KTM Super Duke 990s User Manual

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

ART. NR. 3.211.57

990 SUPER DUKE

BEDIENUNGSANLEITUNG2005

ENGLISH

1

IMPORTANT »

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

Frame number

Engine number

Key number

Stamp of dealer

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

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

COMSUMER INFORMATION FOR AUSTRALIA ONLY
Tampering with noise control system prohibited

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

replacement, of any device or element of design incorporated into any new vehicle for the purpose of
noise control prior to its sale or delivery to the ultimate purchaser or while it is in use; and

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

tive by any person.

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

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

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

THE MOTOR-CYCLE IS NOT ROAD-SAFE ANYMORE.

ENGLISH

2

INTRODUCTION »

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

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

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

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

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

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

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

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

We wish you a lot of fun when driving !

KTM-SPORTMOTORCYCLE AG
5230 MATTIGHOFEN, AUSTRIA

ENGLISH

3

IMPORTANT LIMITED WARRANTY AND LIMITED GUARANTEE INFORMATION »

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

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

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

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

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

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

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

ENGLISH

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INDEX »

Page

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Emergency OFF tip switch, light switch, starter tip switch

.9

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

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

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

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

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

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

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

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

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

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

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

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

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

Damping action during compression of shock absorber

.13

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

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

GENERAL TIPS AND WARNINGS FOR STARTING THE

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

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

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

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

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

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

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

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

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

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

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

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

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

MAINTENANCE WORK ON CHASSIS AND ENGINE . . . .22

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

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

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

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

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

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

Page

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Checking the cooling liquid level in the

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

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

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

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

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

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

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

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

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

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

Changing the engine oil and the oil filter, cleaning

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

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

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

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

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

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

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

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

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

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

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5

SERIAL NUMBER LOCATIONS »

Chassis number, Type label

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

Engine number, engine type

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

Clutch lever

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

Hand brake lever

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

OPERATION INSTRUMENTS »

1

A

2

B

ENGLISH

6

OPERATION INSTRUMENTS »

Multi-functional digital speedometer

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

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

Display

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

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

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

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

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

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

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

TEST

WS

ODO

CLOCK

TRIP 1

TRIP 2

TRIP F

1 2 3

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7

OPERATION INSTRUMENTS »

Setting options in the display

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

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

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

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

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

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

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

1 10 sec

1

2

2

2

ENGLISH

8

OPERATION INSTRUMENTS »

Cooling liquid temperature display

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

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

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

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

Indicator lamps

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

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

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

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

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

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

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

Tachometer

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

120°C (248°F)

110°C (230°F)

100°C (212°F)

70°C (158°F)

60°C (140°F)

50°C (122°F)

40°C (104°F)

1

2

3

ENGLISH

9

OPERATION INSTRUMENTS »

Ignition lock

The ignition lock has 3 switching positions.

Ignition off, (engine can't be started)

Ignition on, (engine can be started)

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

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

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

The ignition key can be withdrawn in position and .

Combination switch

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

= High-beam light

= Low-beam light

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

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

The horn is sounded with button [4].

Emergency OFF tip switch, light switch, starter tip switch

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

The light switch [6] has 3 positions:

= Light off

= Parking light on

= Headlight on

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

1

2

4

3

1

5

6

7

ENGLISH

10

OPERATION INSTRUMENTS »

Filler cap

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

Seat lock, removing the seat

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

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

Baggage loops

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

BAGGAGE WEIGHT: MAX. 5 KG

Tool set

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

1

2

3

4

5

6

6

7

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11

OPERATION INSTRUMENTS »

Helmet lock

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

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

Holding strap

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

Shift lever

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

Side stand

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

Foot brake pedal

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

1

N

2,3,4,5,6

3

1

2

4

5

ENGLISH

12

OPERATION INSTRUMENTS »

Footrests

The passenger footrests [1] fold up.

Compression damping of fork

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

Rebound damping of fork

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

Spring preload of the fork

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

1

2

3

4

ENGLISH

13

OPERATION INSTRUMENTS »

Damping action during compression of shock absorber

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

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

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

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

Rebound damping of shock absorber

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

Spring preload on shock absorber

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

1

2

3

4

– NEW WHEELS HAVE A SMOOTH SURFACE, WHICH MEANS THAT

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

– WHEELS WITH A DIFFERENT RIM DIAMETER OR OTHER RIM WIDTH

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

– OBSERVE THE TRAFFIC REGULATIONS, DRIVE DEFENSIVELY AND

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

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

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

– CHOOSE YOUR DRIVING SPEED ACCORDING TO THE CONDITIONS

AND YOUR DRIVING SKILLS.

– DRIVE CAREFULLY ON UNKNOWN ROADS OR ON UNFAMILIAR

TRIALS.

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

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

– NEVER LEAVE YOUR MOTORCYCLE WITHOUT SUPERVISION IF THE

ENGINE IS RUNNING.

Accessories and payload

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

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

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

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

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

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

TURER'S RECOMMENDED MAXIMUM PAYLOAD.

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

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

– BAGGAGE MUST BE SECURELY AND ADEQUATELY FASTENEND;

LOOSE BAGGAGE WILL SIGNIFICANTLY IMPAIR DRIVING SAFETY.

– A HIGH PAYLOAD WILL CHANGE THE MOTORCYCLE'S HANDLING

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

– NEVER EXCEED THE MAXIMUM PERMISSIBLE LADEN WEIGHT

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

DRIVER AND PASSENGER WITH PROTECTIVE CLOTHING AND HELMET

ENGLISH

14

GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE »

Instructions for initial operation

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

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

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

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

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

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

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

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

possible and in standing position, to improve your feeling for

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

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

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

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

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

ORIGINAL KTM SPARE PARTS. Spare parts from other man-

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

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

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

Running in the LC8 engine

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

– WEAR SUITABLE CLOTHING WHEN DRIVING A MOTORCYCLE.

CLEVER KTM DRIVERS ALWAYS WEAR A HELMET, BOOTS, GLOVES

AND A JACKET, REGARDLESS OF WHETHER DRIVING ALL DAY OR

JUST FOR A SHORT TRIP. THE PROTECTIVE CLOTHING SHOULD

BE BRIGHTLY COLORED SO THAT OTHER VEHICLE CAN SEE YOU

AS EARLY AS POSSIBLE. YOUR PASSENGER WILL ALSO NEED

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

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

OF EACH TRIP TO ALLOW THE TIRES TO REACH THE NECESSARY

OPERATING TEMPERATURE. MAXIMUM ROAD GRIP IS ASSURED

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

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

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

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

A STICKER SHOWING THE MAXIMUM SPEED MUST BE AFFIXED

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

ENGLISH

15

DRIVING INSTRUCTIONS »

Check the following before each start

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

The following checks should be performed:

1 FUEL

Check the fuel quantity in the tanks.

2 CHAIN

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

3 TIRES

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

4 BRAKES

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

5 CABLES

Check the throttle cable for correct adjustment and smooth operation.

6 COOLING FLUID

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

7 ELECTRICAL SYSTEM

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

8 CHECK OIL LEVEL

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

9 BAGGAGE, PAYLOAD

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

10 REAR MIRROR

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

ENGLISH

16

DRIVING INSTRUCTIONS »

Starting the engine

1 Switch on emergency OFF switch [1].
2 Switch on ignition (turn ignition key [2] into position ).

NOTE:
You will hear the operation of the fuel pump for approx. 2 seconds after
switching on the ignition. The FI indicator lamp will also light up during
this time and the engine should not be started.

3 Switch transmission to idle (green indicator lamp N [3] lights up).
4 Do not accelerate; operate starter button [5].
5 The oil pressure warning lamp [4] should go out as soon as the engine is

running.

6 Take the load off the side stand and fold the side stand all the way up.

DO NOT START THE ENGINE AND ALLOW IT TO IDLE IN A CLOSED ROOM. EXHAUST
FUMES ARE POISONOUS AND CAN CAUSE LOSS OF CONSCIOUSNESS AND DEATH.
ALWAYS PROVIDE ADEQUATE VENTILATION WHILE THE ENGINE IS RUNNING.

– IF YOU ACCELERATE WHILE STARTING, THE ENGINE MANAGEMENT WILL NOT

INJECT ANY FUEL AND THE ENGINE WILL NOT START. DO NOT ACCELERATE
WHILE STARTING!

– IF THE OIL PRESSURE WARNING LAMP DOES NOT GO OUT AS SOON AS THE

ENGINE IS RUNNING, IMMEDIATELY SWITCH OFF THE ENGINE. IF THE ENGINE
IS NOT SWITCHED OFF, ENGINE DAMAGE WILL OCCUR WITHIN A SHORT
PERIOD OF TIME. CHECK THE ENGINE OIL LEVEL OR CONTACT A KTM
WORKSHOP.

– MAXIMUM PERIOD FOR CONTINUOUS STARTING: 5 SECONDS. WAIT AT LEAST

5 SECONDS BEFORE TRYING AGAIN.

– DON’T RIDE YOUR MOTORCYCLE WITH FULL LOAD AND DON’T REV ENGINE

WHEN COLD. BECAUSE THE PISTON IS WARMING UP FASTER THAN THE
WATER COOLED CYLINDER, IT CAN CAUSE ENGINE DAMAGE. ALWAYS LET THE
ENGINE WARM UP BEFORE AND REFRAIN FROM DRIVING WITH FULL LOAD
UNTIL THE ENGINE IS WARM.

IF THE ENGINE IS DOES NOT CRANK WHEN YOU ACTUATE THE STARTER
TIP SWITCH:

– the transmission is switched to idle
– Check if the emergency OFF switch is on
– Check if the ignition is on
– the headlight is on (Light switch in position).

– If this is not the case, the battery is discharged
– If the lights are on, proceed as described in the „Trouble-shooting“

section or contact a KTM dealer.

IF THE ENGINE CRANKS BUT DOES NOT START, WHEN YOU ACTUATE THE
STARTER TIP SWITCH:

– whether you accelerated while starting
– whether the FI indicator lamp is blinking

– if yes, check Troubleshooting - Blink codes table

– Check if sufficient fuel is in the tank

– If this is not the case, refill the tank
– if sufficient fuel is in the tank, proceed as described in the „Trouble-

shooting“ section or contact a KTM dealer.

NOTE:
This motorcycle is equipped with a safety starting system. The engine can
only be started if the transmission is in neutral or the clutch lever is pulled.
If the side stand is folded down, the engine can only be started if the trans­mission is in neutral or the clutch lever is pulled. The engine will stall if a
gear is engaged and the clutch lever is released with the side stand folded
down.

1

2

5

3

4

ENGLISH

17

DRIVING INSTRUCTIONS »

Starting off

Turn on the light, pull the clutch lever and engage 1st gear. Slowly
release the clutch lever while you gently accelerate.

– BEFORE YOU START OFF, CHECK THAT THE MAIN STAND HAS BEEN

SWUNG UP FULLY. IF THE STAND DRAGS ON THE GROUND, THE
MOTORCYCLE CAN GO OUT OF CONTROL.

– ALWAYS TURN ON THE LIGHT WHEN YOU DRIVE. OTHER DRIVERS

WILL BE ABLE TO SEE YOU MUCH SOONER.

– DO NOT ATTACH A HELMET OR OTHER OBJECTS TO THE HELMET

LOCK ROPE WHILE DRIVING. YOU CAN EASILY LOSE CONTROL OF
THE MOTORCYCLE.

Shifting/Riding

You are now in first gear, refered to as the drive or uphill gear.
Depending on the conditions (traffic, road gradient, etc.), you can
shift to a higher gear. Close throttle, at the same time pull clutch
lever and shift to the next higher gear. Let clutch lever go again
and open throttle. Do not shift gears and accelerate carefully in
curves.
Only accelerate to the extent that road and weather conditions allow.
Be especially careful when you accelerate in curves. Abrupt open­ing of the throttle can cause the motorcycle to go out of control
and also increases fuel consumption.
By shifting down, use the brakes if necessary and close throttle at
the same time. Pull clutch lever and shift down to the next gear.
Let clutch lever go slowely and open throttle or shift down again.
If the engine is killed f.ex. at a crossing, simply pull the clutch
lever and start. It is not necessary to switch the gear to NEUTRAL.
Stop immediately if the FI indicator lamp lights up while driving.
The FI indicator lamp will start blinking as soon as the transmis­sion is in neutral. The rhythm of the blinking lamp will let you deter­mine the two-digit "blink code", e.g.:
Blink code 34: FI blinks 3x long, 4x short, pause,
Blink code 06: FI blinks 6x short, pause
The blink code will indicate which component is defective (see
Troubleshooting). This makes it possible to pinpoint the defect if
a diagnostic tool is unavailable.

– AVOID ABRUPT LOAD CHANGES WHILE RIDING AROUND BENDS

AND ON WET OR SLIPPERY GROUND. OTHERWISE YOU MIGHT
EASILY LOSE CONTROL OVER YOUR MOTORCYCLE.

– WHILE RIDING YOUR MOTORCYCLE, NEVER SWITCH THE IGNITION

LOCK TO POSITIONS AND .

– DO NOT TRY TO CHANGE THE SETTINGS WHILE DRIVING. YOUR

ATTENTION WILL BE DISTRACTED FROM THE TRAFFIC AND MAY
CAUSE YOU TO LOSE CONTROL OF YOUR MOTORCYCLE.

– THE PASSENGER MUST HOLD ON TO THE DRIVER OR THE HOLD-

ING STRAP ON THE SEAT WHILE RIDING AND KEEP HIS/HER FEET
ON THE PASSENGER FOOTRESTS.

– REGULARLY MAKE SURE THAT THE BAGGAGE AND CASES ARE

TIGHTLY FASTENED.

– AFTER FALLING WITH THE MOTORCYCLE, CHECK ALL FUNCTIONS

THOROUGHLY BEFORE STARTING UP OPERATIONS AGAIN.

– A BENT HANDLEBAR MUST ALWAYS BE REPLACED. NEVER TRY TO

STRAIGHTEN THE HANDLEBAR BECAUSE THIS WILL CAUSE IT TO
LOSE ITS STABILITY.

– HIGH RPM RATES WHEN THE ENGINE IS COLD HAVE AN ADVERSE

EFFECT ON THE LIFE OF YOUR ENGINE. WE RECOMMEND YOU RUN
THE ENGINE IN A MODERATE RPM RANGE FOR A FEW MILES GIV­ING IT A CHANCE TO WARM UP. AFTER THAT NO FURTHER PRE­CAUTIONS IN THIS RESPECT NEED BE TAKEN. THE ENGINE HAS
REACHED OPERATING TEMPERATURE AS SOON AS THE SECOND
BAR ON THE TEMPERATURE INDICATOR LIGHTS UP.

– IF THE RED OIL PRESSURE WARNING LAMP LIGHTS UP WHILE DRIV-

ING, THE OIL PRESSURE IS TOO LOW TO ADEQUATELY LUBRICATE
THE ENGINE. STOP IMMEDIATELY AND SWITCH OFF THE ENGINE.
IF YOU CONTINUE TO DRIVE, ENGINE DAMAGE WILL OCCUR WITHIN
A SHORT PERIOD OF TIME. CHECK THE ENGINE OIL LEVEL OR CON­TACT AN AUTHORIZED KTM WORKSHOP.

– NEVER HAVE THE THROTTLE WIDE OPEN WHEN CHANGING DOWN

TO A LOWER GEAR. THE ENGINE WILL OVERSPEED, DAMAGING THE
VALVES. IN ADDITION, THE REAR WHEEL BLOCKS SO THAT THE
MOTORCYCLE CAN EASILY GET OUT OF CONTROL.

– NEVER USE YOUR MOTORCYCLE WITHOUT AN AIR FILTER.

OTHERWISE DUST AND DIRT MAY ENTER THE ENGINE AND CAUSE
INCREASED WEAR.

– STOP IMMEDIATELY IF A PERCEPTIBLE POWER LOSS OCCURS

WHILE DRIVING DUE TO A DEFECTIVE IGNITION CAUSED BY A
CYLINDER MISFIRING OR BREAKING DOWN. IF THE UNBURNED
FUEL/AIR MIXTURE REACHES THE CATALYTIC CONVERTER, IT WILL
IGNITE AND THE RESULTING HEAT WILL DESTROY THE CATALYTIC
CONVERTER AND THE ADJOINING COMPONENTS.

– THE RED COOLANT WARNING LAMP LIGHTS UP WHEN THE COOLANT

TEMPERATURE HAS REACHED 120°C (248°F).
POSSIBLE CAUSES FOR THE INCREASE IN TEMPERATURE:
– LOW DRIVING VELOCITY AND HIGH LOAD SITUATION IN HIGH AIR

TEMPERATURES
– LEVEL OF COOLANT IN THE SYSTEM IS INSUFFICIENT
– FAN AT RADIATOR IS NOT RUNNING
–

IMPROPER USE OF THE CLUTCH WHILE DRIVING AT LOW VELOCITIES
LET THE ENGINE COOL DOWN. MEANWHILE, CHECK WHETHER ANY
COOLING LIQUID IS LEAKING OUT OF THE MOTORCYCLE. CHECK
THE COOLING LIQUID LEVEL IN THE RADIATOR (NOT ONLY IN THE
COMPENSATING TANK). - CAUTION SCALDING HAZARD! DO NOT
DRIVE ON, UNTIL THERE IS SUFFICIENT LIQUID IN THE COLING
SYSTEM.

– IN THE EVENT THAT, WHILE RIDING ON YOUR MOTORCYCLE, YOU

NOTICE ANY UNUSUAL OPERATION-RELATED NOISE, STOP IMME­DIATELY, TURN THE ENGINE OFF, AND CONTACT AN AUTHORIZED
KTM DEALER.

Braking

Close throttle and apply the hand and foot brakes at the same time.
Carefully apply the brakes on sandy, wet or slippery surfaces.
Always brake with feeling, blocking wheels can cause you to skid
or fall. Also change down to lower gears depending on your speed.
Always finish braking before you enter a curve.
When driving downhill, use the braking effect of the engine. Change
down one or two gears but do not overspeed the engine. In this
way, you will not need to brake so much and the brakes will not
overheat.

– IN THE RAIN, OR AFTER THE MOTORCYCLE HAS BEEN WASHED,

BRAKING ACTION MAY BE DELAYED DUE TO WET BRAKE DISCS.
FIRST, THE BRAKES MUST BE BRAKED DRY.

– ON SALT-SPRAYED OR DIRTY ROADS BRAKE ACTION MAY BE

DELAYED AS WELL. FIRST, THE BRAKES MUST BE BRAKED CLEAN.

– REMEMBER THAT THE STOPPING DISTANCE WILL BE LONGER IF

YOU ARE CARRYING A PASSENGER OR BAGGAGE.

– WHEN YOU BRAKE, THE BRAKE DISCS, BRAKE PADS, BRAKE

CALIPER AND BRAKE FLUID HEAT UP. THE HOTTER THESE PARTS
GET, THE WEAKER THE BRAKING EFFECT. IN EXTREME CASES,
THE ENTIRE BRAKING SYSTEM CAN FAIL.

ENGLISH

18

DRIVING INSTRUCTIONS »

Stopping and parking

Apply the brakes fully and put the engine into neutral. To stop the engine,
switch off the ignition. Fold the side stand forward to the stop with your foot,
put the weight of the motorcycle on the stand and park the bike on a firm sur­face. Lock the motorcycle.

– ALWAYS PARK YOUR MOTORBIKE ON A SOLID AND HORIZONTAL

SURFACE.

– NEVER LEAVE YOUR MOTORCYCLE WITHOUT SUPERVISION AS LONG AS THE

ENGINE IS RUNNING.

– MOTORCYCLE ENGINES PRODUCE A GREAT AMOUNT OF HEAT WHILE RUN-

NING. THE ENGINE RADIATORS, EXHAUST, EXHAUST SYSTEM, BRAKE DISCS,
AND SHOCK ABSORBERS CAN BECOME VERY HOT. DO NOT TOUCH ANY OF
THESE PARTS AFTER OPERATING THE MOTORCYCLE, AND TAKE CARE TO PARK
IT WHERE PEDESTRIANS ARE NOT LIKELY TO TOUCH IT AND GET BURNED

– NEVER PARK YOUR MOTORCYCLE IN PLACES WHERE THERE EXIST FIRE HAZ-

ARDS DUE TO DRY GRASS OR OTHER EASILY FLAMMABLE MATERIALS.

– ALWAYS TAKE OUT THE IGNITION KEY WHEN PARKING YOUR MOTORCYCLE

SO THAT IT CANNOT BE USED BY UNAUTHORIZED PERSONS.

– THE SIDE STAND IS DIMENSIONED FOR THE WEIGHT OF THE MOTORCYCLE

ONLY. SITTING ON THE MOTORCYCLE WILL INCREASE THE WEIGHT ON THE
SIDE STAND. THE SIDE STAND OR ENGINE CASE CAN BE DAMAGED AND THE
MOTORCYCLE CAN TIP OVER.

Fuel

In the condition at delivery, the LC8 engine requires unleaded fuel with at
least RON 95 (USA = Premium RON 91).

THIS MOTORCYCLE IS EQUIPPED WITH A CATALYTIC CONVERTER THAT WILL BE
DESTROYED IF YOU USE LEADED FUEL. ALWAYS USE UNLEADED FUEL.

Fuel expands when its temperature rises. Therefore do not fill the tank to the
top (see fig.).

GASOLINE IS HIGHLY FLAMMABLE AND POISONOUS. EXTREME CAUTION SHOULD
BE USED WHEN HANDLING GASOLINE. DO NOT REFUEL THE MOTORCYCLE NEAR
OPEN FLAMES OR BURNING CIGARETTES. ALWAYS SWITCH OFF THE ENGINE
BEFORE REFUELLING. BE CAREFUL NOT TO SPILL GASOLINE ON THE ENGINE OR
EXHAUST PIPE WHILE THE ENGINE IS HOT. WIPE UP SPILLS PROMPTLY. IF GASO­LINE IS SWALLOWED OR SPLASHED IN THE EYES, SEEK A DOCTOR’S ADVICE
IMMEDIATELY.

MAX

ENGLISH

19

ENGLISH

20

PERIODIC MAINTENANCE »

A CLEAN MOTORCYCLE CAN BE CHECKED MORE QUICKLY WHICH SAVES MONEY!

1st Service
after
1000 km

every
7500 km
or
once a year

every
15000 km
or
every 2 years

ENGINE

Change engine oil and oil filter

z z z

Clean oil screens of engine and oil tank

z z z

Clean magnetic drain plugs of engine and oil tank

z z z

Check oil lines for damage and kink-less arrangement

z z z

Renew spark plugs

z

Check and adjust valve clearance

z z

Check engine fastening bolts for tight fit

z z z

Check all engine bolts accessible from the outside for tight fit

z z z

Check clutch linings

z

Check clutch pressure booster system

z

FUEL INJECTION

Check rubber boot for cracks or leaks

z z

Check fault memory with the KTM diagnosis tool

z z z

Perform a status check of neutral, clutch, 2nd/3rd gear and side stand
switch using the KTM diagnosis tool

z z z

Check the fuel hose, hoses on the vacuum sensors and secondary air sys­tem hoses for correct installation and damage

z z z

Replace the O-ring on the fuel hose connection and check for leaks

z z z

Check the wiring harness on the throttle body for proper installation and
damage

z z

Check the vent hoses and fuel lines for damage and kink-free installation

z z

ADD-ON-PARTS

Check cooling system for leaks and antifreeze protection

z z z

Check radiator fan for proper operation

z z z

Check the exhaust system for leaks and correct suspension and the clamps
for a tight fit

z z z

Replace the graphite gasket in the rear exhaust manifold slide

z

Check actuating cables for damage, smooth operation, and kink-less arran­gement,adjust and lubricate

z z z

Check the oil level in the hydraulic clutch reservoir

z z

Check air filter, renew if necessary, clean air filter box

z

Check cables for damage and kink-less arrangement

z z z

Check headlamp adjustment

z z z

Check electrical system for function (low/high beams, stop light, turn indi­cators,headlamp, flasher, tell-tale lamps, speedometer illumination, horn,
side-stand switch, clutch switch, emergency-off switch)

z z z

Make sure all bolts and nuts are tight

z z z

BRAKES

Check brake fluid level, lining thickness, and brake discs

z z z

Change brake fluid

z

Check brake lines for damage and leaks

z z z

Check/adjust smooth operation, free travel of handbrake/footbrake levers

z z z

Check bolts of brake system for tight fit

z z z

CHASSIS

Check suspension strut and fork for leaks and proper operation

z z z

Clean fork dust sleeves

z z

Bleed fork legs

z z z

Check swinging-fork pivot

z z z

Check/adjust steering-head bearing

z z z

Check all chassis bolts for tight fit (fork plates, fork leg, axle nuts/bolts,
swinging-fork pivot, reversing lever, suspension strut)

z z z

ENGLISH

21

PERIODIC MAINTENANCE »

IMPORTANT RECOMENDED MAINTENANCE PROCEDURES TO BE PERFORMED BASED ON A SEPARATE SUPPLEMENT ORDER

at least
once a year

every 2 years
or 15000 km

Perform complete fork maintenance

z

Perform complete suspension strut maintenance

z

Clean and lubricate steering-head bearing and sealing elements

z

Treat the electrical contacts and switches with contact spray

z

Treat battery connections with contact grease

z

Change coolant fluid

z

A CLEAN MOTORCYCLE CAN BE CHECKED MORE QUICKLY WHICH SAVES MONEY!

1st Service
after
1000 km

every
7500 km
or
once a year

every
15000 km
or
every 2 years

Wheels

Check rim joint

z z z

Check tire condition and inflation pressure

z z z

Check chain, sprockets and chain guides for wear, force fit and tension

z z z

Check bolts on pinion and chain sprocket for locking devices and a tight fit

z z z

Lubricate chain

z z z

Check wheel bearings and jerk damper for play

z z

IF MOTORCYCLE IS USED FOR COMPETITION 7500 KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE!
Service intervalls should never be exceeded by more than 500 km.
Maintenance work performed by an authorized KTM workshop is not a substitute for care and maintenance by the driver!

VITAL CHECKS AND CARE PROCEDURES TO CONDUCTED BY THE OWNER OR THE MECHANIC

before
each start

after
every cleaning

every 1000 km or
after off road use

Check oil level

z

Check brake fluid level

z

Check brake pads for wear

z

Check lighting system for proper operation

z

Check horn for proper operation

z

Lubricate and adjust actuating cables and nipples

z

Clean chain

z

Lubricate chain

z z

Check chain tension

z

Check tire pressure and wear

z

Check coolant level

z

Check fuel lines for leaks

z

Check all control elements for smooth running

z

Grease the hand brake lever and clutch lever

z

Check brake performance

z z

Treat exposed metal components (except for the braking and exhaust
system) with wax-based anti-corrosion agents

z

Treat ignition/steering lock and light switch with contact spray

z

ALL MAINTENANCE AND ADJUSTMENT WORK MARKED WITH AN ASTERISK * REQUIRES SPECIAL TECHNICAL SKILLS. IN YOUR OWN INTE­REST, HAVE THIS WORK PERFORMED BY AN AUTHORIZED KTM WORKSHOP, WHERE YOUR MOTORCYCLE WILL BE SERVICED BY SPECIALLY
TRAINED TECHNICIANS.

– DO NOT CLEAN THE MOTORCYCLE WITH A POWER WASHER OTHERWISE WATER WILL GET INTO THE BEARINGS, ELECTRIC SOCKET CON-

NECTORS, ETC.

– USE SPECIAL KTM SCREWS WITH THE CORRECT THREAD LENGTH TO FASTEN THE SPOILER TO THE TANK. MOUNTING OTHER SCREWS

OR LONGER SCREWS COULD PUNCTURE THE TANK AND CAUSE FUEL TO LEAK OUT.

– IF YOU DISCONNECT SOCKET CONNECTORS WITH SELF-LOCKING NUTS, REPLACE THEM BEFORE REMOUNTING. IF NO NEW SELF-

LOCKING NUTS ARE AVAILABLE, APPLY LOCTITE 243 TO THE THREAD OF THE OLD NUTS. IF THE THREAD IS DAMAGED, REPLACE THE
SCREWS AND NUTS.

– DO NOT USE TOOTHED DISKS OR SPLIT WASHERS FOR THE ENGINE FASTENING BOLTS SINCE THEY WILL WORK THEIR WAY INTO THE

FRAME COMPONENTS AND BECOME LOOSE. ALWAYS USE SELF-LOCKING NUTS.
– LET THE MOTORCYCLE COOL DOWN BEFORE SERVICING TO AVOID BEING BURNED.
– PROPERLY DISPOSE OF OILS GREASE, FILTERS, FUEL, CLEANSERS, ETC. OBSERVE THE REGULATIONS EFFECTIVE IN YOUR COUNTRY.
– NEVER POUR USED OIL IN THE SEWER OR DISPOSE OF IT OUTDOORS. 1 LITER OF USED OIL WILL POLLUTE 1,000,000 LITERS OF WATER.

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22

MAINTENANCE WORK ON CHASSIS AND ENGINE »

BASIC SETTING
FORK
990 SUPER DUKE

Driving Comfort

Basic Setting

Driving Sport

Maximum Payload
Compression adjuster (clicks) 201510 15
Rebound adjuster (clicks) 201510 15
Spring preload (turns) 5

5

5 6

1

2

2

Adjusting the fork and shock absorber

There are a number of ways to adjust the fork and shock absorber to match
the chassis to your driving style and the payload.
We have provided a table with pragmatical values to help you tune up your
motorcycle. These tune-up specifications are reference values only and should
serve as a basis for your personal chassis and suspension tuning. Do not make
arbitrary changes to the settings (maximum ±40%) since this may impair the
handling characteristics (particularly in the high-speed range).
Make sure both fork legs are equally adjusted.

Adjusting compression damping of fork

Hydraulic compression damping determines the reaction when the fork is com­pressed.
Turn the adjusting screws [1] clockwise to increase damping, turn it counter­clockwise to reduce damping during compression.

STANDARD ADJUSTMENT

– Turn adjusting screw clockwise as far as it will go.
– Turn 15 clicks in a counterclockwise direction.

Adjusting rebound damping of fork

Hydraulic rebound damping determines the reaction when the fork is
rebound. By turning the adjusting screw [2] (REB), the degree of damping of
the rebound can be adjusted. Turn the knob clockwise to increase damping,
turn it counterclockwise to reduce damping during rebounding. Make the same
damping rate adjustment to both fork legs.

STANDARD ADJUSTMENT

– Turn adjusting screw clockwise as far as it will go.
– Turn 15 clicks in a counterclockwise direction.

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23

MAINTENANCE WORK ON CHASSIS AND ENGINE »

Compression damping of shock absorber

The shock absorber can synchronize the compression damping in the low and
high-speed range separately (Dual Compression Control).
Low and high speed refers to the movement of the shock absorber during com­pression and not to the speed of the motorcycle.
The low and high-speed technology overlaps.
The low-speed setting is primarily for slow to normal shock absorber compres­sion rates.
The high-speed setting is effective at fast compression rates.
Turning in a clockwise direction will increase the damping, turning counter­clockwise will decrease the damping.

STANDARD ADJUSTMENT LOW-SPEED:

– Turn adjusting screw [3] clockwise as far as it will go.
– Turn 20 clicks in a counterclockwise direction.

1

2

BASIC SETTING
SHOCK ABSORBER
950 ADVENTURE

Driving Comfort

Basic Setting

Driving Sport

Maximum Payload
Compression adjuster Low Speed (clicks)

252010 15

Compression adjuster High Speed (turns)

2,522 1,5
Rebound adjuster (clicks) 221710 5
Spring preload (turns) 6

6

6 6

3

Adjusting the spring preload on the fork

The fork spring preload can be adjusted by turning the adjusting screws [1]
(wrench size 24 mm) ± 5 mm (0,2 in).
Turning in a clockwise direction will increase the preload, turning in a coun­terclockwise direction will decrease the preload. 1 turn will change the pre­load by 1 mm.
Changing the preload will not affect the rebound damping adjustment, although
adjusting screw [2] will turn at the same time.
Generally, if the preload is higher, the rebound damping should also be set
higher.

STANDARD ADJUSTMENT:

– Turn adjusting screw counterclockwise as far as it will go.
– Turn 5 turns in a clockwise direction.

STANDARD ADJUSTMENT HIGH-SPEED:

– Turn adjusting screw (wrench size 17 mm) clockwise as far as it will go.
– Turn 2 turns in a counterclockwise direction.

THE DAMPING UNIT OF THE SHOCK ABSORBER IS FILLED WITH HIGH-COMPRES­SION NITROGEN. NEVER TRY TO TAKE THE SHOCK ABSORBER APART OR TO DO
ANYMAINTENANCE WORK YOURSELF. SEVERE INJURIES COULD BE THE RESULT.
NEVER UNSCREW THE BLACK SCREW CONNECTION (24MM).

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24

MAINTENANCE WORK ON CHASSIS AND ENGINE »

Checking the chain tension

Place the motorcycle on the side stand. Switch the transmission to neutral
and push the chain up. The distance between the chain and the swing arm
should be 7 mm when the upper part of the chain [A] is tensioned (see draw­ing). Correct the chain tension if necessary.

– IF CHAIN TENSION IS TOO GREAT, PARTS WITHIN THE SECONDARY POWER

TRANSMISSION (CHAIN, CHAIN SPROCKETS, TRANSMISSION AND REAR WHEEL
BEARINGS) WILL BE SUBJECTED TO UNNECESSARY STRESS, RESULTING IN
PREMATURE WEAR AND EVEN CHAIN BREAKAGE.

– TOO MUCH SLACK IN THE CHAIN, ON THE OTHER HAND, CAN RESULT IN THE

CHAIN JUMPING OFF THE CHAIN WHEELS. IF THIS HAPPENS, THE CHAIN COULD
ALSO BLOCK THE REAR WHEEL OR DAMAGE THE ENGINE.

– IN EITHER CASE THE OPERATOR IS LIKELY TO LOSE CONTROL OF THE MOTOR-

CYCLE.

Correcting the chain tension

Loosen the collar nut [2], loosen the counternuts [3] and turn the left and
right adjustment screws [4] the same distance. Tighten the counternuts [3].
To make sure the rear wheel is aligned, the marks on the chain tensioners
must be in the same position on the left and right in relation to the reference
marks [A]. Before tightening the wheel spindle make sure the chain tensioner
[5] rests against the adjustment screws and the rear wheel is aligned with the
front wheel.
Tighten the collar nut [2] to 90 Nm.

IF YOU DON’T HAPPEN TO HAVE A TORQUE WRENCH AT HAND, MAKE SURE YOU
HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POS­SIBLE. A LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAVIOR OF YOUR
MOTORCYCLE.

7 mm

A

1

2

3

4

5

5

A

Rebound damping of shock absorber

By using the adjusting screw [1], the degree of damping of the rebound can
be adjusted. Turn the knob in a clockwise direction to increase damping, turn
it in a counterclockwise direction to reduce damping during rebounding.

STANDARD ADJUSTMENT:

– Turn adjusting screw clockwise as far as it will go.
– Turn 17 clicks in a counterclockwise direction.

THE DAMPING UNIT OF THE SHOCK ABSORBER IS FILLED WITH HIGH-COMPRES­SION NITROGEN. NEVER TRY TO TAKE THE SHOCK ABSORBER APART OR TO DO
ANY MAINTENANCE WORK YOURSELF. SEVERE INJURIES COULD BE THE RESULT.

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25

MAINTENANCE WORK ON CHASSIS AND ENGINE »

Chain maintenance

For long chain life, good maintenance is very important. X-ring chains require
only modest maintenance. The best way is to use lots of water, but never use
brushes or solvents. After letting the chain dry, you can use a special X-ring
chain spray (Motorex Chainlube 622).

NO LUBRICATION IS ALLOWED TO REACH THE REAR TIRE OR THE BRAKE DISK,
EITHERWISE THE ROAD ADHERENCE AND THE REAR WHEEL BRAKING EFFECTS
WOULD BE STRONGLY REDUCED AND THE MOTORCYCLE COULD EASILY GET OUT
OF CONTROL.

– THE CHAIN DOES NOT HAVE A CHAIN JOINT FOR SAFETY REASONS. ALWAYS

HAVE THE CHAIN REPLACED IN AN AUTHORIZED KTM WORKSHOP WHERE THE
SERVICE TECHNICANS HAVE THE REQUIRED RIVETING TOOL.

– NEVER MOUNT A NORMAL CHAIN JOINT.

Also check sprockets and chain guides for wear, and replace if necessary.

Checking the chain for wear

To check the chain for wear proceed as follows:
Switch the transmission to idle and put a load of approx. 15 kilograms
(33 lbs) on the lower part of the chain (see illustration). Now measure the
distance between 18 chain rollers on the upper part of the chain. The chain
needs to be replaced when the distance is 272 mm (10.70 in). Since chains
do not always wear evenly, repeat the measurement at different parts of the
chain.
Replace the chain if any X-rings are missing.

NOTE:
If you mount a new chain, the sprockets should also be replaced. New chains
wear faster if used on old used sprockets.

15 KG

max. 272 mm

1 2 3

16 17 18

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26

MAINTENANCE WORK ON CHASSIS AND ENGINE »

General information on KTM disk brakes

BRAKE CALIPERS:
The front brake calipers [1] have 4 brake pistons each and are firmly con­nected to the fork legs. The front brake disks are designed as "floating" brake
disks, i.e. they are not firmly connected to the front wheel.
The lateral balance ensures that the brake pads always have the best possi­ble contact to the brake disk. Apply Loctite 243 to the screws [2] on the brake
caliper support and tighten to 45 Nm.
The rear brake caliper [3] has 1 brake piston and is designed as a "floating
brake caliper, i.e. it is not firmly connected to the brake caliper support. The
lateral balance ensures that the brake pads always have the best possible con­tact to the brake disk.

FOR SAFETY REASONS, ALWAYS HAVE MAINTENANCE WORK AND REPAIRS TO THE
BRAKE SYSTEM PERFORMED BY AN AUTHORIZED KTM WORKSHOP.

A

1

2

3

4

BRAKE PADS:
Your motorcycle is equipped with sintered brake pads in the front and rear
and homologated accordingly. They guarantee maximum braking
performance.
Front brake pads: Toshiba TT 2172 HH
Rear brake pads: Toshiba TTH 38 GF

BRAKE PADS AVAILABLE IN THE ACCESSORY TRADE ARE OFTEN NOT AUTHOR­IZED FOR OPERATION OF YOUR KTM MOTORCYCLE IN ROAD TRAFFIC. THE BRAKE
PADS DESIGN AND FRICTION FACTOR AND THEREFORE THE BRAKING POWER CAN
DEVIATE SIGNIFICANTLY FROM ORIGINAL KTM BRAKE PADS. IF YOU USE DIFFER­ENT BRAKE PADS THAN THOSE PROVIDED WITH THE ORIGINAL EQUIPMENT, IT
CANNOT BE WARRANTED THAT THEY ARE AUTHORIZED FOR USE IN ROAD TRAF­FIC. YOUR MOTORCYCLE WILL NOT LONGER COMPLY WITH THE REGULATIONS
AUTHORIZING THE USE OF VEHICLES FOR ROAD TRAFFIC AND THE WARRANTY
WILL BE VOID.

BRAKE FLUID RESERVOIRS:
The brake fluid reservoirs on the front and rear wheel brakes have been
designed in such a way that even if the brake pads are worn it is not neces­sary to top up the brake fluid. There is no reason to remove the reservoir cap
under normal conditions. If the brake fluid level drops below the minimum
either the brake system has a leak or the brake pads are completely worn down.
In this case, consult an authorized KTM dealer immediately.

BRAKE FLUID:
KTM fills the brake systems with Motorex Brake Fluid DOT 5.1 brake fluid,
one of the best brake fluids that is currently available. We recommend that
you continue to use it. DOT 5.1 brake fluid is based on glycol ether and of an
amber color. If you do not have any DOT 5.1 for refilling, you may use DOT
4 brake fluid. However, you should replace it as soon as possible
by DOT 5.1.
Never use DOT 5 braking fluid. It is based on silicone oil and has a purple
color. Gaskets and brake hoses are not compatible with it.
Brake fluid is exposed to a high thermal load and absorbs moisture from the
air, which lowers the boiling point. The brake fluid should therefore be changed
at the prescribed intervals.

HAVE THE BRAKE FLUID FOR THE FRONT AND REAR BRAKE CHANGED AT AN
AUTHORIZED KTM WORKSHOP EVERY 2 YEARS.

BRAKE DISCS:
Wear reduces the thickness of the brake disc in the area of contact [4] with
the brake pads. The brake disk should not be thinner than 4 mm (0.16 in) at
the weakest point [A]. Check the wear at several points.

BRAKE DISKS THAT ARE LESS THAN 4 MM (0.16 IN) THICK ARE A SAFETY HAZ­ARD. HAVE WORN BRAKE DISKS REPLACED IMMEDIATELY.

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27

MAINTENANCE WORK ON CHASSIS AND ENGINE »

Adjusting the basic position of the hand brake lever

The basic position of the hand brake lever can be modified by turning the
adjusting screw [1]. This lets you adapt the position of the pressure point (the
resistance you feel on the hand brake lever when the brake pads are pressed
against the brake disk) to fit any hand.

AT THE HAND BRAKE LEVER, FREE TRAVEL MUST AT LEAST BE 3 MM (0.12 IN).
ONLY THEN MAY THE PISTON IN THE HAND BRAKE CYLINDER BE MOVED (TO BE
RECOGNIZED BY THE GREATER RESISTANCE OF THE HAND BRAKE LEVER). IF
THIS FREE TRAVEL IS NOT PROVIDED, PRESSURE WILL BUILD UP IN THE BRAK­ING SYSTEM, AND THE FRONT WHEEL BRAKE MAY FAIL DUE TO OVERHEATING.

Checking the front brake fluid level

The brake fluid reservoir for the front brake is located on the left side of the
handlebar and has a "MIN" and a "MAX" mark. The brake fluid level may not
fall below the "MIN" mark when the vehicle is parked in a vertical position.

– IF THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM EITHER THE BRAKE

SYSTEM HAS A LEAK OR THE BRAKE PADS ARE COMPLETELY WORN DOWN.
IN THIS CASE, CONSULT AN AUTHORIZED KTM DEALER IMMEDIATELY.

– HAVE THE BRAKE FLUID CHANGED AT AN AUTHORIZED KTM WORKSHOP

EVERY 2 YEARS.

Refilling front brake fluid *

It is not necessary to refill brake fluid under normal conditions (see General
information on KTM disk brakes).
However, brake fluid must be refilled as soon as the brake fluid level reaches
the MIN mark.
Remove the screws [2] and cover [3] with the rubber boot [4]. Move the hand
brake cylinder in a horizontal position and add DOT 5.1 (Motorex Brake Fluid
DOT 5.1). Press the rubber boot together and remount the cover. Wash off
any overflowing or spilled brake fluid with water. Actuate the front brake until
you feel the pressure point.

– ACTUATE THE FRONT BRAKE UNTIL YOU FEEL THE POINT OF PRESSURE.
– NEVER USE DOT5 BRAKE FLUID! IT IS BASED ON SILICONE OIL AND OF A PUR-

PLE COLOR. SEALS AND BRAKE HOSES MUST BE ESPECIALLY ADAPTED

TO IT.
– STORE BRAKE FLUID OUT OF REACH OF CHILDREN.
– BRAKE FLUID CAN CAUSE SKIN IRRITATION. AVOID CONTACT WITH SKIN AND

EYES. IF YOU GET BRAKE FLUID IN YOUR EYES, RINSE WITH PLENTY OF WATER

AND CONSULT A DOCTOR.

– DON’T LET BRAKE FLUID GET IN CONTACT WITH PAINT, IT IS AN EFFECTIVE

PAINT REMOVER.
– USE ONLY CLEAN BRAKE FLUID TAKEN FROM A TIGHTLY SEALED CONTAINER.

Checking the front brake pads

The brake pads can be inspected from below. The linings must be at least
1 mm (0.04 in) thick.

AT THEIR MOST WORN POINT BRAKE PAD LININGS SHOULD NOT BE THINNER
THAN 1 MM, OTHERWISE THEY COULD LEAD TO BRAKE FAILURE. FOR YOUR OWN
SAFETY DON’T PUT OFF HAVING YOUR BRAKE PADS CHANGED.

IF THE BRAKE PADS ARE REPLACED TOO LATE WHEN THE LINING IS PARTLY OR
COMPLETELY WORN OFF, THE STEEL PARTS ON THE BRAKE PADS WILL GRIND
AGAINST THE BRAKE DISKS. THIS SIGNIFICANTLY DECREASES THE BRAKING
EFFECT AND DESTROYS THE BRAKE DISKS.

min. 3 mm

1

2

3

4

min.

1 mm

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28

MAINTENANCE WORK ON CHASSIS AND ENGINE »

min.

1 mm

3

4

1

2

6 mm

Changing the basic position of the foot brake lever *

Loosen the counternut [1] and turn the push rod [2] until the foot brake lever
is in the right position. Tighten the counternut again. For the best possible
connection, the push rod should be screwed at least 6 turns (6 mm) into the
heim joint (see drawing).
If the push rod is not screwed in far enough, the connection can brake and
cause the rear brake to fail in extreme cases.

Checking the rear brake fluid level

The brake fluid reservoir for the rear brake is located on the rear right of the
vehicle and has a "MIN" and a "MAX" mark. The brake fluid level may not fall
below the "MIN" mark when the vehicle is parked in an upright position.

– IF THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM EITHER THE BRAKE

SYSTEM HAS A LEAK OR THE BRAKE PADS ARE COMPLETELY WORN DOWN.

IN THIS CASE, CONSULT AN AUTHORIZED KTM DEALER IMMEDIATELY.
– HAVE THE BRAKE FLUID CHANGED AT AN AUTHORIZED KTM WORKSHOP

EVERY 2 YEARS.

Refilling rear brake fluid *

It is not necessary to refill brake fluid under normal conditions (see General
information on KTM disk brakes).
However, brake fluid must be refilled as soon as the brake fluid level reaches
the MIN mark.
Remove the cover [3] and rubber boot [4]. Add DOT 5.1 (Motorex Brake Fluid
DOT 5.1). Press the rubber boot together and remount the cover. Wash off
any overflowing or spilled brake fluid with water. Actuate the rear brake until
you feel the pressure point.

– ACTUATE THE REAR BRAKE UNTIL YOU FEEL THE POINT OF PRESSURE.
– NEVER USE DOT5 BRAKE FLUID! IT IS BASED ON SILICONE OIL AND OF A PUR-

PLE COLOR. SEALS AND BRAKE HOSES MUST BE ESPECIALLY ADAPTED

TO IT.
– STORE BRAKE FLUID OUT OF REACH OF CHILDREN.
– BRAKE FLUID CAN CAUSE SKIN IRRITATION. AVOID CONTACT WITH SKIN AND

EYES. IF YOU GET BRAKE FLUID IN YOUR EYES, RINSE WITH PLENTY OF WATER

AND CONSULT A DOCTOR

– DON’T LET BRAKE FLUID GET IN CONTACT WITH PAINT, IT IS AN EFFECTIVE

PAINT REMOVER.
– USE ONLY CLEAN BRAKE FLUID TAKEN FROM A TIGHTLY SEALED CONTAINER.

Checking the rear brake pads

The brake pads can be inspected from the rear. The thickness of the linings
may not be less than 1 mm (0.04 in).

AT THEIR MOST WORN POINT BRAKE PAD LININGS SHOULD NOT BE THINNER
THAN 1 MM, OTHERWISE THEY COULD LEAD TO BRAKE FAILURE. FOR YOUR OWN
SAFETY DON’T PUT OFF HAVING YOUR BRAKE PADS CHANGED.

IF THE BRAKE PADS ARE REPLACED TOO LATE SO THAT THE LINING IS PARTLY
OR ENTIRELY WORN AWAY, THE STEEL COMPONENTS OF THE BRAKE PAD WILL
RUB AGAINST THE BRAKE DISC, IMPARING THE BRAKING EFFECT AND DESTROY­ING THE BRAKE DISC.

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29

MAINTENANCE WORK ON CHASSIS AND ENGINE »

A

B

1

1

2

3

3

4

5

Dismounting and remounting the front wheel *

Place the front of the motorcycle on a motorcycle stand (available as an acces­sory), lifting the front wheel entirely off the ground.
To remove the left and right brake caliper, remove the two screws [1] on each
caliper and pull the brake caliper off the brake disk towards the back.
Loosen the collar screw [2] and the clamping screws [3] on both fork leg axle
passages.
Unscrew the collar screw approx 8 turns, press on the collar screw with your
hand to push the wheel spindle out of the fork leg axle passage and remove
the collar screw. Hold the front wheel while you pull out the wheel spindle.
Lift the front wheel off the fork.
Take the left [4] and right distance bushing out of the shaft seal rings.

– DO NOT OPERATE THE HAND BRAKE WHEN THE FRONT WHEEL HAS BEEN

DISMOUNTED.
– BE CAREFUL NOT TO DAMAGE THE BRAKE DISKS WHEN YOU LAY THE FRONT

WHEEL DOWN.

Before you remount the front wheel, clean and grease the shaft seal rings [5]
and the bearing surface [A] of the distance bushings and mount the distance
bushings (wide distance bushing in the left shaft seal ring). When mounting
the distance bushing, be careful not to press the sealing lips towards the inside.
position the front wheel according to the running direction shown by the arrows
[B] on the rim.

To remount the front wheel, lift the wheel on the fork and mount the wheel
spindle.
Mount the collar screw [2] and tighten slightly, tighten the clamping screws
[3] on the right fork leg axle passage to prevent the wheel spindle from turn­ing and tighten the collar nut to 60 Nm.
Remount the brake calipers. Apply Loctite 243 to the screws [1] on the brake
caliper support and tighten to 45 Nm.
Loosen the clamping screws on the right fork leg axle passage, pull the motor­cycle off the stand, actuate the front wheel brake and vigorously compress
the fork several times to align the fork legs.
Finally, tighten the clamping screws on both fork leg axle passages to 15 Nm.

– IF YOU DO NOT HAVE A TORQUE WRENCH TO MOUNT THE WHEEL, HAVE THE

TORQUES CORRECTED BY AN AUTHORIZED KTM WORKSHOP AS SOON AS POS-

SIBLE. A LOOSE AXLE PASSAGE CAN CAUSE THE MOTORCYCLE'S HANDLING

PERFORMANCE TO BECOME INSTABLE.
– AFTER MOUNTING THE FRONT WHEEL, KEEP OPERATING THE HAND BRAKE

UNTIL THE PRESSURE POINT RETURNS.
– ALWAYS KEEP THE BRAKE DISKS FREE FROM OIL AND GREASE, OTHERWISE

THE BRAKING EFFECT WILL BE SIGNIFICANTLY REDUCED.

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30

MAINTENANCE WORK ON CHASSIS AND ENGINE »

1

3

5

2

A

4

6

Dismounting and remounting the rear wheel *

Place the back of the motorcycle on a motorcycle stand (available as an acces­sory), lifting the rear wheel entirely off the ground.

Unscrew the collar nut [1], remove the chain tensioner [2], hold the rear wheel
while you pull out the wheel spindle [3]. Push the rear wheel forward as far
as possible and remove the chain from the rear sprocket. Carefully take the
rear wheel off the swing arm.

– DO NOT OPERATE THE REAR BRAKE WHEN THE REAR WHEEL HAS BEEN DIS-

MOUNTED.
– ALWAYS PLACE THE WHEEL ON THE GROUND WITH THE BRAKE DISC POINT-

ING UPWARDS. OTHERWISE THE BRAKE DISC MAY BE DAMAGED.
– IF THE AXLE IS DISMOUNTED, CLEAN THE THREAD OF THE WHEEL SPINDLE

AND COLLAR NUT THOROUGHLY AND APPLY A NEW COAT OF GREASE (MOTOREX

LONG THERM 2000) TO PREVENT THE THREAD FROM JAMMING.

Before remounting the rear wheel, clean and grease the bearing surface of
the bushings [5] and the shaft seal ring [6].

The rear wheel is remounted in the reverse order. Make sure the chain ten­sioners [4] are mounted in the same way on the left and right. The marks on
the chain tensioners must be in the same position on the left and right in
relation to the reference marks [A]. Before you tighten the collar nut to
90 Nm, press the rear wheel towards the front to allow the chain tensioner to
rest against the clamping screws.

– IF YOU DON’T HAPPEN TO HAVE A TORQUE WRENCH AT HAND, MAKE SURE

YOU HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON

AS POSSIBLE. A LOOSE WHEEL SPINDLE MAY LEAD TO AN UNSTABLE DRIV-

ING BEHAVIOR OF YOUR MOTORCYCLE.
– AFTER MOUNTING THE REAR WHEEL, KEEP OPERATING THE FOOTBRAKE

UNTIL THE PRESSURE POINT RETURNS.
– IT IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND

GREASE, OTHERWISE THE BRAKING EFFECT WOULD BE STRONGLY REDUCED.

ENGLISH

31

MAINTENANCE WORK ON CHASSIS AND ENGINE »

TIRES – AIR PRESSURE

990 Super Duke front rear

Road, driver only 2,4 bar 2,4 bar
Road, with passenger 2,4 bar 2,6 bar
maximum payload 2,4 bar 2,6 bar

1

Tires, air pressure

Tire type, tire condition, and how much air pressure the tires have in them
affect the way your motorcycle rides, and they must therefore be checked when­ever you’re getting ready to go anywhere on your motorcycle.

FOR DRIVING SAFETY AND MAXIMUM HANDLING, ONLY USE TIRES AUTHORIZED
BY KTM CORRESPONDING TO THE "ZR" SPEED INDEX (OVER 240 KPH). OTHER
TIRES CAN HAVE A NEGATIVE EFFECT ON THE MOTORCYCLE'S HANDLING (E.G.
CAN CAUSE IT TO "WOBBLE" AT HIGHER SPEEDS).

– Tire type and size can be found in the technical specifications and in the

homologation certificate
– Tire condition has to be checked every time you want to ride your motor-

cycle. Before leaving check for punctures and nails or other sharp objects

that might have become embedded in the tire.
– Refer to the specific regulations in your country for minimum tire tread

requirements. We recommend replacing tires at the latest when the tread

is down to 2 mm (0.08 in).
– Tire pressure should be checked regularly on a “cold” tire. Adapt the air

pressure to the motorcycle's total weight. Proper pressure ensures opti-

mum driving comfort and extends the life of your tires.

– DO NOT MOUNT TIRES WHICH HAVE NOT BEEN APPROVED BY KTM. OTHER

TIRES COULD HAVE ADVERSE EFFECTS ON THE WAY YOUR MOTORCYCLE

RIDES.
– USE TIRES OF THE SAME BRAND AND TYPE FOR THE FRONT AND REAR

WHEELS.
– FOR YOUR OWN SAFETY REPLACE DAMAGED TIRES IMMEDIATELY.
– WORN TIRES CAN HAVE A NEGATIVE EFFECT ON HOW YOUR MOTORCYCLE

PERFORMS, ESPECIALLY ON WET SURFACES
– IF AIR PRESSURE IS TOO LOW, ABNORMAL WEAR AND OVERHEATING OF THE

TIRE CAN RESULT
– NEW WHEELS HAVE A SMOOTH SURFACE, WHICH MEANS THAT THEY MUST

BE RUN IN TO ACHIEVE FULL GRIP. FOR THIS PURPOSE, RIDE THE MOTOR-

CYCLE CAREFULLY AT MODERATE SPEED DURING THE FIRST 200 KILOMETERS

(125 MILES) WITH NEW TIRES, TILTING THE VEHICLE AT DIFFERENT ANGLES

SO THAT ALL SECTIONS ARE PROPERLY ROUGHENED. TIRES WILL NOT DIS-

PLAY

THEIR FULL GRIP CHARACTERISTICS UNTIL THEY ARE PROPERLY RUN IN.

– FOR REASONS OF SAFETY, IT IS RECOMMENDED TO EXCHANGE THE VALVE

INSERT WHENEVER A NEW TIRE IS MOUNTED.

Battery

The battery is located in the front spoiler in front of the engine and is main­tenance-free. It is not necessary to check the electrolyte level or to refill water.
Simply keep the battery poles clean and slightly grease them with an acid­free grease if necessary.

NEVER REMOVE THE CLOSING COVER [1] OTHERWISE THE BATTERY WILL BE
DAMAGED.

ENGLISH

32

MAINTENANCE WORK ON CHASSIS AND ENGINE »

VOLT

3

3

4

1

2

2

Removing and remounting the battery *

The battery only needs to be removed if the motorcycle is being immobilized.
Remove the screws [1] on both sides, loosen the screws [2] 2 turns and remove
the front spoiler towards the front. Push the cables to the side. Remove the
screws [3] and fold the battery cover [4] down.
First disconnect the negative terminal, then the positive terminal from the
battery. Make sure the battery terminals are not bent when they are removed.
Remove the battery cover and take out the battery.
Charge the battery before and after storage. Storage temperature 0 - 35°C.
When remounting the battery, position it in the battery compartment and mount
the battery cover. First connect the cables on the positive terminal, then con­nect the negative terminal to the battery to avoid a short-circuit. Open the
battery cover and fasten with 2 screws. Remount the front spoiler. Apply Loctite
243 to the screws [1] and tighten to 10 Nm.

– IF ELECTROLYTE (SULPHURIC ACID) LEAKS FROM THE BATTERY, PROCEED WITH

GREAT CARE. THE ELECTROLYTE CAN CAUSE SEVERE BURNS.
– IN THE CASE OF SKIN CONTACT RINSE THOROUGHLY WITH WATER.
– IN THE CASE OF CONTACT WITH THE EYES, THOROUGHLY RINSE EYES WITH

WATER FOR AT LEAST 15 MINUTES. IMMEDIATELY CONSULT A DOCTOR.
– THE BATTERY IS A CLOSED MODEL BUT CAN NEVERTHELESS EMIT EXPLO-

SIVE GASES. AVOID SPARKS AND OPEN FIRE NEAR THE BATTERY.
– DEFECTIVE BATTERIES MUST BE STORED OUT OF THE REACH OF CHILDREN.

ENSURE PROPER DISPOSAL OF DISCARDED BATTERIES.
– THE SCREWS ON THE UNDERRIDE PROTECTION MUST BE SECURED WITH LOC-

TITE 243 TO PREVENT THEM FROM BECOMING LOOSE.

NEVER DISCONNECT THE BATTERY WHILE THE ENGINE IS RUNNING. THIS WILL
DESTROY THE RECTIFIER-REGULATOR.

Charging the battery

Note: a battery charger, item no. 58429074000, is available from your KTM
dealer. You can also use the battery charger to test the off load voltage, starta­bility of the battery and the generator capacity.

Remove the front spoiler and fold the battery cover down; then determine the
battery's charge condition. To determine the charge condition, use a voltmeter
to measure the voltage between the battery terminals (off load voltage). For
a precise measurement, the battery should not have been charged or discharged
for at least 30 minutes.
If the voltage exceeds 12.4 V, it does not need to be charged.
If the voltage is below 12.4 V, the battery should be charged.

CHARGING:
Disconnect the negative terminal from the battery to avoid damage to the motor­cycle's electronic system.
Connect the battery charger to the battery terminals. First connect the cables
to the positive terminal, then to the negative terminal on the battery. Charge
the battery for 5 to a max. of 10 hours with 1.4 amperes and a max. of 14.4
volts. For a quick charge, do not charge the battery with 4.5 amperes and a
max. of 14.4 volts for more than 1 hour.

– ALWAYS DISCONNECT THE NEGATIVE TERMINAL FROM THE BATTERY PRIOR TO

CHARGING TO AVOID DAMAGE TO THE MOTORCYCLE'S ELECTRONIC SYSTEM.
– IF THE CHARGE CONDITION CANNOT BE ESTABLISHED, THE BATTERY MAY ONLY BE

CHARGED 5 TO A MAX. OF 10 HOURS WITH 1.4 AMPERES AND A MAX. OF 14.4 VOLTS.
– ALWAYS CONNECT THE BATTERY TO THE CHARGING UNIT BEFORE TURNING THE

CHARGING UNIT ON.
– WHEN RECHARGING THE BATTERY IN CLOSED ROOMS THERE IS SUFFICIENT

VENTILATION. EXPLOSIVE GASES ARE RELEASED DURING THE BATTERY CHARGING

PROCESS.
– CHARGING TIME AND CHARGING VOLTAGE SHOULD NOT EXCEED THE STATED VAL-

UES. OTHERWISE ELECTROLYTE WILL BE RELEASED THROUGH THE SAFETY VALVES.
– AVOID QUICK CHARGING IF POSSIBLE.
– TO AVOID DAMAGE, DO NOT REMOVE THE LOCKING BAR.

Jump start

Jump starts are not recommended since they can damage the motorcycle's
electronic system.

ENGLISH

33

MAINTENANCE WORK ON CHASSIS AND ENGINE »

6

5

3

4

1

2

7

8

Main fuse

The main fuse protects all of the motorcycle's electric power consumers. The
main fuse is located on the left under the front spoiler.

Pull the connector [1] out of the bracket, remove the cap [2] and check the
main fuse [3]. A spare fuse [4](30 amperes)is also plugged into the bracket.
Always replace blown fuses with an equivalent fuse. Visit an authorized KTM
workshop if a new fuse blows again after it is inserted.

NEVER USE A STRONGER FUSE OR A REPAIRED FUSE. IMPROPER USE CAN
DESTROY THE ENTIRE ELECTRIC SYSTEM.

Fuses for individual power consumers

A fuse box is mounted under the seat containing additional fuses that pro­tect the individual electric power consumers.
The power consumers and the corresponding capacities are listed on the cover
of the fuse box [5]. Spare fuses [6] of 10 and 15 amperes are located next
to the fuse box.

Replace a blown fuse only with an equivalent one. If a new fuse that has just
been set in gets blown again, you are strongly advised to have it
inspected by a KTM dealer.

UNDER NO CIRCUMSTANCES IS A STRONGER FUSE ALLOWED TO BE SET IN OR
A FUSE ALLOWED TO BE “REPAIRED”. AN INEXPERT TREATMENT COULD DAM­AGE THE WHOLE ELECTRICAL INSTALLATION!

The ACC fuse [7] is designed for accessories with a maximum power con­sumption of 10 amperes. A connector [8] to connect the equipment is pro­vided under the seat. Ask your authorized KTM workshop for details.

ENGLISH

34

MAINTENANCE WORK ON CHASSIS AND ENGINE »

1

1

2

3

4

A

B

5

6

Replacing the headlight lamp *

Remove the screws [1] on the left and right and tilt the headlight mask down
towards the front.

NEVER TOUCH THE GLASS OF THE BULB WITH YOUR FINGERS. THE GLASS OF
THE BULB MUST REMAIN ABSOLUTELY FREE FROM GREASE. HEAT WILL OTHER­WISE CAUSE THE GREASE TO EVAPORATE AND SETTLE DOWN ON THE
REFLECTOR.

BULB FOR HIGH BEAM [A]:
Remove the rubber cap [2] and pull off the connector [3]. Detach the retain­ing clip and remove the bulb.
Insert a new bulb, attach the retaining clip, connect the connector and mount
the rubber cap.

BULB FOR LOW BEAM [B]:
Remove the rubber cap [4] and pull off the connector [5]. Detach the retain­ing clip and remove the bulb.
When you insert the new bulb, make sure the tab fits in the corresponding
recess in the socket.
Attach the retaining clip, connect the connector to the bulb and mount the
rubber cap.

BULB FOR THE PARKING LIGHT:
Since a number of parts need to be removed to replace the parking light bulb,
we recommend that you have the lamp replaced at an authorized KTM
workshop.

Adjusting the headlight range

The payload can make it necessary to correct the headlight range.
The headlight range can be adjusted with the adjusting screw [6]. Turning in
a clockwise direction will increase the headlight range, turning in a counter­clockwise direction will reduce the headlight range.

CONTROL:
Make a mark on a light colored wall behind a horizontal surface, at the height
corresponding to the center of the headlight. Position your motorcycle 5
meters from the wall in a fully loaded condition (baggage, driver, passenger)
and switch on the low beams. The light/dark boundary should be at the mark.

5 m

x

5 cm

ENGLISH

35

MAINTENANCE WORK ON CHASSIS AND ENGINE »

2

3

4

1

Replacing the brake light and taillight bulbs

Remove the seat.

BULB FOR BRAKE LIGHT:
Turn the bulb socket [1] approx. 30° in a counterclockwise direction and pull
it out of the taillight housing. Slightly press in the bulb, turn approx. 30° in
a counterclockwise direction and remove it from the socket.
Proceed in the reverse order to mount a new bulb.

BULBS FOR THE TAILLIGHT:
Remove the bulb socket [2] from the housing and pull the bulb out of the
socket. Insert a new bulb and press the bulb socket all the way into the tail­light housing.
Mount the seat.

Replacing the flasher bulbs

Remove the screw on the back of the turn signal, carefully fold the lens [3]
towards the motorcycle and remove. Turn the cap [4] approx. 15° in a coun­terclockwise direction and remove.

Slightly depress the bulb, turn it approx. 30° counterclockwise and pull it out
of the socket.
To mount the lamp reverse the worksteps indicated above.

ENGLISH

36

MAINTENANCE WORK ON CHASSIS AND ENGINE »

6

5

4

2

3

1

Cooling system

The water pump in the engine ensures a forced circulation of the cooling liq­uid. When the engine is cold, the cooling liquid only circulates in the cylin­ders and cylinder heads. After the engine reaches the operating temperature
(approx. 75°C, 167°F), the thermostat opens and the cooling liquid is also
pumped through the aluminum radiator.
Cooling is by means of the air stream. The lower the speed, the lower the cool­ing effect. Soiled cooling fins also impair the cooling effect.
If, for example, slow urban traffic or waiting at a traffic light cause little or
no air to stream through the radiator, the temperature of the cooling liquid
will rise. The radiator fan [1] switches on when the cooling liquid reaches a
temperature of 102°C (216°F). Additional air is blown through the radiator
to prevent the cooling system from overheating.

THE TEMPERATURE INDICATOR [2] WILL BEGIN TO BLINK AND THE RED COOL­ING LIQUID TEMPERATURE WARNING LAMP [3] WILL LIGHT UP WHEN THE COOL­ING LIQUID REACHES APPROX. 120°C (248°F), HAVING EXCEEDED THE NORMAL
OPERATING TEMPERATURE. POSSIBLE CAUSES:

– SLOW RIDING WITH LARGE LOADS AT A HIGHER AIR TEMPERATURE:

IF POSSIBLE INCREASE YOUR RUNNING SPEED, SO THAT MORE AIR CAN BLOW

THROUGH THE RADIATORS. SHOULD THE WARNING LIGHT STILL BE ON OFF

AFTER 1500 METERS (1 MILE), STOP IMMEDIATELY, SWITCH OFF THE ENGINE

AND LOOK FOR OTHER POSSIBLE CAUSES.
– THE COOLING FAN ON THE RADIATOR IS NOT WORKING:

THE COOLING FAN MUST BE RUNNING, WHEN THE COOLING LIQUID TEMPER-

ATURE IS 120°C (248°F) AND THE IGNITION IS ON. IF THE FAN IS NOT WORK-

ING, AND THERE APPEARS TO BE SUFFICIENT COOLING LIQUID, THE ONLY

THING YOU CAN DO IS TO DRIVE ON TO YOUR NEAREST AUTHORIZED KTM

WORKSHOP AT THE LEAST POSSIBLE ENGINE LOAD.
– TOO LITTLE COOLING LIQUID IN THE SYSTEM:

CHECK WHETHER ANY COOLING LIQUID IS LEAKING OUT (ALSO ON THE BOT-

TOM OF THE MOTORCYCLE).

LET THE ENGINE COOL DOWN AND CHECK THE COOLING LIQUID LEVEL IN

THE RADIATOR (SEE CHAPTER CHECKING THE COOLING LIQUID LEVEL IN THE

RADIATOR). ONLY CONTINUE TO DRIVE IF THERE IS ENOUGH COOLING LIQ-

UID IN THE SYSTEM. CONTACT AN AUTHORIZED KTM WORKSHOP TO HAVE

THE ERROR ELIMINATED. YOU WILL DAMAGE THE ENGINE IF YOU CONTINUE

TO DRIVE WHEN THE COOLING LIQUID TEMPERATURE WARNING LAMP IS ON.
– EXCESSIVE USE OF THE CLUTCH AT SLOW SPEED

A mixture of 50% antifreeze and 50% distilled water is used as the cooling
liquid. How-ever, the anti-freeze protection must be at least -25° C
(-13° F). Aside from antifreezing protection, this mixture also provides great
corrosion protection which is why it must not be replaced by pure water.

– FOR THE COOLING SYSTEM, USE ONLY HIGH-GRADE ANTIFREEZER (MOTOREX

ANTI-FREEZE). USING LOWERGRADE ANTIFREEZE AGENTS, CAN CAUSE COR-

ROSION AND COOLANT FOAMING.
– MORE ANTIFREEZE MUST BE ADDED IF YOU PLAN TO TRAVEL TO A REGION

WHERE TEMPERATURES ARE EXPECTED TO DROP BELOW -25°C (-13°F).

Pressure induced by heating of the cooling liquid in the cooling system is con­trolled by a valve in the radiator cap [4]; a water temperature rising up to 125°
C (257° F) is admissible, without fear of problems.
Any excess cooling liquid caused by thermal expansion is conducted to the
compensating tank [5]. It will be sucked back in as soon as the temperature
in the cooling system drops.

Checking the cooling liquid level in the compensating tank

Check the level of the cooling liquid when the engine is cold. It should fall
between the MIN and MAX marks on the compensating tank [6].
Add cooling liquid (see above for mixture ratio) if the cooling liquid level drops
below the MIN mark.
If you need to add cooling liquid quite often, the cooling system may leak. If
the compensating tank is empty, also check the cooling liquid level in the
radiator. Have the cooling system checked by an authorized KTM
workshop.

ENGLISH

37

MAINTENANCE WORK ON CHASSIS AND ENGINE »

4

1

2

2

3

3

5

Checking the cooling liquid level in the radiator *

Hold the radiator cap [1] with a cloth, carefully turn in a counterclockwise
direction and remove. The radiator should be completely filled with cooling
liquid; no air should be in the radiator.
If any cooling liquid is missing, the cooling system is probably leaking. Have
the cooling system checked at an authorized KTM workshop.

IF POSSIBLE, CHECK THE COOLING LIQUID LEVEL WHEN THE ENGINE IS COLD.
IF YOU NEED TO REMOVE THE RADIATOR CAP WHEN THE ENGINE IS HOT, HOLD
THE CAP WITH A CLOTH AND OPEN SLOWLY, ALLOWING ANY EXCESS PRESSURE
TO ESCAPE (DANGER OF SCALDING).

IF MORE THAN 1 LITER OF COOLING LIQUID NEEDS TO BE ADDED, YOU WILL NEED
TO BLEED THE COOLING SYSTEM.

Bleeding the cooling system *

Take off the left and right spoilers. To take off the spoilers, remove the screws
[2] and [3] on each side.

Remove the bleeder screw [4] on the left side of the radiator.

To completely bleed the cooling system, the motorcycle must be raised approx.
50 cm in the front.
Add cooling liquid until it runs out of the vent holes without bubbles and imme­diately mount the screw to prevent air from entering the radiator.
Completely fill the radiator with cooling liquid. Mount the radiator cap and
move the motorcycle into a horizontal position again. Now fill the compen­sating tank [5] with cooling liquid until it reaches a level between the MIN
and MAX marks. Close the compensating tank and mount both spoilers.

ENGLISH

38

MAINTENANCE WORK ON CHASSIS AND ENGINE »

1

3

4

2

2

Changing the basic position of the clutch lever

The basic position of the clutch lever can be modified by turning the adjust­ing screw [1]. This lets you adjust the best clutch lever position for any hand
size.
To adjust, pull the clutch lever towards the front. Turning the adjusting screw
in a clockwise direction will move the clutch lever away from the driver.
Turning the adjusting screw in a counterclockwise direction will move the clutch
lever towards the driver.

ADJUSTMENT OF THE CLUTCH LEVER POSITION IS ONLY POSSIBLE WITHIN CER­TAIN LIMITS. ONLY TURN THE ADJUSTING SCREW MANUALLY AND NEVER APPLY
EXCESSIVE FORCE.

Checking the oil level of the hydraulic clutch

The oil level should be between the "MIN" and "MAX" marks with the master
cylinder in a horizontal position.
If necessary, add SAE 10 biodegradable hydraulic oil (Motorex clutch fluid

75), available from your authorized KTM workshop.

KTM USES BIODEGRADABLE, HYDRAULIC MINERAL OIL TO ACTUATE THE HYDRAULIC
CLUTCH. DO NOT MIX THIS OIL WITH ANY OTHER HYDRAULIC OIL. ALWAYS USE
ORIGINAL KTM HYDRAULIC OIL (AVAILABLE FROM YOUR AUTHORIZED KTM WORK­SHOP) TO MAKE SURE YOUR CLUTCH OPERATES SMOOTHLY.
NEVER REFILL WITH BRAKE FLUID.

Adjusting the handlebar tilt

Loosen the screws [2]. Adjust the handlebar and tighten the screws to 20 Nm.
Make sure the handlebar instruments do not touch the fuel tank when the
handlebar is completely turned.

TILTING THE HANDLEBAR TOO FAR BACK WILL REDUCE THE STEERING ANGLE
SINCE THE HANDLEBAR INSTRUMENTS WILL TOUCH THE FUEL TANK

IF THE HANDLEBAR IS TILTED TOO FAR BACK, THE HANDLEBAR INSTRUMENTS
MAY DAMAGE THE FUEL TANK

Checking and adjusting the throttle cable play *

When starting to turn the throttle grip, you should feel an initial backlash of
3-5 mm (0.12-0.2 in).
To adjust, loosen the counter nut [3], turn the adjusting screw [4] as needed
and tighten the counter nut again.
Make sure that the throttle grip will return to the idle position automatically
once you let go of it.
To check the correctness of this setting, start the engine, turn the handlebar
left and right, in both cases as far as it will go. This must not cause any changes
in idling speed. Otherwise, you have to increase the backlash of the throttle
cable.

ENGLISH

39

MAINTENANCE WORK ON CHASSIS AND ENGINE »

10W/50

5W/40

JASO T903 MA

TEMPERATURE

0°C

32°F

3

3

2

1

2

4

Engine oil

Automobile engine oil used to be used for four-stroke motorcycles before there
were separate motorcycle specifications. Different technical developments made
it necessary to have a separate specification for four-stroke motorcycles - the
JASO T903 MA standard. Whereas car engines require long changing inter­vals, motorcycle engines require a higher power output at higher speeds. Most
motorcycle engines also use the same oil to lubricate the transmission and
the clutch. The JASO MA standard responds to these special requirements.
Only use fully synthetic engine oils that meet the JASO MA quality require­ments (see information on the can).
KTM recommends Motorex Power Synt 4T in the 10W/50 viscosity (for tem­peratures over 0°C, 32°F) or 5W/40 (for temperatures under 0°C, 32°F).

Checking the engine oil level

Check the engine oil level when the engine is warm (at least 4 bars on the
temperature indicator light up). Allow the warm engine to run idle for approx.
1 minute and place the motorcycle on a level surface (not on the side stand).
Wait 20 seconds to allow the oil level in the inspection glass to adjust to the
oil level in the oil tank. The oil level should be between the MIN and MAX
marks, add engine oil if necessary.

ALWAYS CHECK THE OIL LEVEL WHEN THE ENGINE IS WARM. A COLD ENGINE
CAN DISTORT THE MEASURING RESULTS. ENGINE OIL EXPANDS WHEN HEATED,
INCREASING THE OIL LEVEL.

Refilling engine oil

To refill engine oil, take off the right spoiler [1] by removing the screws [2].

Also remove the screws [3] and take off the spoiler.

Unscrew the plug [4] and refill engine oil. Wait 20 seconds and check the oil
level again. The quantity of oil between the MIN and MAX marks is 0.3 liter.
Mount the plug and check the engine for leaks.
Finally, mount the spoilers.

– INSUFFICIENT AMOUNTS OF OR LOW-GRADE ENGINE OIL LEAD TO PREMA-

TURE WEAR IN THE ENGINE.
– DO NOT OVERFILL THE ENGINE CASE.
– DO NOT UNDERFILL THE ENGINE CASE.

ENGLISH

40

MAINTENANCE WORK ON CHASSIS AND ENGINE »

6

7

7

8

9

5

4

3

1

2

4

Changing the engine oil and the oil filter, cleaning the oil screen *

NOTE: The LC8 engine has a dry-sump lubrication system. The engine oil is
pumped from the oil sump in the engine case to the oil tank. The engine oil
must also be drained from the oil tank during an oil change. Since many parts
must be demounted for an oil change, we recommend having the engine oil
changed by an authorized KTM workshop.
During the guaranty period, the oil change must be performed by an author­ized KTM mechanic. Otherwise, the guarantee will become void.

The engine oil change is to be carried out when the engine is still warm.

AN ENGINE HAVING BEEN RUN WARM, AND THE ENGINE OIL IN IT IS VERY
HOT – DO NOT BURN YOURSELF.

Park the motorcycle on an even surface in an upright position. Place a ves­sel under the engine to catch the used oil and remove the oil drain plug [1].
Remove the oil drain plug [1], take off the cap [2] and pull the oil sieve out
of the engine case with a pair of pliers.

Remove the oil filter cover [3] and pull the oil filter out of the engine case
with circlip pliers (upside-down).

Remove the screws [4], loosen the screws [5] by 2 turns and remove the front
spoiler towards the front.

Remove the drain plug [6] on the oil tank and allow the oil to drain into a
receptacle. Remove the screws [7] and tilt the oil return valve [8] to the side.

Carefully pull the oil screen [9] out of the oil tank.

Thoroughly clean the drain plugs, the cover and both oil screens. Clean all
rubber seal rings and check for damage. Replace if necessary.

ENGLISH

41

MAINTENANCE WORK ON CHASSIS AND ENGINE »

Mount the oil drain plug on the engine with a new seal ring and tighten
to 20 Nm.

Slide the oil screen [1] into the guides in the oil pump housing with the TOP
mark facing up. Make sure the form ring is in place and mount the cap [2].
Tighten the screws to 10 Nm.

Insert a new oil filter [3] in the engine case, grease the O-ring and mount the
oil filter cover together with the O-ring. Tighten the screws to 6 Nm.

ONLY USE ORIGINAL KTM OIL FILTERS. THE ENGINE CAN BE DAMAGED IF OTHER
FILTERS ARE USED.

Mount the oil drain plug on the oil tank with a new seal ring and tighten
to 20 Nm.

Grease the seal ring [4] and carefully slide the oil screen into the oil tank.
Position the oil return valve [5], mount the screws and tighten to 10 Nm.

Add 2.5 liters (0.7 USgal) of fully synthetic engine oil meeting the JASO MA
standard (e.g. Motorex Power Synt 4T) and mount the oil dipstick [6]. Start
the engine, allow to run warm for 4 minutes and switch off the engine. Remove
the oil dipstick and add engine oil up to the MAX mark (approx. 0.5 liters,

0.13 USgal).

Check the engine and the oil tank for oil leakage.

Fit the slots in the front spoiler on the lower screws [7] and tighten. Apply
Loctite 243 to the side screws [8] and tighten to 10 Nm.

Finally, mount the spoiler (see Refilling the engine oil).

1

2

3

4

5

6

7

8

ENGLISH

42

TROUBLESHOOTING »

If you have your motorcycle serviced as set forth in this manual, no malfunctioning is to be expected. Nevertheless, if an error does
arise, we recommend that you look for the error according to the following chart.
Please note that you cannot perform all of the work yourself. If you are not sure, contact your KTM dealer.

TROUBLE CAUSE REMEDY

Engine does not start when the
starter button is actuated

Operating error

Discharged battery

Blown fuse IGNITION.

Main fuse is blown

Defect ignition lock or emergency
OFF switch

Defect safe-starting system.

Turn on the ignition, switch the gear to neutral and switch the
emergency OFF switch on.

Recharge the battery and investigate the causes for discharg­ing; contact an authorized KTM workshop.

Replace fuse IGNITION

Remove the front spoiler and replace the main fuse

Check ignition lock and emergency OFF switch, contact an
authorized KTM workshop.

Contact an authorized KTM workshop.

The engine cranks only with
pulled clutch lever

A gear is engaged

A gear is engaged and the side stand
is still folded down

Defect safe-starting system.

Shift the transmission to neutral.

Shift the transmission to neutral.

Contact an authorized KTM workshop.

Engine cranks with gear engaged. Defect safe-starting system. Contact an authorized KTM workshop.

Engine cranks but doesn’t start. Operating error

Blown fuse for the fuel pump

Clutch not attached to the fuel line

The plug and socket connector on the
wiring harness is oxidized

Error in the injection system

A gear is engaged and the side stand
is folded down

Pay attention to starting off information (see driving instruc­tions).

Replace the fuel pump fuse

Connect the clutch to the fuel line

Remove the panel and fuel tank, clean the plug and socket
connector and spray with contact spray

Visit an authorized KTM workshop

Switch to neutral gear

Engine will not reach full power Air filter/fuel filter heavily soiled

Error in the injection system

Have the air filter/fuel filter replaced at an authorized KTM
workshop

Visit an authorized KTM workshop

Engine overheats Insufficient cooling liquid

Radiator fins are extremely dirty

Foam forms in cooling system

Radiator hose is kinked or
damaged

Thermostat defective

Blown fan fuse

Defect fan or thermoswitch for fan

Air in the cooling system

Refill cooling liquid (see maintenace work), check cooling sys­tem for leaks

Clean radiator with water jet

Replace cooling liquid, use antifreezer with brand name

Run the radiator hose correctly or replace

Have the thermostat checked (opening temperature 75°C,
167°F) or replaced; contact an authorized KTM workshop

Replace fuse FAN

Contact an authorized KTM workshop.

Bleed the cooling system (see Maintenance work)

ENGLISH

43

TROUBLESHOOTING »

TROUBLE CAUSE REMEDY

FI lamp is blinking / lights up Error in the injection system Visit an authorized KTM workshop

Engine stalls while driving No fuel

Fuse for fuel pump has blown

Refuel

Replace fuse FUEL PUMP

High oil consumption Engine oil level too high

Engine oil too thin (viscosity)

Check engine oil level when the engine is warm; correct if
necessary

Use thicker engine oil; see chapter „Engine oil“

Headlight and position light fail Blown fuse Replace fuse H/L BEAM POSITION.

Flasher lights, brake light, horn
and multi-functional digital
speedometer fail

Blown fuse Replace fuse HORN BRAKELIGHT SPEEDO.

Time is not displayed or not
correctly displayed

Blown fuse, thus no continuous
power supply

Replace fuse CLOCK and set the clock.

The battery is discharged The ignition (power consumer) has-

n’t been switched off

The battery isn’t charged by the
generator

Recharge the battery according to the relevant instructions.

Voltage regulator and generator should be checked by an
authorized KTM workshop.

No values are visible in the
multi-functional digital
speedometer display.

Blown fuse Replace fuse HORN BRAKELIGHT SPEEDO.

The speed indication on the mul­tifunctional digital speedometer
is not working

Pickup cable is damaged or contacts
on the cable connector have oxidized

Check the pickup cable for damage, visit an authorized KTM
workshop

ENGLISH

44

TROUBLESHOOTING »

BLINK CODE SIGNAL / COMPONENT ERROR DESCRIPTION ENGINE

02 Pulse generator Malfunction Stalls
06 Throttle sensor Output signal too low /high Continues to run
07 Sensor for 2nd throttle valve Output signal too low /high Continues to run
09 Intake manifold air pressure for sensor rear cylinder Output signal too low /high Continues to run
11 Intake manifold air pressure sensor for front cylinder Output signal too low /high Continues to run
12 Coolant temperature sensor Output signal too low /high Continues to run
13 Air temperature sensor Output signal too low /high Continues to run
14 Ambient air pressure sensor Output signal too low /high Continues to run
15 Tilt angle sensor Output signal too low /high Continues to run
17 Lambda probe for rear cylinder Malfunction Continues to run
18 Lambda probe for front cylinder Malfunction Continues to run
24 Control unit voltage supply Malfunction Continues to run
25 Side stand switch Short circuit to ground Continues to run
33 Injection nozzle for rear cylinder Malfunction Stalls
34 Injection nozzle for front cylinder Malfunction Stalls
37 Ignition coil for rear cylinder Malfunction Stalls
38 Injection coil for front Malfunction Stalls
41 Fuel pump relay Short circuit to ground / positive Stalls
45 Lambda probe heater for rear cylinder Short circuit to ground / positive Continues to run
46 Lambda probe heater for front cylinder Short circuit to ground / positive Continues to run
49 Idle control motor Malfunction Continues to run
53 Purge valve for carbon canister Short circuit to ground / positive Continues to run
54 Secondary air valve Short circuit to ground / positive or interruption Continues to run
65 EEPROM error Malfunction Continues to run
68 Vacuum hose for front cylinder is defective Malfunction Continues to run
69 Vacuum hose for rear cylinder is defective Malfunction Continues to run
72 Stepper motor for 2nd throttle valve Malfunction Continues to run

The blink code indicates which component is affected by an error. This allows the error to be identified if no diagnosis tool is
available.

ENGLISH

45

CLEANING »

CONSERVATION FOR WINTER OPERATION »

STORAGE »

Regular cleansing and paintwork care are part of the maintenance work and help to maintain the value of your motorcycle.

NEVER CLEAN THE MOTORCYCLE WITH A POWER WASHER OR A STRONG WATER JET, OTHERWISE THE PRESSURE WILL ALLOW WATER TO
ENTER THE ELECTRIC COMPONENTS, PLUGS, CABLES, BEARINGS, ETC. WHICH CAN CAUSE MALFUNCTIONING OR CAN LEAD TO PREMATURE
WEAR OF THESE COMPONENTS.

– Before you wash your motorcycle, close the muffler openings.
– Use warm water with a commercial detergent and sponge. Coarse dirt can be removed with a soft water jet. Areas that are heavily

soiled can be sprayed with a motorcycle cleaner (e.g. Motorex 900) and cleaned with a brush.

– After the motorcycle has been rinsed with a soft water jet, it should be dried by air pressure and a cloth. Then take a short drive

until the engine has reached the working temperature and also use the brakes. Due to the heat, the water also evaporates at the
unapproachable parts of the engine and the brakes.

– After the motorcycle has cooled down, oil or lubricate all of the friction bearings and bearing positions and treat the chain with

chain spray. Treat all bare areas (except brake disks) with a corrosion inhibitor (e.g. Motorex Protect & Shine).

– The exhaust pipes can be polished with a chrome care product. The mufflers are made of stainless steel and should be treated with

a suitable care product.

– To prevent failures in the electric system, you should treat the ignition lock, the emergency OFF switch, light switch and the socket

connectors with contact spray.

– Treat all of the painted parts with a mild paint care product (e.g. Motorex Moto Polish).

In the event that the motorcycle is also used in winter and on roads where one has to expect salt spraying, you will have to take
precautions against the aggressive road salt.

– clean motorcycle thoroughly and let it dry
– treat engine, swing arm, and all other bare parts (except for brake discs) with a wax-based anti-corrosion agent.

KEEP ANTI-CORROSION AGENT FROM GETTING INTO CONTACT WITH THE BRAKE DISCS, FOR OTHERWISE THIS WILL SIGNIFICANTLY REDUCE
THE BRAKING POWER.

AFTER RIDES ON SALTED ROADS, CLEAN MOTORCYCLE THOROUGHLY WITH COLD WATER AND LET IT DRY WELL!

If you plan to immobilize your motorcycle for a longer period of time, proceed as follows:

– Run the tank empty to be able to add fresh fuel when starting up again.
– Clean the motorcycle thoroughly (see CLEANING chapter).
– Change the engine oil and the oil filter (old engine oil contains aggressive impurities).
– Check the quantity of antifreeze and cooling liquid.
– Remove and charge the battery (see Charging the battery chapter).
– If possible, jack up the motorcycle to lift the wheels off the ground.
– The storage site should be dry and not subject to larger temperature fluctuations.
– Cover the motorcycle with a permeable cover or blanket. Do not use impermeable material since it will not allow and moisture to

escape and will cause corrosion.

DO NOT BRIEFLY RUN THE ENGINE OF AN IMMOBILIZED MOTORCYCLE SINCE THE ENGINE WILL NOT BECOME WARM ENOUGH AND ANY VAPOR
PRODUCED DURING THE COMBUSTION PROCESS WILL CONDENSE AND CAUSE THE VALVES AND EXHAUST TO RUST.

STARTING UP AFTER IMMOBILIZATION

– Mount the charged battery (pay attention to the polarity).
– Fill fresh fuel in the tank.
– Inspect the motorcycle as you would before each start-up (see "Driving Instructions").
– Go on a short, cautious test ride

NOTE: before you store your motorcycle at the end of the season, check all parts for proper functioning and wear. If service, repairs or
conversions are necessary, have them carried out while the motorcycle is immobilized (workshops are not fully utilized). This will help
to avoid long waiting periods at the beginning of the season.

ENGLISH

46

TECHNICAL SPECIFICATIONS – CHASSIS »

CHASSIS 990 SUPER DUKE

Frame Tubular chrome-molybdenum-steel space frame
Fork

WP Suspension – Up Side Down 4860 ROMA

Spring travel front 135 mm
Rear suspension WP Suspension 4618 BAVP
Spring travel rear 160 mm
Front brake Disk brake, 2 perforated brake disks Ø 320 mm, fixed brake calipers
Rear brake Disk brake, perforated brake disk Ø 240 mm, floating brake caliper
Tires, front 120/70 ZR17 M/C 58W

Air pressure Road, driver only ....................................2,4 bar

Road, with passenger ..............................2,4 bar

maximum payload ..................................2,4 bar

Tires, rear 180/55 ZR17 M/C 73W

Air pressure Road, driver only ....................................2,4 bar

Road, with passenger ..............................2,6 bar

maximum payload ..................................2,6 bar

Fuel tank capacity 15 liters, 4 liters reserve
Gear ratio – rear wheel 17:38
Chain 5/8 x 5/16” X-ring

Lighting high beam ............................................H3 12V 55W (Sockel PK22s)

low beam ..............................................H7 12V 55W (Sockel PX26d)

position light front ..................................12V 5W (Sockel W2,1x9,5d)

indicator lamps .....................................LED

position light rear ..................................12V 5W (Sockel W2,1x9,5d)

stoplight ...............................................12V 21W (Sockel BA15s)

licens plate illumination .........................12V 5W (Sockel W2,1x9,5d)

Battery maintenance-free battery 12V 11,2 Ah
Steering head angle 66,5°
Wheel base 1438 ± 10 mm
Seat height, unloaded 855 mm
Ground clearance, unloaded 165 mm
Dry weight 184 kg (406 lbs)
Max. axle load, front 200 kg (441.5 lbs)
Max. axle load, rear 220 kg (485.6 lbs)
Max. total weight 380 kg (838.8 lbs)

BASIC SETTING
FORK
990 SUPER DUKE

Driving Comfort

Basic Setting

Driving Sport

Maximum Payload
Compression adjuster (clicks) 201510 15
Rebound adjuster (clicks) 201510 15
Spring preload (turns) 5

5

5 6

BASIC SETTING
SHOCK ABSORBER
990 SUPER DUKE

Driving Comfort

Basic Setting

Driving Sport

Maximum Payload

Compression adjuster Low Speed (clicks)

252010 15

Compression adjuster High Speed (turns)

2,522 1,5
Rebound adjuster (clicks) 221710 5
Spring preload (turns) 6

6

6 6

STANDARD ADJUSTMENT - FORK

990 SUPER DUKE
WP 4860 ROMA

Spring 9 N/mm
Air chamber length 110 mm
Fork oil SAE 5 (WP 4860.0211)

STANADARD ADJUSTMENT-SHOCK ABSORBER

990 SUPER DUKE
WP 4618 BAVP

Spring 160/185

ENGLISH

47

TECHNICAL DATA - CHASSIS »

TIGHTENING TORQUES – CHASSIS

Collar bolt on front wheel spindle M24x1,5 60 Nm
Collar nut wheel spindle rear M25x1,5 90 Nm
AH bolt shock absorber top/bottom M14x1,5 80 Nm
Collar nut for swing arm bolt M19x1,5 130 Nm
AH bolts on subframe M8 Loctite 243 + 25 Nm
AH bolts on back of footrest support M8 Loctite 243 + 25 Nm
Engine carrier bolts M10 45 Nm
HH clamp bolts on top triple clamp M8 20 Nm
HH clamp bolts on bottom triple clamp M8 15 Nm
HH screw for steering head M20x1,5 12 Nm
HH clamp bolts on fork legs M8 15 Nm
Collar bolts for handlebar clamps M8 20 Nm
AH bolt for handlebar mount M10 20 Nm
HH clamp bolts for steering stem M8 20 Nm
Collar bolt front/rear brake disk M8x1,25 Loctite 243 + 30 Nm
HH bolts on front brake caliper M10x1,25 Loctite 243 + 45 Nm
HH bolts on handbrake cylinder M6 10 Nm
HH bolts on footbrake cylinder M6 Loctite 243 + 10 Nm
AH bearing bolt for foot brake pedal, shift lever M8 Loctite 243 + 25 Nm
HH screw on cover plate for foot brake lever/shift mechanism M6 Loctite 243 + 10 Nm
Relay for shift shaft (on connecting support) M8 Loctite 243 + 25 Nm
Relay for shift shaft (on shift shaft) M6 Loctite 243 + 18 Nm
Gearshift rod attachment M6 Loctite 243 + 10 Nm
HH bolts on foot brake pedal surface M5 Loctite 243 + 6 Nm
AH bolts for side stand bracket - engine M10 Loctite 243 + 45 Nm
HH bolts for side stand fixture - side stand bracket M10 Loctite 243 + 25 Nm
HH bolts for side stand mounting M10 Loctite 243 + 35 Nm
HH bolt for spring rest on side stand M8 Loctite 243 + 25 Nm
HH bolt for side stand switch M4 Loctite 243 + 2 Nm
HH nuts on rear sprocket bolts M10x1,25 Loctite 243 + 50 Nm
Drain plug on oil tank M12x1,5 20 Nm
Exhaust nuts on manifold M8 evenly, do not bend sheet metal
Exhaust clamps M8 8 Nm
Exhaust clamps for ball joint M8 35 Nm
AH bolts on tank cover M5 5 Nm
AH/HH bolts on tank mounting M6 6 Nm
Collar screws for in-tank pump M6 6 Nm
AH screw on arm for tank support M10 25 Nm
Collar screw for gas pressure shock absorber M6 6 Nm
Seat fixing plate M5 4 Nm
Jerk damper bolt M10x1,25 Loctite 243 + 50 Nm
HH nut for seat lock M19x1 8 Nm
Chainguard M5 5 Nm
Chain sliding guard M5 5 Nm
Front spoiler M6 Loctite 243 + 10 Nm
Taillight M6 8 Nm

Other bolts on chassis M6

M8
M10

10 Nm
25 Nm
45 Nm

Other collar nuts on chassis M6

M8
M10

15 Nm
30 Nm
50 Nm

ENGLISH

48

TECHNICAL SPECIFICATIONS – ENGINE »

10W/50

5W/40

JASO T903 MA

TEMPERATURE

0°C

32°F

ENGINE 990 LC8

Design

Liquid-cooled, 2-cylinder 4-stroke engine with 75° V arrangement with balancer shaft and electric starter

Displacement 999 cm

3

Bore / Stroke 101/62,4 mm
Compression ratio 11,5:1
Fuel unleaded fuel with at least RON 95 (USA: Premium RON 91) *
Valve timing 4 valves controlled over bucket tappet and 2 camshafts, camshaft drive with gears/chain
Valve diameter Intake: 38 mm Exhaust: 33 mm
Valve clearance, cold Intake: 0,10 - 0,15 mm Exhaust: 0,25 - 0,30 mm
Crankcase bearing Friction bearings (2 main bearings / 1 supporting bearing)
Conrod bearing Friction bearing
Piston pin bearing Dual-fuel bearing
Piston Light alloy – forged
Piston rings 1 compression ring, 1 taper face ring, 1 single-piece oil scraper ring with spiral-type expander
Engine lubrication Dry sump with 2 trochoidal pumps (pressure pump and suction pump)
Engine oil SAE 5W/40, 10W/50 (Motorex Power Synt 4T) #
Quantity of engine oil approx. 3.1 liters during oil/filter change
Primary drive Straight-toothed spur wheels 35 : 67
Clutch Multi-disc clutch in oil bath
Transmission 6-speed claw shifted
Gear ratio 1stgear 14:36

2ndgear 16:30
3rdgear 20:30
4thgear 21:27
5thgear 23:26

6thgear 25:26
Ignition system breakerless transistorized electronic ignition system with digital ignition advance
Ignition timing Map-controlled via TPS
Generator 12V 450W bei 6000 U/min
Spark plug NGK DCPR 8 E
Electrode distance 0,8 mm
Cooling system liquid cooled, permanent circulation of cooling liquid through water pump
Cooling liquid 2.1 liters, 50% antifreeze, 50% water, at least –25° C
Starting aid electric starter

#

PON / CLC RON / ROZ MON

87 91 83

91 Premium 95 87

RON = Pump Octane Number
CLC = Cost of Living Council
RON = Research Octane Number
ROZ = Research Oktan Zahl
MON = Motor Octane Number

*

ENGLISH

49

HEAD WORD INDEX »

Page

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

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

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

Adjusting the basic position of the hand brake lever .27

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

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

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

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

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

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

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

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

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

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

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

Changing the engine oil and the oil filter, cleaning

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

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

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

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

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

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

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

Checking the cooling liquid level in the compensating tank

. .36

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

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

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

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

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

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

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

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

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

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

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

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

Conservation for winter operation . . . . . . . . . . . . . . .45

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

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

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

Damping action during compression of shock absorber

.13

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

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

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

Driving instructions . . . . . . . . . . . . . . . . . . . . . . . . .15

Emergency OFF tip switch, light switch, starter tip switch

. .9

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

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

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

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

Page

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

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

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

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

General tips and warnings for starting the motorcycle .14

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

Head word index . . . . . . . . . . . . . . . . . . . . . . . . . . .49

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

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

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

Important LIMITED warranty and LIMITED guarantee

information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

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

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

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

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

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

Maintenance work on chassis and engine . . . . . . . . . .22

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

Operation instruments . . . . . . . . . . . . . . . . . . . . . . . .5

Periodic maintenance . . . . . . . . . . . . . . . . . . . . . . .20

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

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

Technical Data - Chassis . . . . . . . . . . . . . . . . . . . . .47

Technical specifications – chassis . . . . . . . . . . . . . . .46

Technical specifications – engine . . . . . . . . . . . . . . .48

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

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

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

ENGLISH

50

KTM-Sportmotorcycle AG

A–5230 Mattighofen

www.ktm.at

KTM Group Partner