 172
CLEANING, CARE .............................................................. 173
Cleaning motorcycle ....................................................... 173
Protective treatment for winter operation .......................... 175
STORAGE .......................................................................... 176
Storage.......................................................................... 176
Preparing for use after storage ......................................... 177
TROUBLESHOOTING.......................................................... 178
IMMOBILIZER BLINK CODE................................................ 181
ENGINE CONTROL BLINK CODE ......................................... 183
TECHNICAL DATA - ENGINE ............................................... 189
Capacity- engine oil ........................................................ 190
Capacity - coolant........................................................... 190
TABLE OF CONTENTS 6
TECHNICAL DATA - ENGINE TIGHTENING TORQUES........... 191
TECHNICAL DATA - CHASSIS ............................................. 194
Lighting equipment ........................................................ 195
Tires ............................................................................. 196
Capacity - fuel................................................................ 196
TECHNICAL DATA - FORK................................................... 197
TECHNICAL DATA - SHOCK ABSORBER .............................. 199
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ......... 201
SUBSTANCES.................................................................... 205
AUXILIARY SUBSTANCES................................................... 209
STANDARDS...................................................................... 211
INDEX ............................................................................... 212
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.
Identifies a page reference (more information is provided on the specified page).
Formats used
The typographical formats used in this document are explained below.
Specific name Identifies a proprietary name.
®
Name
Brand™ Identifies a brand available on the open market.
Identifies a protected name.
IMPORTANT INFORMATION 8
Use definition
KTM sport motorcycles are designed and constructed to meet the normal demands of regular road operation but not for use on race
courses or offroad.
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.
Fuels, oils, etc.
The fuels and lubricants named in the owner's manual must be used according to specifications.
IMPORTANT INFORMATION 9
Spare parts, accessories
For your own safety, only use spare parts and accessory products that have been approved and/or recommended by KTM and have them
installed by an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage.
Some of the spare parts and accessory products are specified in parentheses under the respective descriptions. Your KTM dealer will be
glad to advise you.
You will find the current KTM PowerParts for your vehicle on the KTM website.
International KTM Website: http://www.ktm.com
Work rules
Special tools are necessary for some of the work. These are not included with the vehicle and can be ordered under the number in parentheses. Ex: valve spring mounter (59029019000)
During assembly, non-reusable parts (e.g. self-locking screws and nuts, seals and seal rings, O-rings, pins, lock washers) must be replaced
by new parts.
Where thread lockers are used on screw connections (e.g., Loctite®), follow the instructions for use from the manufacturer.
Parts that you want to reuse following repairs and servicing should be cleaned and checked for damage and wear. Change damaged or
worn parts.
Following repairs or servicing, the vehicle must be checked for roadworthiness.
Transport
Note
Danger of damage The parked vehicle may roll away or fall over.
– Always place the vehicle on a firm and even surface.
Note
Fire hazard Some vehicle components become very hot when the vehicle is operated.
– Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from being
run. Always let the vehicle cool first.
IMPORTANT INFORMATION 10
– Switch off the engine and remove the ignition key.
– Secure the motorcycle against falling over or rolling away using straps or other suitable devices.
Environment
Motorcycling is a wonderful sport and we naturally hope that you can enjoy it to the full. However, it can also lead to problems with the
environment and conflict with other persons. Responsible behavior in handling the motorcycle can help to avoid such problems and conflicts. To protect the future of motorcycle sport, make sure that you use your motorcycle legally, display environmental consciousness, and
respect the rights of others.
11
IMPORTANT INFORMATION 12
2.1Overview of labels
B00691-10
IMPORTANT INFORMATION 13
1 Information on emission control
2 Type label, Canada
3 Information on operating substances and tires
4 Information on noise emission
5 Information on preparing for use
6 Information on the fuel evaporation system
7 Information on chain tension
7 Information on suspension setting
8 Type label, USA
B00692-01
Information on emission control
IMPORTANT INFORMATION 14
B00693-01
Type label, Canada
B00694-01
Information on operating substances and tires
IMPORTANT INFORMATION 15
B00695-01
Information on noise emission
Information on preparing for use
600961-01
IMPORTANT INFORMATION 16
B00696-01
Information on the fuel evaporation system
Information on chain tension
600966-01
IMPORTANT INFORMATION 17
Information on suspension setting
B00697-01
B00698-01
Type label, USA
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 18
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.
Reporting safety defects
If you believe that your vehicle has a defect which could cause an accident resulting in injury or death, you should immediately inform the
National Highway Traffic Safety Administration (NHTSA) in addition to notifying KTM North America, Inc.
If NHTSA receives similar complaints, it may open an investigation. If it finds that a safety defect exists in a group of vehicles, it may
order a recall and remedy campaign. However, NHTSA cannot become involved in individual problems between you, your dealer, or KTM
North America, Inc.
IMPORTANT INFORMATION 19
To contact NHTSA, you may either call the Vehicle Safety Hotline toll-free at 1–888–327–4236 or visit the website www.nhtsa.dot.gov, or
write to: NHTSA Headquarters, 1200 New Jersey Avenue, SE, West Building, Washington, DC 20590. You can also obtain other information about motor vehicle safety from the Hotline.
Noise emission warranty
KTM Sportmotorcycle AG warrants that this exhaust system, at the time of sale, meets all applicable U.S. EPA Federal noise standards.
This warranty extends to the first person who buys this exhaust system for purposes other than resale, and to all subsequent buyers.
Warranty claims should be directed to:
KTM North America, Inc., Customer Support, 1119 Milan Ave., Amherst, OH 44001, USA
Phone: (440) 985–3553
www.ktmusa.com
KTM Canada, Inc., Customer Support, 1375-1 Marie-Victorin, Saint-Bruno, QC J3V 6B7
Phone: (450) 441–4451 x 4250
www.ktmcanada.com
Tampering warning
It is not permitted to make changes to the components of the noise damping system. Federal law prohibits the following acts or causing
thereof:
1 The removal or rendering inoperative 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.
Among those acts presumed to constitute tampering are the acts listed below.
1 Removal or puncturing of the muffler, baffles, header pipes or any other component which conducts exhaust gases.
2 Removal or puncturing of any part of the intake system.
3 Lack of proper maintenance.
4 Replacing any moving parts of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by the manu-
facturer.
IMPORTANT INFORMATION 20
Operating noise warning
This product should be checked for repair or replacement of parts if the motorcycle noise has increased significantly through use. Otherwise, the owner may become subject to penalties according to the applicable laws and regulations.
Consumer rights
Warranty claims should be submitted to an authorized KTM workshop. If you are not satisfied, please contact:
KTM North America, Inc., Customer Support, 1119 Milan Ave., Amherst, OH 44001, USA
Phone: (440) 985–3553
www.ktmusa.com
KTM Canada, Inc., Customer Support, 1375-1 Marie-Victorin, Saint-Bruno, QC J3V 6B7
Phone: (450) 441–4451 x 4250
www.ktmcanada.com
Your rights may vary under national and regional laws.
21
VIEW OF VEHICLE 22
3.1View of vehicle, front left side (vehicle differs slightly from photo)
B00690-10
VIEW OF VEHICLE 23
1 Combination instrument ( p. 35)
2 Rear mirror
3 Clutch lever ( p. 30)
4 Seat
5 Handrails ( p. 48)
6 Level viewer, engine oil
7 Shift lever ( p. 51)
8 Engine number ( p. 28)
9 Compression damping of the shock absorber ( p. 76)
VIEW OF VEHICLE 24
3.2View of vehicle, rear right side (vehicle differs slightly from photo)
B00689-10
VIEW OF VEHICLE 25
1 Seat lock ( p. 49)
2 Light switch ( p. 31)
2 Headlight flasher switch ( p. 32)
2 Turn signal switch ( p. 32)
2 Horn button ( p. 33)
3 Filler cap
4 Emergency OFF switch ( p. 34)
4 Electric starter button ( p. 35)
5 Hand brake lever ( p. 30)
6 Fork rebound setting and spring preload setting
7 Shock absorber rebound adjustment
8 Passenger footrests ( p. 50)
9 Foot brake lever ( p. 52)
10 Chassis number/type label ( p. 26)
11 Fork compression adjustment
SERIAL NUMBERS 26
4.1Chassis number/type label
The chassis number is stamped on the frame behind the steering head on the right.
B00664-10
The type label for the USA is fitted on the frame tube on the right.
601116-10
SERIAL NUMBERS 27
The type label for Canada is fitted on the frame tube on the left.
601115-10
4.2Key number
The Code number key number can be found on the KEYCODECARD.
Info
You need the key number to order a spare key. Keep the KEYCODECARD in a safe
place.
Use the orange programming key to activate and deactivate the black ignition key.
Keep the orange programming key in a safe place: it must only be used for learning
and programming functions.
700563-01
SERIAL NUMBERS 28
4.3Engine number
The engine number is stamped on the left side of the engine under the engine sprocket.
B00120-10
4.4Fork part number
The fork part number is stamped on the inner side of the fork stub.
B00606-10
Loading...