KTM 990 Supermoto R 2010 Owner's manual
OWNER'S MANUAL 2010
990 Supermoto R USA
990 Supermoto T USA
Art. no. 3211562en
DEAR KTM CUSTOMER 1
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. 32) Dealer's stamp
Engine number ( p. 34)
Key number ( p. 33)
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 misprints and other errors. The models portrayed partly contain special equipment
that does not form part of the regular scope of delivery.
DEAR KTM CUSTOMER 2
© 2010 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
MEANS OF REPRESENTATION ............................................... 7
IMPORTANT INFORMATION ................................................... 8
Overview of labels (Supermoto T) ....................................... 12
Overview of labels (Supermoto R)....................................... 18
VIEW OF VEHICLE................................................................ 28
View of vehicle, front left side (vehicle differs slightly from
photo) ............................................................................. 28
View of vehicle, rear right side (vehicle differs slightly from
photo) ............................................................................. 30
LOCATION OF SERIAL NUMBERS ......................................... 32
Chassis number/type label ................................................. 32
Key number ..................................................................... 33
Engine number................................................................. 34
Fork part number.............................................................. 34
Shock absorber part number .............................................. 35
CONTROLS.......................................................................... 36
Clutch lever ..................................................................... 36
Hand brake lever .............................................................. 36
Light switch ..................................................................... 37
Headlight flasher switch.................................................... 37
Turn signal switch ............................................................ 38
Horn button ..................................................................... 38
Ignition/steering lock ........................................................ 39
Immobilizer ..................................................................... 39
Emergency OFF switch...................................................... 40
Electric starter button ....................................................... 40
Combination instrument .................................................... 41
Combination instrument - function buttons ......................... 41
Combination instrument - tachometer................................. 42
Combination instrument - indicator lamps........................... 42
Combination instrument - display....................................... 43
Combination instrument - speedometer............................... 44
Setting kilometers or miles ................................................ 44
Combination instrument - time .......................................... 45
Setting the clock .............................................................. 46
Combination instrument - ODO display ............................... 46
Combination instrument - setting/resetting TRIP 1............... 47
Combination instrument - setting/resetting TRIP 2............... 47
Combination instrument - TRIP F display............................ 48
Combination instrument - ambient temperature display........ 49
Setting the temperature units ............................................ 49
Combination instrument - warning of slippery roads ............. 50
Combination instrument - coolant temperature indicator ...... 50
Opening the filler cap ....................................................... 51
Closing the filler cap......................................................... 51
Handrails......................................................................... 52
Seat lock ......................................................................... 52
Tool set ........................................................................... 53
Helmet lock ..................................................................... 53
Passenger footrests........................................................... 54
Shift lever........................................................................ 54
Foot brake lever................................................................ 55
Side stand ....................................................................... 56
TIPS ON PUTTING INTO OPERATION .................................... 57
Information on first use..................................................... 57
Running in the engine....................................................... 58
Loading the vehicle .......................................................... 58
TABLE OF CONTENTS 4
RIDING INSTRUCTIONS ....................................................... 61
Checks before putting into operation .................................. 61
Starting ........................................................................... 62
Starting up ...................................................................... 63
Shifting, riding ................................................................. 64
Braking ........................................................................... 67
Stopping, parking ............................................................. 68
Refueling......................................................................... 70
SERVICE SCHEDULE............................................................ 72
Service schedule .............................................................. 72
MAINTENANCE WORK ON FRAME AND ENGINE.................... 75
Jacking up motorcycle at the front ..................................... 75
Taking the front from the work stand .................................. 75
Jacking up motorcycle at the rear....................................... 76
Taking the rear from the workstand .................................... 76
Fork/shock absorber .......................................................... 77
Adjusting the compression damping of the fork ................... 77
Adjusting the rebound damping of the fork.......................... 79
Adjusting the spring preload of the fork .............................. 80
Bleeding the fork legs ....................................................... 81
Compression damping of the shock absorber ....................... 82
Adjusting the low-speed compression damping of the shock
absorber .......................................................................... 82
Adjusting the high-speed compression damping of the
shock absorber ................................................................. 84
Adjusting the rebound damping of the shock absorber.......... 85
Adjusting the spring preload of the shock absorber x ......... 86
Checking the chain for dirt ................................................ 88
Cleaning the chain............................................................ 88
Checking the chain tension ............................................... 90
Adjusting the chain tension ............................................... 91
Checking the chain, rear sprocket and engine sprocket......... 93
Checking the front brake discs ........................................... 95
Checking the rear brake disc.............................................. 96
Adjusting the basic position of the hand brake lever............. 97
Checking the free travel of the foot brake lever .................... 97
Checking the front brake fluid level .................................... 98
Adding front brake fluid x ............................................... 99
Brake linings.................................................................. 100
Checking the front brake linings....................................... 100
Checking the rear brake fluid level ................................... 102
Adding rear brake fluid x .............................................. 102
Checking the rear brake linings ........................................ 104
Removing the front wheel x........................................... 105
Installing the front wheel x............................................ 106
Removing the rear wheel x ............................................ 108
Installing the rear wheel x............................................. 109
Checking rear hub shock absorbers x ............................. 111
Checking the tire condition.............................................. 112
Checking the tire air pressure .......................................... 114
Removing the seat .......................................................... 115
Mounting the seat .......................................................... 115
Mounting the helmet lock on the vehicle........................... 116
Removing the battery x................................................. 116
Installing the battery x.................................................. 118
Recharging the battery x............................................... 119
Changing the main fuse .................................................. 121
Changing the fuses of individual power consumers............. 123
TABLE OF CONTENTS 5
Changing the headlight bulb ............................................ 125
Changing the parking light bulb ....................................... 128
Changing the turn signal bulb .......................................... 131
Changing the brake light bulb .......................................... 132
Changing the tail light bulbs............................................ 136
Changing the license plate lamp ...................................... 140
Checking the headlight setting......................................... 141
Adjusting headlight range................................................ 142
Activating/deactivating the ignition key ............................. 143
Cooling system ............................................................... 146
Checking the antifreeze and coolant level ......................... 147
Checking the coolant level in the compensating tank ......... 149
Draining the coolant x .................................................. 150
Filling/bleeding the cooling system x.............................. 151
Reinstalling the fuel tank ................................................ 154
Positioning the fuel tank ................................................. 155
Removing the mask spoiler (Supermoto T) ........................ 157
Installing the mask spoiler (Supermoto T) ......................... 158
Adjusting the basic position of the clutch lever.................. 159
Checking/rectifying the fluid level of the hydraulic clutch ... 160
Checking the play in the throttle cable.............................. 161
Adjusting the play in the throttle cable x ........................ 162
Checking the engine oil level ........................................... 162
Changing the engine oil and filter, cleaning the oil
screens x..................................................................... 163
Draining the engine oil and filter, cleaning the oil
screens x..................................................................... 164
Filling up with engine oil x............................................ 168
Adding engine oil ........................................................... 170
Ignition curve plug-in connector....................................... 171
Adjusting the ignition curve to the fuel quality................... 171
IMMOBILIZER BLINK CODE................................................ 173
ENGINE CONTROL BLINK CODE ......................................... 175
TROUBLESHOOTING.......................................................... 181
CLEANING......................................................................... 184
Cleaning motorcycle ....................................................... 184
PROTECTIVE TREATMENT FOR WINTER OPERATION........... 186
Conserving for winter operation ........................................ 186
STORAGE .......................................................................... 187
Storage.......................................................................... 187
Putting into operation after storage .................................. 188
TECHNICAL DATA - ENGINE ............................................... 189
Capacity- engine oil ........................................................ 190
Capacity - coolant........................................................... 190
TECHNICAL DATA - ENGINE TIGHTENING TORQUES........... 191
TECHNICAL DATA - CHASSIS ............................................. 195
Lighting equipment ........................................................ 196
Tires ............................................................................. 197
Capacity - fuel................................................................ 197
TECHNICAL DATA - FORK................................................... 198
Supermoto R.................................................................. 198
Supermoto T .................................................................. 199
TECHNICAL DATA - SHOCK ABSORBER .............................. 200
Supermoto R.................................................................. 200
Supermoto T .................................................................. 201
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ......... 203
SUBSTANCES.................................................................... 206
AUXILIARY SUBSTANCES................................................... 210
TABLE OF CONTENTS 6
STANDARDS...................................................................... 212
INDEX ............................................................................... 213
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
®
Identifies a protected name.
Brand™ Identifies a brand available on the open market.
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.
Maintenance
A prerequisite for fault-free operation and avoiding premature wear is compliance with the instructions for maintenance, care and adjustments of the engine and suspension provided 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 inspection and maintenance 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; 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.
If a thread lock (e.g. Loctite®) is used for screw connections, be sure to comply with the manufacturer's specific instructions on its usage.
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.
IMPORTANT INFORMATION 11
IMPORTANT INFORMATION 12
Overview of labels (Supermoto T)
601100-10
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 the fuel evaporation system
6 Information on chain tension
6 Information on suspension setting
7 Type label, USA
8 Information on preparing for use
601102-01
Information on emission control
IMPORTANT INFORMATION 14
600962-01
Type label, Canada
600969-01
Information on operating substances and tires
IMPORTANT INFORMATION 15
601103-01
Information on noise emission
600968-01
Information on the fuel evaporation system
IMPORTANT INFORMATION 16
600966-01
Information on chain tension
601104-01
Information on suspension setting
IMPORTANT INFORMATION 17
600963-01
Type label, USA
600961-01
Information on preparing for use
IMPORTANT INFORMATION 18
Overview of labels (Supermoto R)
601101-10
IMPORTANT INFORMATION 19
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
600964-01
Information on emission control
IMPORTANT INFORMATION 20
600962-01
Type label, Canada
600969-01
Information on operating substances and tires
IMPORTANT INFORMATION 21
600965-01
Information on noise emission
600961-01
Information on preparing for use
IMPORTANT INFORMATION 22
600968-01
Information on the fuel evaporation system
600966-01
Information on chain tension
600967-01
Information on suspension setting
IMPORTANT INFORMATION 23
600963-01
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 24
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 25
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 26
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.
27
VIEW OF VEHICLE 28
View of vehicle, front left side (vehicle differs slightly from photo)
B00143-10
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