KTM Motorcycle 990 SUPER DUKE User Manual
OWNER’S MANUAL 2006  
990 SUPER DUKE  
ART. NR. 3.211.83EN  
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INTRODUCTION »  
2
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 spe-  
cific needs and how to protect yourself against injury. Besides, this manual contains important information on motorcycle mainte-  
nance. 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 signifi-  
cantly increase the life of your motorcycle. To ensure that all work to your KTM is performed properly and to avoid warranty con-  
flicts, 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  
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IMPORTANT LIMITED WARRANTY AND LIMITED GUARANTEE INFORMATION »  
3
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 main-  
tenance 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 main-  
tenance 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.  
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INDEX »  
4
IMPORTANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1  
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2  
IMPORTANT LIMITED WARRANTY AND  
Compression damping of fork . . . . . . . . . . . . . . . . . . . . . .19  
Rebound damping of fork . . . . . . . . . . . . . . . . . . . . . . . . .19  
Spring preload of the fork . . . . . . . . . . . . . . . . . . . . . . . . .20  
Damping action during compression of shock absorber . . . . . .20  
Rebound damping of shock absorber . . . . . . . . . . . . . . . . .21  
GENERAL TIPS AND WARNINGS FOR STARTING  
LIMITED GUARANTEE INFORMATION . . . . . . . . . . . . . . . . . .3  
SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . .6  
Chassis number, Type label . . . . . . . . . . . . . . . . . . . . . . . . .6  
Engine number, engine type . . . . . . . . . . . . . . . . . . . . . . . .6  
OPERATION INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . . . .7  
Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7  
Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7  
Multi-functional digital speedometer . . . . . . . . . . . . . . . . .8  
Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8  
Setting options in the display . . . . . . . . . . . . . . . . . . . . . .10  
Cooling liquid temperature display . . . . . . . . . . . . . . . . . .12  
Indicator lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13  
Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13  
Ignition lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14  
Combination switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14  
Emergency OFF tip switch, light switch,  
THE MOTORCYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22  
Instructions for initial operation . . . . . . . . . . . . . . . . . . . .22  
Running in the LC8 engine . . . . . . . . . . . . . . . . . . . . . . . .22  
Accessories and payload . . . . . . . . . . . . . . . . . . . . . . . . . .23  
DRIVING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . .24  
Check the following before each start . . . . . . . . . . . . . . . .24  
Starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26  
Starting off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27  
Shifting/Riding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27  
Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28  
Stopping and parking . . . . . . . . . . . . . . . . . . . . . . . . . . . .29  
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30  
PERIODIC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . .32  
MAINTENANCE WORK ON CHASSIS AND ENGINE . . . . . . . .36  
Adjusting the fork and shock absorber . . . . . . . . . . . . . . .37  
Adjusting compression damping of fork . . . . . . . . . . . . . . .37  
Adjusting rebound damping of fork . . . . . . . . . . . . . . . . . .37  
Adjusting the spring preload on the fork . . . . . . . . . . . . . . .38  
Compression damping of shock absorber . . . . . . . . . . . . . .38  
Rebound damping of shock absorber . . . . . . . . . . . . . . . . .39  
Checking the chain tension . . . . . . . . . . . . . . . . . . . . . . .40  
Correcting the chain tension . . . . . . . . . . . . . . . . . . . . . .40  
Chain maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41  
Checking the chain for wear . . . . . . . . . . . . . . . . . . . . . . .41  
starter tip switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15  
Filler cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15  
Seat lock, removing the seat . . . . . . . . . . . . . . . . . . . . . .16  
Baggage loops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16  
Tool set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17  
Helmet lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17  
Holding strap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17  
Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18  
Side stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18  
Foot brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18  
Footrests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19  
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INDEX »  
5
General information on KTM disk brakes . . . . . . . . . . . . . .42  
Adjusting the basic position of the hand brake lever . . . . . .44  
Checking the front brake fluid level . . . . . . . . . . . . . . . . .44  
Refilling front brake fluid . . . . . . . . . . . . . . . . . . . . . . . .44  
Checking the front brake pads . . . . . . . . . . . . . . . . . . . . .45  
Changing the basic position of the foot brake lever . . . . . . .46  
Checking the rear brake fluid level . . . . . . . . . . . . . . . . . .46  
Refilling rear brake fluid . . . . . . . . . . . . . . . . . . . . . . . . .46  
Checking the rear brake pads . . . . . . . . . . . . . . . . . . . . . .47  
Dismounting and remounting the front wheel . . . . . . . . . .48  
Dismounting and remounting the rear wheel . . . . . . . . . . .50  
Tires, air pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51  
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52  
Removing and remounting the battery . . . . . . . . . . . . . . .53  
Charging the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . .54  
Jump start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54  
Main fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55  
Fuses for individual power consumers . . . . . . . . . . . . . . . .56  
Replacing the headlight lamp . . . . . . . . . . . . . . . . . . . . .57  
Adjusting the headlight range . . . . . . . . . . . . . . . . . . . . . .58  
Replacing the brake light and taillight bulbs . . . . . . . . . . .58  
Replacing the flasher bulbs . . . . . . . . . . . . . . . . . . . . . . .59  
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60  
Checking the cooling liquid level  
Checking and adjusting the throttle cable play . . . . . . . . . .65  
Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66  
Checking the engine oil level . . . . . . . . . . . . . . . . . . . . . .66  
Refilling engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67  
Changing the engine oil and the oil filter, cleaning  
the oil screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68  
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72  
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77  
CONSERVATION FOR WINTER OPERATION . . . . . . . . . . . . . .77  
STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78  
STARTING UP AFTER IMMOBILIZATION . . . . . . . . . . . . . . . .78  
TECHNICAL SPECIFICATIONS – CHASSIS . . . . . . . . . . . . . . .79  
TECHNICAL SPECIFICATIONS – ENGINE . . . . . . . . . . . . . . .83  
Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84  
HEAD WORD INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85  
in the compensating tank . . . . . . . . . . . . . . . . . . . . . . . . .61  
Checking the cooling liquid level in the radiator . . . . . . . . .62  
Bleeding the cooling system . . . . . . . . . . . . . . . . . . . . . .62  
Changing the basic position of the clutch lever . . . . . . . . .64  
Checking the oil level of the hydraulic clutch . . . . . . . . . . .64  
Adjusting the handlebar tilt . . . . . . . . . . . . . . . . . . . . . . .65  
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SERIAL NUMBER LOCATIONS »  
6
Chassis number, Type label  
The chassis number is stamped on the right side of the steering head tube. Enter this num-  
ber 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.  
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OPERATION INSTRUMENTS »  
7
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 chas-  
sis and engine).  
A
The clutch is hydraulically actuated and adjusts itself automatically.  
1
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).  
B
2
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OPERATION INSTRUMENTS »  
8
Multi-functional digital speedometer  
1
2
3
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 dis-  
play.  
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.  
TEST  
WS  
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.  
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OPERATION INSTRUMENTS »  
9
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.  
CLOCK  
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.  
ODO  
TRIP 1  
The TRIP 1 mode shows the speed, the temperature of the cooling liquid and the trip odo-  
meter 1.  
TRIP 1  
TRIP 2  
TRIP F  
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 odo-  
meter 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 dis-  
tance traveled since reaching the low-fuel mark (the low-fuel indicator lamp lights up).  
To return to the UHR mode, press the MODE button.  
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OPERATION INSTRUMENTS »  
10  
Setting options in the display  
1
10 sec  
KILOMETERS OR MILES.  
You can have the speed and distance shown in kilometers or miles in the display. The dis-  
play 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 dis-  
tances will be converted and displayed in miles.  
To return to kilometers, proceed as described above.  
CLOCK  
1
2
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.  
2
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OPERATION INSTRUMENTS »  
11  
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.  
2
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 light up. 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.  
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OPERATION INSTRUMENTS »  
12  
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.  
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
POSSIBLE CAUSES FOR AN INCREASE IN TEMPERATURE, CAUSING THE RED WARNING LIGHT  
FOR THE COOLING LIQUID TEMPERATURE TO LIGHT UP:  
– DRIVING TOO SLOWLY AND DRIVING WITH A HEAVY LOAD AT HIGH AIR TEMPERATURES  
– NOT ENOUGH COOLING LIQUID IN THE SYSTEM  
– THE VENTILATOR ON THE LEFT RADIATOR IS NOT RUNNING  
– IMPROPER USE OF THE CLUTCH WHEN DRIVING SLOWLY  
2
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OPERATION INSTRUMENTS »  
13  
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 tempera-  
ture of approx. 120°C (248°F).  
The orange warning lamp will light up 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.  
3
The speed limiter will set in at 9600 rpm, drastically reducing the engine power above this  
rotational speed.  
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OPERATION INSTRUMENTS »  
14  
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 to the left, then turn the ignition key to the left.  
The ignition key can be withdrawn in position  
and  
.
2
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].  
1
The indicator switch [3] returns to central position after actuation. Press flasher  
switch towards switch housing to switch off the flasher.  
1
The horn is sounded with button [4].  
3
4
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OPERATION INSTRUMENTS »  
15  
Emergency OFF tip switch, light switch, starter tip switch  
The emergency off switch [1] is provided for emergency situations and should not be used  
to switch off the engine.  
1
The engine is ready for operation in position  
(ignition circuit and starter circuit are switched  
(ignition circuit and starter circuit are inter-  
on).  
The engine cannot be started in position  
rupted).  
2
3
The light switch [2] has 3 positions:  
Light off  
Parking light on  
Headlight on  
Use the starter tip switch [3] to operate the electric starter.  
Filler cap  
The filler cap [4] 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.  
4
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OPERATION INSTRUMENTS »  
16  
Seat lock, removing the seat  
1
The seat lock [1] 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 [2] on the bottom of  
the seat behind the dollies [3] on the subframe. Press down on the seat near the holding  
strap while sliding it forwards. The two tabs [4] 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.  
2
4
3
Baggage loops  
5
4 loops [5] 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  
5
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OPERATION INSTRUMENTS »  
17  
Tool set  
The tool set [1] is located in the storage compartment under the seat.  
1
Helmet lock  
The steel rope [2] in the tool bag can be used to secure a helmet.  
3
To secure, remove the seat, run the rope through the helmet, attach both ends to the hook  
[3] 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.  
2
Holding strap  
The passenger should hold on to the holding strap [4] or the driver while riding.  
4
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OPERATION INSTRUMENTS »  
18  
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).  
2,3,4,5,6  
N
1
Side stand  
Fold the side stand [1] forward to the stop with your foot and put the weight of the motor-  
cycle 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.  
1
Foot brake pedal  
The foot brake pedal [2] is located in front of the right footrest. Its basic position can be  
adjusted to your seat position (see maintenance work).  
2
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OPERATION INSTRUMENTS »  
19  
Footrests  
The passenger footrests [1] fold up.  
1
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.  
2
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.  
3
More information is provided in the chapter "Adjusting the fork and shock absorber.“  
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OPERATION INSTRUMENTS »  
20  
Spring preload of the fork  
The fork's preload can be adjusted by means of the adjusting screws [1].  
More information is provided in the chapter „Adjusting the fork and shock absorber“.  
1
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.  
3
2
The adjusting screw [2] for the low-speed range can be adjusted with a screwdriver.  
The adjusting screw [3] 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“.  
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OPERATION INSTRUMENTS »  
21  
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 [1] is located on the bottom of the shock absorber.  
More information is provided in the chapter "Adjusting the fork and shock absorber.“  
1
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GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE »  
km (620 miles). The maximum number of  
22  
Instructions for initial operation  
– 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 motor-  
cycle and always use ORIGINAL KTM  
SPARE PARTS. Spare parts from other  
manufacturers can impair the safety of  
the motorcycle.  
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.  
– Make sure the work for the „pre-delivery  
inspection“ was performed by your author-  
ized KTM workshop. The DELIVERY CER-  
TIFICATE and SERVICE MANUAL will  
be handed over when you pick up your  
vehicle.  
– Read these operating instructions care-  
fully before your first ride.  
– Enter the chassis, engine and key num-  
bers 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 conven-  
ient for you.  
– This motorcycle is equipped with a three-  
way catalytic converter. Leaded fuel will  
destroy the converter. Always use unleaded  
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.  
– You may only be accompanied by a pas-  
senger if your motorcycle is fitted and reg-  
istered for such purposes. The passenger  
must hold on to the supporting strap or  
the driver and keep his feet on the pas-  
senger footrests throughout the ride.  
– New tires 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 with new tires,  
tilting the vehicle at different angles so  
that all sections are properly roughened.  
Tires will not display their full grip char-  
acteristics until they are properly run in.  
– Motorcycles are sensitive to changes in  
the weight distribution. Read the section  
on „Accessories and payload“ when car-  
rying luggage.  
– WEAR SUITABLE CLOTHING WHEN DRIV-  
ING A MOTORCYCLE. CLEVER KTM DRIV-  
ERS 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 DRIVERS 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 NECES-  
SARY OPERATING TEMPERATURE. MAXIMUM  
ROAD GRIP IS ASSURED WHEN THE TIRES  
ARE WARM.  
– 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  
– THE FRONT AND REAR WHEEL ARE  
ALLOWED TO BE FITTED ONLY WITH TIRES  
THAT HAVE THE SAME PROFILE TYPE.  
–
Hold the handlebars with both hands  
and leave your feet on the foot rests while  
driving.  
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GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE »  
23  
– NEVER LEAVE YOUR MOTORCYCLE WITHOUT  
SUPERVISION IF THE ENGINE IS RUNNING.  
– A HIGH PAYLOAD WILL CHANGE THE MOTOR-  
CYCLE'S HANDLING AND CONSIDERABLY  
INCREASE THE BRAKING DISTANCE; ADAPT  
YOUR DRIVING SPEED ACCORDINGLY.  
– NEVER EXCEED THE MAXIMUM PERMISSI-  
BLE LADEN WEIGHT AND THE AXLE  
WEIGHTS. THE MAXIMUM PERMISSIBLE  
LADEN WEIGHT IS MADE UP OF THE FOL-  
LOWING COMPONENTS:  
– THE TIRES MUST BE DESIGNED FOR A  
SPEED OF OVER 240 KPH (SPEED SYMBOL  
ZR) AND MUST BE RELEASED BY KTM.  
– NEW TIRES HAVE A SMOOTH SURFACE,  
WHICH MEANS THAT THEY MUST BE RUN  
IN TO ACHIEVE FULL GRIP. FOR THIS PUR-  
POSE, RIDE THE MOTORCYCLE CAREFULLY  
AT MODERATE SPEED DURING THE FIRST  
200 KILOMETERS WITH NEW TIRES, TILT-  
ING 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.  
Accessories and payload  
Accessory parts and baggage can signifi-  
cantly decrease a motorcycle's driving stabil-  
ity. Please observe the following warnings.  
– MOTORCYCLE READY FOR OPERATION  
AND TANK FULL  
– LUGGAGE  
– DRIVER AND PASSENGER WITH PROTEC-  
TIVE CLOTHING AND HELMET  
– 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 MOTORCYCLE IS LOADED  
WITH CASES OR OTHER BAGGAGE. THEY  
WILL IMPAIR THE MOTORCYCLE'S HAN-  
DLING AT HIGHER SPEEDS AND CAN EAS-  
ILY CAUSE IT TO GO OUT OF CONTROL  
– IF YOU HAVE CASES MOUNTED, DO NOT  
EXCEED THE MANUFACTURER'S RECOM-  
MENDED MAXIMUM PAYLOAD.  
– FOUR LOOPS ARE PROVIDED ON THE BOT-  
TOM OF THE SEAT TO ATTACH YOUR LUG-  
GAGE. MAKE SURE YOUR LUGGAGE DOES  
NOT EXTEND BEYOND THE SILENCER, OTH-  
ERWISE IT MAY BECOME SINGED FROM  
THE HEAT.  
– MAKE SURE YOUR LUGGAGE DOES NOT  
COVER THE TAIL LIGHT.  
– BAGGAGE MUST BE SECURELY AND ADE-  
QUATELY FASTENEND; LOOSE BAGGAGE  
WILL SIGNIFICANTLY IMPAIR DRIVING  
SAFETY.  
– WHEELS WITH A DIFFERENT RIM DIAMETER  
OR OTHER RIM WIDTH MAY NOT BE  
MOUNTED OTHERWISE THE VEHICLE HAN-  
DLING 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 SEN-  
SITIVE YOUR MOTORCYCLE WILL BE TO  
CROSSWIND AND CHANGING ROAD CONDI-  
TIONS. 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 ON  
TIME SO AS TO ENSURE OPTIMUM VISION  
IN ANY SITUATION. WHEN LIGHT SHINES  
DIRECTLY ON SCRATCHED VISOR, THE OPER-  
ATOR WILL BE BLINDED.  
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DRIVING INSTRUCTIONS »  
24  
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 con-  
trol. A chain that is too tight or not greased will cause unnecessary wear to the chain  
and sprockets.  
3
4
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.  
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 com-  
plete 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.  
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DRIVING INSTRUCTIONS »  
25  
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
9
CHECK OIL LEVEL  
Insufficient oil results in premature wear and consequently to engine damage.  
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.  
Make sure your luggage is correctly fastened before you drive off.  
10 REAR MIRROR  
Sit on the motorcycle and check the adjustment of the rear mirror.  
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DRIVING INSTRUCTIONS »  
26  
Starting the engine  
1
2
Switch on emergency OFF switch [1].  
Switch on ignition (turn ignition key [2] into position ).  
NOTE:  
1
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
4
Switch transmission to idle (green indicator lamp N [3] lights up).  
Do not accelerate; operate starter button [5].  
NOTE:  
If you accelerate during the starting process you will hear a loud, metallic  
sound caused by the torque limiter. The torque limiter protects the  
components in the starter drive from being damaged.  
The oil pressure warning lamp [4] should go out as soon as the engine is running.  
Take the load off the side stand and fold the side stand all the way up.  
5
6
3
4
– 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.  
– NEVER OPERATE THE MOTORCYCLE WITH A RUN-DOWN BATTERY OR WITHOUT THE BATTERY.  
THIS CAN DAMAGE THE ELECTRONIC COMPONENTS OR SAFETY EQUIPMENT IN EITHER CASE-  
AND THE MOTORCYCLE WILL NO LONGER BE ROADWORTHY.  
2
– 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 RUN-  
NING, 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.  
5
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DRIVING INSTRUCTIONS »  
27  
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  
pulled. The engine will stall if a gear is  
ful when you accelerate in curves. Abrupt  
opening of the throttle can cause the motor-  
cycle to go out of control and also increases  
fuel consumption.  
By shifting down, use the brakes if neces-  
sary and close throttle at the same time. Pull  
clutch lever and shift down to the next gear.  
Let clutch lever go slowely and open throt-  
tle or shift down again.  
If the engine is killed f.ex. at a crossing, sim-  
ply 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.:  
engaged and the clutch lever is released with  
the side stand folded down.  
– the headlight is on (Light switch in  
position).  
– If this is not the case, the battery is dis-  
charged  
– If the lights are on, proceed as described  
in the „Trouble-shooting“ section or  
contact a KTM dealer.  
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.  
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  
Blink code 34: FI blinks 3x long, 4x short,  
pause,  
Blink code 06: FI blinks 6x short, pause  
The blink code will indicate which compo-  
nent is defective (see Troubleshooting). This  
makes it possible to pinpoint the defect if a  
diagnostic tool is unavailable.  
– Check if sufficient fuel is in the tank  
– If this is not the case, refill the tank  
– if sufficient fuel is in the tank, pro-  
ceed as described in the „Trouble-  
shooting“ section or contact a KTM  
dealer.  
Shifting/Riding  
You are now in first gear, refered to as the  
drive or uphill gear. Depending on the con-  
ditions (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 carefully open throttle. Do not shift gears  
and accelerate carefully in curves.  
– AVOID ABRUPT LOAD CHANGES WHILE RID-  
ING AROUND BENDS AND ON WET OR SLIP-  
PERY GROUND. OTHERWISE YOU MIGHT  
EASILY LOSE CONTROL OVER YOUR MOTOR-  
CYCLE.  
NOTE:  
This motorcycle is equipped with a safety start-  
ing 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 trans-  
mission is in neutral or the clutch lever is  
Only accelerate to the extent that road and  
weather conditions allow. Be especially care-  
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DRIVING INSTRUCTIONS »  
28  
SURE IS TOO LOW TO ADEQUATELY LUBRI-  
CATE THE ENGINE. STOP IMMEDIATELY AND  
SWITCH OFF THE ENGINE. IF YOU CON-  
TINUE TO DRIVE, ENGINE DAMAGE WILL  
OCCUR WITHIN A SHORT PERIOD OF TIME.  
CHECK THE ENGINE OIL LEVEL OR CONTACT  
AN AUTHORIZED KTM WORKSHOP.  
LET THE ENGINE COOL DOWN. MEANWHILE,  
CHECK WHETHER ANY COOLING LIQUID IS  
LEAKING OUT OF THE MOTORCYCLE. CHECK  
THE COOLING LIQUID LEVEL IN THE RADI-  
ATOR (NOT ONLY IN THE COMPENSATING  
TANK). - CAUTION SCALDING HAZARD! DO  
NOT DRIVE ON, UNTIL THERE IS SUFFI-  
CIENT 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.  
– WHILE RIDING YOUR MOTORCYCLE, NEVER  
SWITCH THE IGNITION LOCK TO POSITIONS  
AND  
.
– DO NOT TRY TO CHANGE THE SETTINGS OF  
THE MULTI-FUNCTIONAL SPEEDOMETER  
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 HOLDING STRAP ON THE  
SEAT WHILE RIDING AND KEEP HIS/HER  
FEET ON THE PASSENGER FOOTRESTS.  
– REGULARLY MAKE SURE THAT THE BAG-  
GAGE 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.  
– NEVER HAVE THE THROTTLE WIDE OPEN  
WHEN CHANGING DOWN TO A LOWER GEAR.  
THE ENGINE WILL OVERSPEED, DAMAG-  
ING THE VALVES. IN ADDITION, THE REAR  
WHEEL BLOCKS SO THAT THE MOTORCY-  
CLE 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).  
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.  
– 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 4TH BAR ON THE TEMPER-  
ATURE INDICATOR LIGHTS UP.  
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  
– 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.  
– FAN AT RADIATOR IS NOT RUNNING  
–
IMPROPER USE OF THE CLUTCH WHILE  
DRIVING AT LOW VELOCITIES  
– IF THE RED OIL PRESSURE WARNING LAMP  
LIGHTS UP WHILE DRIVING, THE OIL PRES-  
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DRIVING INSTRUCTIONS »  
29  
– 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 BRAK-  
ING SYSTEM CAN FAIL.  
„SPONGY“ (TOO MUCH PLAY), THIS IS AN  
INDICATION THAT SOMETHING IS WRONG  
WITH THE BRAKE SYSTEM. DON’T RIDE  
YOUR MOTORCYCLE ANYMORE WITHOUT  
FIRST HAVING THE BRAKE SYSTEM LOOKED  
OVER BY A KTM DEALER.  
– 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.  
– IF THE RESISTANCE IN THE HAND BRAKE  
LEVER OR FOOT BRAKE PEDAL FEELS  
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 motor-  
cycle 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 RUNNING. 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 MOTOR-  
CYCLE, 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 HAZARDS DUE TO  
DRY GRASS OR OTHER EASILY FLAMMABLE MATERIALS.  
– ALWAYS TAKE OUT THE IGNITION KEY WHEN PARKING YOUR MOTORCYCLE SO THAT IT CAN-  
NOT 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.  
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DRIVING INSTRUCTIONS »  
30  
Fuel  
In the condition at delivery, the LC8 engine requires unleaded fuel with at least RON 95  
(USA = Premium RON 91, see technical specifications – engine).  
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:  
MAX  
Press the SET key for 2 seconds to immediately turn off the fuel warning lamp.  
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 BURN-  
ING 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.  
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31  
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PERIODIC MAINTENANCE »  
32  
1st Service  
after  
1000 km  
every  
every  
990 SUPER DUKE 2006  
A clean motorcycle can be checked more quickly which saves money!  
7500 km  
or  
15000 km  
or  
once a year  
every 2 years  
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
Change engine oil and oil filter  
Clean oil screens of engine and oil tank  
Clean magnetic drain plugs of engine and oil tank  
Check oil lines for damage and kink-less arrangement  
Renew spark plugs  
z
z
z
Check and adjust valve clearance  
z
z
Check engine fastening bolts for tight fit  
Check all engine bolts accessible from the outside for tight fit  
Check clutch linings  
Check clutch pressure booster system  
Check rubber boots for cracks or leaks  
Check fault memory with the KTM diagnosis tool  
z
z
z
z
Perform a status check of neutral, clutch, 2nd/3rd gear and side stand switch  
using the KTM diagnosis tool  
z
z
Make sure the fuel hose, hoses on the vacuum sensors, SAS hoses and vent  
hoses are run correctly and check for damage  
z
z
z
z
z
z
z
z
Replace the O-ring on the fuel hose connection and check for leaks  
Check the wiring harness on the throttle body for proper installation  
and damage  
z
z
z
z
z
z
Check cooling system for leaks and antifreeze protection  
Check radiator fan for proper operation  
Check the exhaust system for leaks and correct suspension and the clamps  
for a tight fit  
z
z
z
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PERIODIC MAINTENANCE »  
33  
1st Service  
after  
1000 km  
every  
every  
990 SUPER DUKE 2006  
A clean motorcycle can be checked more quickly which saves money!  
7500 km  
or  
15000 km  
or  
once a year  
every 2 years  
z
Replace the graphite gasket in the rear exhaust manifold slide  
Check actuating cables for damage, smooth operation, and kink-less arrange-  
ment,adjust and lubricate  
z
z
z
z
z
z
z
z
Check the oil level in the hydraulic clutch reservoir  
Check air filter, renew if necessary, clean air filter box  
Check cables for damage and kink-less arrangement  
Check headlamp adjustment  
z
z
z
z
Check electrical system for function (low/high beams, stop light, turn indica-  
tors,headlamp, flasher, tell-tale lamps, speedometer illumination, horn, side-  
stand switch, clutch switch, emergency-off switch)  
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
Make sure all bolts and nuts are tight  
Check brake fluid level, lining thickness, and brake discs  
Change brake fluid  
z
z
z
z
z
z
z
z
z
z
z
z
Check brake lines for damage and leaks  
Check/adjust smooth operation, free travel of handbrake/footbrake levers  
Check bolts of brake system for tight fit  
Check shock absorber and fork for leaks and proper operation  
Clean fork dust sleeves  
z
z
z
Bleed fork legs  
Check swinging-fork pivot  
Check/adjust steering-head bearing  
Check all chassis bolts for tight fit (fork plates, fork leg, axle nuts/bolts,  
swinging-fork pivot, reversing lever, shock absorber)  
z
z
z
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34  
PERIODIC MAINTENANCE »  
1st Service  
after  
1000 km  
every  
every  
990 SUPER DUKE 2006  
A clean motorcycle can be checked more quickly which saves money!  
7500 km  
or  
15000 km  
or  
once a year  
every 2 years  
z
z
z
z
z
z
z
z
z
Check rim joint  
Check tire condition and inflation pressure  
Check chain, sprockets and chain guides for wear, force fit and tension  
Check bolts on pinion and chain sprocket for locking devices  
and a tight fit  
z
z
z
z
z
z
z
z
Lubricate chain  
Check wheel bearings and jerk damper for play  
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!  
990 SUPER DUKE 2006  
IMPORTANT RECOMENDED MAINTENANCE PROCEDURES TO BE PERFORMED BASED ON A SEPARATE SUPPLEMENT ORDER  
at least  
once a year  
every 15000 km  
or every 2 years  
z
Perform complete fork maintenance  
z
Perform complete shock absorber maintenance  
Clean and lubricate steering-head bearing and sealing elements  
Treat the electrical contacts and switches with contact spray  
Treat battery connections with contact grease  
Change coolant fluid  
z
z
z
z
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PERIODIC MAINTENANCE »  
35  
990 SUPER DUKE 2006  
VITAL CHECKS AND CARE PROCEDURES TO CONDUCTED BY THE OWNER OR THE MECHANIC  
before  
each start  
after  
every cleaning  
every  
1000 km  
z
Check oil level  
z
z
z
z
Check brake fluid level  
Check brake pads for wear  
Check lighting system for proper operation  
Check horn for proper operation  
Lubricate actuating cables and nipples  
Bleed fork legs  
z
z
z
z
z
Clean chain  
Lubricate chain  
z
z
z
z
z
Check chain tension  
Check tire pressure and wear  
Check coolant level  
Check fuel lines for leaks  
Check all control elements for smooth running  
Grease the hand brake lever and clutch lever  
Check brake performance  
z
z
z
Treat exposed metal components (except for the braking and exhaust  
system) with wax-based anti-corrosion agents  
z
z
Treat ignition/steering lock and light switch with contact spray  
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MAINTENANCE WORK ON CHASSIS AND ENGINE »  
36  
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 SERV-  
ICED BY SPECIALLY TRAINED TECHNICIANS.  
– DO NOT CLEAN THE MOTORCYCLE WITH A POWER WASHER OTHERWISE WATER WILL GET INTO THE BEARINGS, ELECTRIC SOCKET  
CONNECTORS, 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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MAINTENANCE WORK ON CHASSIS AND ENGINE »  
37  
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.  
BASIC SETTING  
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 per-  
sonal chassis and suspension tuning. Do not make arbitrary changes to the settings (maxi-  
mum ±40%) since this may impair the handling characteristics (particularly in the high-  
speed range).  
FORK WP 4860 ROMA  
990 SUPER DUKE  
Compression adjuster (clicks)  
Rebound adjuster (clicks)  
Spring preload (turns)  
20 15 10 15  
Make sure both fork legs are equally adjusted.  
20 15 10 15  
5
5
5
6
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. 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.  
1
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.  
2
STANDARD ADJUSTMENT  
2
– Turn adjusting screw clockwise as far as it will go.  
– Turn 15 clicks in a counterclockwise direction.  
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MAINTENANCE WORK ON CHASSIS AND ENGINE »  
38  
Adjusting the spring preload on the fork  
The fork spring preload can be adjusted by turning the adjusting screws [2] (wrench size 24  
mm) ± 5 mm (0,2 in).  
1
Turning in a clockwise direction will increase the preload, turning in a counterclockwise direc-  
tion 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 [1 will turn at the same time. Make the same spring preload adjustments to both fork  
legs.  
2
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.  
BASIC SETTING  
SHOCK ABSORBER WP 4618 BAVP  
990 SUPER DUKE  
Compression adjuster Low Speed (clicks) 25 20 10 10  
Compression adjuster High Speed (turns) 2,5 2 1,5  
2
Rebound adjuster (clicks)  
Spring preload (mm)  
22 17 10  
5
6
6
6
6
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.  
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MAINTENANCE WORK ON CHASSIS AND ENGINE »  
39  
STANDARD ADJUSTMENT LOW-SPEED:  
– Turn adjusting screw [1] clockwise as far as it will go.  
– Turn 20 clicks in a counterclockwise direction.  
1
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 YOUR-  
SELF. SEVERE INJURIES COULD BE THE RESULT.  
NEVER UNSCREW THE BLACK SCREW CONNECTION (24MM).  
Rebound damping of shock absorber  
By using the adjusting screw [2], 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 [2] clockwise as far as it will go.  
– Turn 17 clicks in a counterclockwise direction.  
2
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 YOUR-  
SELF. SEVERE INJURIES COULD BE THE RESULT.  
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MAINTENANCE WORK ON CHASSIS AND ENGINE »  
40  
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 [1] is tensioned (see drawing). Correct the chain tension if  
necessary.  
1
7 mm  
–
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 JUMP-  
ING 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 MOTORCYCLE.  
4
2
3
5
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].  
5
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 TIGHT-  
ENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POSSIBLE. A LOOSE AXLE MAY LEAD  
A
TO AN UNSTABLE DRIVING BEHAVIOR OF YOUR MOTORCYCLE.  
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MAINTENANCE WORK ON CHASSIS AND ENGINE »  
41  
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.  
15 KG  
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 meas-  
urement at different parts of the chain.  
max. 272 mm  
Replace the chain if any X-rings are missing.  
1
2
3
16 17 18  
NOTE:  
If you mount a new chain, the sprockets should also be replaced. New chains wear faster if  
used on old used sprockets.  
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MAINTENANCE WORK ON CHASSIS AND ENGINE »  
42  
General information on KTM disk brakes  
2
BRAKE CALIPERS:  
1
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 SYS-  
TEM PERFORMED BY AN AUTHORIZED KTM WORKSHOP.  
3
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:  
Rear brake pads:  
HAWK 7342-49  
TOSHIBA TTH 38 GF  
BRAKE PADS AVAILABLE IN THE ACCESSORY TRADE ARE OFTEN NOT AUTHORIZED FOR OPERA-  
TION 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 ORIG-  
INAL EQUIPMENT, IT CANNOT BE WARRANTED THAT THEY ARE AUTHORIZED FOR USE IN ROAD  
TRAFFIC. YOUR MOTORCYCLE WILL NOT LONGER COMPLY WITH THE REGULATIONS AUTHORIZ-  
ING 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 com-  
pletely worn down. In this case, consult an authorized KTM dealer immediately.  
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MAINTENANCE WORK ON CHASSIS AND ENGINE »  
43  
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 pos-  
sible 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.  
A
BRAKE DISKS THAT ARE LESS THAN 4 MM (0.16 IN) THICK ARE A SAFETY HAZARD. HAVE WORN  
BRAKE DISKS REPLACED IMMEDIATELY.  
4
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MAINTENANCE WORK ON CHASSIS AND ENGINE »  
44  
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.  
1
min. 3 mm  
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).  
3
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 cylin-  
der in a horizontal position and add DOT 5.1 (Motorex Brake Fluid DOT 5.1). Press the rub-  
ber 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.  
4
2
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MAINTENANCE WORK ON CHASSIS AND ENGINE »  
45  
– 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 PURPLE 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 the rear. The linings must be at least 1 mm (0.04  
in) thick.  
min.  
1 mm  
AT THEIR MOST WORN POINT BRAKE PAD LININGS SHOULD NOT BE THINNER THAN 1 MM, OTH-  
ERWISE THEY COULD LEAD TO BRAKE FAILURE. FOR YOUR OWN SAFETY DON’T PUT OFF HAV-  
ING 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.  
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MAINTENANCE WORK ON CHASSIS AND ENGINE »  
46  
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.  
6 mm  
2
1
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).  
3
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.  
4
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47  
– 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 PURPLE 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).  
min.  
1 mm  
AT THEIR MOST WORN POINT BRAKE PAD LININGS SHOULD NOT BE THINNER THAN 1 MM, OTH-  
ERWISE THEY COULD LEAD TO BRAKE FAILURE. FOR YOUR OWN SAFETY DON’T PUT OFF HAV-  
ING 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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48  
Dismounting and remounting the front wheel *  
Special stands are required to dismount the wheels to make sure the motorcycle is securely  
fixed. The front stand only adequately fixes the motorcycle together with the rear stand. The  
stands shown in the illustration can be found in the KTM Power Parts catalog.  
First mount the rear stand (see Dismounting and remounting the rear wheel), then the front  
stand. Make sure the stands rest on solid ground and are correctly mounted. The front wheel  
should not touch 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.  
1
Lift the front wheel off the fork.  
1
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.  
2
3
3
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49  
Before you remount the front wheel, clean and grease the shaft seal rings [5] and the bear-  
ing 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.  
4
A
5
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 screw  
to 60 Nm.  
Remount the brake calipers. Apply Loctite 243 to the screws [1] on the brake caliper sup-  
port and tighten to 45 Nm.  
B
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 COR-  
RECTED BY AN AUTHORIZED KTM WORKSHOP AS SOON AS POSSIBLE. A LOOSE AXLE PAS-  
SAGE 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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50  
Dismounting and mounting the rear wheel *  
Special stands are required to dismount the wheels to make sure the motorcycle is securely  
fixed. The stands shown in the illustration can be found in the KTM Power Parts catalog.  
Mount the rear stand. Make sure the stand rests on solid ground and is correctly mounted.  
The rear wheel should not touch 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.  
1
– DO NOT OPERATE THE REAR BRAKE WHEN THE REAR WHEEL HAS BEEN DISMOUNTED.  
– ALWAYS PLACE THE WHEEL ON THE GROUND WITH THE BRAKE DISC POINTING 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 TERM 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].  
2
4
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.  
3
A
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51  
– 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 DRIVING BEHAVIOR OF YOUR MOTORCYCLE.  
– AFTER MOUNTING THE REAR WHEEL, KEEP OPERATING THE FOOTBRAKE UNTIL THE PRES-  
SURE POINT RETURNS.  
– IT IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND GREASE, OTHERWISE  
THE BRAKING EFFECT WOULD BE STRONGLY REDUCED.  
6
5
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 COR-  
RESPONDING 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).  
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52  
– Tire type and size can be found in the technical specifications and in the homologation  
certificate.  
TIRES – AIR PRESSURE  
990 Super Duke  
front  
2.4 bar 2.4 bar  
34 psi 34 psi  
Road, with passenger 2.4 bar 2.6 bar  
34 psi 37 psi  
2.4 bar 2.6 bar  
34 psi 37 psi  
rear  
– For the type of tires authorized by KTM, contact your authorized KTM dealer or special-  
ized tire dealer.  
– Tire condition has to be checked every time you want to ride your motorcycle. 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 optimum driving comfort and extends  
the life of your tires.  
Road, driver only  
maximum payload  
– 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.  
AT MODERATE SPEED DURING THE FIRST  
200 KILOMETERS (125 MILES) WITH NEW  
TIRES, TILTING THE VEHICLE AT DIFFERENT  
ANGLES SO THAT ALL SECTIONS ARE PROP-  
ERLY ROUGHENED. TIRES WILL NOT DISPLAY  
THEIR FULL GRIP CHARACTERISTICS UNTIL  
THEY ARE PROPERLY RUN IN.  
– FOR REASONS OF SAFETY, IT IS RECOM-  
MENDED TO EXCHANGE THE VALVE INSERT  
WHENEVER A NEW TIRE IS MOUNTED.  
– 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 DAM-  
AGED TIRES IMMEDIATELY.  
–
NEW TIRES HAVE A SMOOTH SURFACE,  
WHICH MEANS THAT THEY MUST BE RUN  
IN TO ACHIEVE FULL GRIP. FOR THIS PUR-  
POSE, RIDE THE MOTORCYCLE CAREFULLY  
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 acid-free grease if necessary. The charge condition  
and type of charge are very important for the battery's service life.  
1
NEVER OPERATE THE MOTORCYCLE WITH A RUN-DOWN BATTERY OR WITHOUT THE BATTERY.  
THIS CAN DAMAGE THE ELECTRONIC COMPONENTS OR SAFETY EQUIPMENT IN EITHER CASE-  
AND THE MOTORCYCLE WILL NO LONGER BE ROADWORTHY.  
NEVER REMOVE THE CLOSING COVER [1] OTHERWISE THE BATTERY WILL BE DAMAGED.  
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53  
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 (32 - 95°F).  
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.  
1
2
2
– IF ELECTROLYTE (SULPHURIC ACID) LEAKS FROM THE BATTERY, PROCEED WITH GREAT  
CARE. THE ELECTROLYTE CAN CAUSE SEVERE BURNS.  
3
– 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 EXPLOSIVE GASES. AVOID  
SPARKS AND OPEN FIRE NEAR THE BATTERY.  
3
– 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 LOCTITE 243 TO  
PREVENT THEM FROM BECOMING LOOSE.  
NEVER DISCONNECT THE BATTERY WHILE THE ENGINE IS RUNNING. THIS WILL DESTROY THE  
RECTIFIER-REGULATOR.  
STORAGE:  
4
If the motorcycle is being immobilized for longer periods of time, remove and charge the  
battery. Storage temperature 0 - 35°C (32 - 95°F), avoid direct sunlight.  
Charge the battery every 3 months.  
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54  
Charging the battery  
The battery discharges every day, even if it is not used.  
Always disconnect the battery when charging. Charge the battery as described in the instruc-  
tions [1] on the battery housing. Do not exceed the amperage and charging time. Quick charg-  
ing at a high amperage has an adverse effect on the service life.  
Always use special charging devices to charge maintenance-free batteries, e.g. the KTM charg-  
ing device (item no. 58429074000). You can also use this charging device to test the off-  
load voltage and startability of the battery and generator. It is impossible to overcharge the  
battery with this device.  
1
Charge the battery immediately if it is empty when you start the motorcycle. If left to stand  
in an uncharged condition for a longer period of time, the battery will run down and sulfa-  
tize, destroying the battery.  
Recharge the battery every 3 months if it is being stored for a longer period of time.  
– NEVER REMOVE THE CLOSURE SINCE IT WILL BE DAMAGED.  
– TO AVOID DAMAGE TO THE ON-BOARD ELECTRONIC SYSTEM, ALWAYS DISCONNECT THE  
MINUS POLE BEFORE YOU CHARGE THE BATTERY.  
– TO CHARGE, CONNECT THE BATTERY TO THE BATTERY CHARGER BEFORE YOU SWITCH ON  
THE BATTERY CHARGER. WHEN THE BATTERY IS CHARGED, SWITCH OFF THE BATTERY  
CHARGER BEFORE YOU DISCONNECT THE BATTERY.  
– PROVIDE ADEQUATE VENTILATION WHEN CHARGING THE BATTERY IN A CLOSED ROOM; THE  
BATTERY EMITS EXPLOSIVE GASES WHEN CHARGING.  
– ELECTROLYTES WILL ESCAPE THROUGH THE SAFETY VALVES IF THE BATTERY IS CHARGED  
TOO LONG OR AT AN EXCESSIVE VOLTAGE OR AMPERAGE. THIS WILL REDUCE BATTERY  
CAPACITY.  
– TRY TO AVOID QUICK CHARGES.  
Jump start  
VOLT  
Jump starts are not recommended since they can damage the motorcycle's electronic  
system.  
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55  
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.  
1
2
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.  
4
NEVER USE A STRONGER FUSE OR A REPAIRED FUSE. IMPROPER USE CAN DESTROY THE ENTIRE  
ELECTRIC SYSTEM.  
3
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56  
Fuses for individual power consumers  
A fuse box is mounted under the seat containing additional fuses that protect the individ-  
ual electric power consumers.  
The power consumers and the corresponding capacities are listed on the cover of the fuse  
box [1]. Spare fuses [2] of 10 and 15 amperes are located next to the fuse box.  
1
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.  
2
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 INSTAL-  
LATION!  
The ACC fuse [3] is designed for accessories with a maximum power consumption of 10  
amperes. A connector [4] to connect the equipment is provided under the seat. Ask your  
authorized KTM workshop for details.  
4
3
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57  
Replacing the headlight lamp *  
Remove the screws [1] on the left and right and tilt the headlight mask down towards the  
front.  
1
1
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 EVAP-  
ORATE AND SETTLE DOWN ON THE REFLECTOR.  
BULB FOR HIGH BEAM [A]:  
2
4
Remove the rubber cap [2] and pull off the connector [3]. Detach the retaining clip and  
3
remove the bulb.  
Insert a new bulb, attach the retaining clip, connect the connector and mount the rubber  
cap.  
B
A
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.  
5
BULB FOR THE PARKING LIGHT:  
Since a number of parts need to be removed to replace the parking light bulb, we recom-  
mend that you have the lamp replaced at an authorized KTM workshop.  
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58  
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 [1]. Turning in a clockwise  
direction will increase the headlight range, turning in a counterclockwise direction will  
reduce the headlight range.  
1
CONTROL:  
Make a mark on a light colored wall behind a horizontal surface, at the height correspon-  
ding to the center of the headlight. Position your motorcycle 5 meters (16.4 ft) from the  
wall in a fully loaded condition (baggage, driver, passenger) and switch on the low beam.  
The light/dark cut-off should be 5 cm (2 in) under the mark (see drawing).  
5 m  
5 cm  
x
Replacing the brake light and taillight bulbs  
Remove the seat.  
2
BULB FOR BRAKE LIGHT:  
Turn the bulb socket [2] 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 direc-  
tion and remove it from the socket.  
Proceed in the reverse order to mount a new bulb.  
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59  
BULB FOR THE TAILLIGHT:  
Remove the bulb socket [1] 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.  
1
Mount the seat.  
Replacing the flasher bulbs  
Remove the screw on the back of the turn signal, carefully fold the lens [2] towards the  
motorcycle and remove. Turn the cap [3 approx. 15° in a counterclockwise direction and  
remove.  
3
2
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.  
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60  
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. The  
thermostat will open when the engine reaches approx. 75°C (167°F) and the cooling liquid  
will also be 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.  
1
THE TEMPERATURE INDICATOR [2] WILL BEGIN TO BLINK AND THE RED COOLING LIQUID TEM-  
PERATURE 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:  
2
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.  
3
– THE COOLING FAN ON THE RADIATOR IS NOT WORKING:  
THE COOLING FAN MUST BE RUNNING, WHEN THE COOLING LIQUID TEMPERATURE IS 120°C  
(248°F) AND THE IGNITION IS ON. IF THE FAN IS NOT WORKING, 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 BOTTOM 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 LIQUID 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  
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61  
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 pro-  
tection, this mixture also provides great corrosion protection which is why it must not be  
replaced by pure water.  
4
–
FOR THE COOLING SYSTEM, USE ONLY HIGH-GRADE ANTIFREEZER (MOTOREX ANTI-  
FREEZE). USING LOWERGRADE ANTIFREEZE AGENTS, CAN CAUSE CORROSION AND  
COOLANT FOAMING.  
– MORE ANTIFREEZE MUST BE ADDED IF YOU PLAN TO TRAVEL TO A REGION WHERE TEMPER-  
ATURES 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 admissi-  
ble, 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.  
5
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 compen-  
sating tank is empty, also check the cooling liquid level in the radiator. Have the cooling  
system checked by an authorized KTM workshop.  
6
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62  
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.  
2
1
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).  
– ACCUMULATED SOIL AND LIME ON THE RADIATOR CAP WILL CAUSE YOU TO LOSE COOLING  
LIQUID. CAREFULLY CLEAN THE RADIATOR CAP, GASKET [2] AND SEALING AREA EACH TIME.  
– 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 [3] and [4]  
on each side.  
3
3
4
4
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MAINTENANCE WORK ON CHASSIS AND ENGINE »  
63  
Remove the bleeder screw [5] on the left side of the radiator.  
5
To completely bleed the cooling system, the motorcycle must be raised approx. 50 cm (20  
in) 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 motor-  
cycle into a horizontal position again. Now fill the compensating tank [6] with cooling liq-  
uid until it reaches a level between the MIN and MAX marks. Close the compensating tank  
and mount both spoilers.  
6
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MAINTENANCE WORK ON CHASSIS AND ENGINE »  
64  
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.  
1
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 USEORIGINAL KTM HYDRAULIC  
OIL (AVAILABLE FROM YOUR AUTHORIZED KTM WORKSHOP) TO MAKE SURE YOUR CLUTCH  
OPERATES SMOOTHLY.  
NEVER REFILL WITH BRAKE FLUID.  
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MAINTENANCE WORK ON CHASSIS AND ENGINE »  
65  
Adjusting the handlebar tilt  
1
Loosen the screws [1]. 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 com-  
pletely turned.  
TILTING THE HANDLEBAR TOO FAR BACK WILL REDUCE THE STEERING ANGLE SINCE THE HAN-  
DLEBAR INSTRUMENTS WILL TOUCH THE FUEL TANK  
1
IF THE HANDLEBAR IS TILTED TOO FAR BACK, THE HANDLEBAR INSTRUMENTS MAY DAMAGE  
THE FUEL TANK  
Checking and adjusting the throttle cable play *  
This work will require a diagnostics tool. Visit your authorized KTM dealer.  
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MAINTENANCE WORK ON CHASSIS AND ENGINE »  
66  
Engine oil  
Automobile engine oil used to be used for four-stroke motorcycles before there were sepa-  
rate 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 out-  
put at higher speeds. Most motorcycle engines also use the same oil to lubricate the trans-  
mission 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 infor-  
mation on the can).  
JASO T903 MA  
TEMPERATUR  
0°C  
32°F  
5W/40  
10W/50  
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 indi-  
cator light up). Allow the warm engine to run idle for approx. 1 minute and place the motor-  
cycle 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.  
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MAINTENANCE WORK ON CHASSIS AND ENGINE »  
67  
Refilling engine oil  
To refill engine oil, take off the right spoiler [1] by removing the screws [2].  
1
2
2
Also remove the screws [3] and take off the spoiler.  
3
3
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.  
4
– INSUFFICIENT AMOUNTS OF OR LOW-GRADE ENGINE OIL LEAD TO PREMATURE WEAR IN THE  
ENGINE.  
– DO NOT OVERFILL THE ENGINE CASE.  
– DO NOT UNDERFILL THE ENGINE CASE.  
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MAINTENANCE WORK ON CHASSIS AND ENGINE »  
68  
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.  
1
The engine oil change is to be carried out when the engine is still warm.  
2
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.  
3
Remove the oil filter cover [3] and pull the oil filter out of the engine case with circlip pli-  
ers (upside-down).  
Remove the screws [4], loosen the screws [5] by 2 turns and remove the front spoiler towards  
the front.  
4
4
5
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MAINTENANCE WORK ON CHASSIS AND ENGINE »  
69  
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.  
8
7
6
7
Carefully pull the oil screen [9] out of the oil tank.  
9
Thoroughly clean the drain plugs, the cover and both oil screens. Clean all rubber seal rings  
and check for damage. Replace if necessary.  
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MAINTENANCE WORK ON CHASSIS AND ENGINE »  
70  
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 fac-  
ing up. Make sure the form ring is in place and mount the cap [2]. Tighten the screws to  
10 Nm.  
2
1
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.  
3
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.  
5
4
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MAINTENANCE WORK ON CHASSIS AND ENGINE »  
71  
Remove the right spoiler (see Refilling the engine oil) and unscrew the plug [6]. Add 2.5  
liters (0.7 USgal) of fully synthetic engine oil meeting the JASO MA standard (e.g. Motorex  
Power Synt 4T) and remount the plug. Start the engine and allow to run warm in neutral  
until 4 bars on the temperature indicator light up. Switch off the engine and check the oil  
level (see Checking the engine oil level).  
6
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).  
7
8
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TROUBLESHOOTING »  
72  
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 Operating error  
starter button is actuated  
Turn on the ignition, switch the gear to neutral and switch the  
emergency OFF switch on.  
Discharged battery  
Recharge the battery and investigate the causes for discharg-  
ing; contact an authorized KTM workshop.  
Blown fuse IGNITION.  
Main fuse is blown  
Replace fuse IGNITION  
Remove the front spoiler and replace the main fuse  
Defect ignition lock or emergency  
OFF switch  
Check ignition lock and emergency OFF switch, contact an  
authorized KTM workshop.  
Defect safe-starting system.  
Contact an authorized KTM workshop.  
The engine cranks only with  
pulled clutch lever  
A gear is engaged  
Shift the transmission to neutral.  
Shift the transmission to neutral.  
A gear is engaged and the side  
stand is still folded down  
Defect safe-starting system.  
Defect safe-starting system.  
Contact an authorized KTM workshop.  
Contact an authorized KTM workshop.  
Engine cranks with gear  
engaged.  
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73  
TROUBLESHOOTING »  
TROUBLE  
CAUSE  
REMEDY  
Engine cranks but doesn’t start. Operating error  
Pay attention to starting off information  
(see driving instructions).  
Blown fuse for the fuel pump  
Replace the fuel pump fuse  
Clutch not attached to the fuel line Connect the clutch to the fuel line  
The plug and socket connector on  
the wiring harness is oxidized  
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  
Error in the injection system  
A gear is engaged and the side  
stand is folded down  
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  
Refill cooling liquid (see maintenace work), check cooling sys-  
tem for leaks  
Radiator fins are extremely dirty  
Foam forms in cooling system  
Clean radiator with water jet  
Replace cooling liquid, use antifreezer with brand name  
Run the radiator hose correctly or replace  
Radiator hose is kinked or  
damaged  
Thermostat defective  
Have the thermostat checked (opening temperature 75°C,  
167°F) or replaced; contact an authorized KTM workshop  
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74  
TROUBLESHOOTING »  
TROUBLE  
CAUSE  
REMEDY  
Engine overheats  
Blown fan fuse  
Replace fuse FAN  
Defect fan or thermoswitch for fan  
Contact an authorized KTM workshop.  
Air in the cooling system  
Bleed the cooling system (see Maintenance work)  
Visit an authorized KTM workshop  
FI lamp is blinking / lights up  
Engine stalls while driving  
Error in the injection system  
No fuel  
Refuel  
Fuse for fuel pump has blown  
Replace fuse FUEL PUMP  
High oil consumption  
Engine oil level too high  
Check engine oil level when the engine is warm; correct if  
necessary  
Engine oil too thin (viscosity)  
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 Sicherung durchgeschmolzen  
and multi-functional digital  
speedometer fail  
Replace fuse HORN BRAKELIGHT SPEEDO.  
Time is not displayed or not cor- Blown fuse, thus no continuous  
Replace fuse CLOCK and set the clock.  
rectly displayed  
power supply  
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75  
TROUBLESHOOTING »  
TROUBLE  
CAUSE  
REMEDY  
The battery is discharged  
The ignition (power consumer) has- Recharge the battery according to the relevant instructions.  
n’t been switched off  
The battery isn’t charged by the  
generator  
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 con-  
tacts on the cable connector have  
oxidized  
Check the pickup cable for damage, visit an authorized KTM  
workshop  
The blink code indicates which component is affected by an error. This allows the error to be identified if no diagnosis tool is available.  
BLINK CODE  
SIGNAL / COMPONENT  
ERROR DESCRIPTION  
ENGINE  
02  
06  
07  
09  
11  
Pulse generator  
Malfunction  
Stalls  
Throttle sensor  
Output signal too low /high  
Output signal too low /high  
Output signal too low /high  
Output signal too low /high  
Continues to run  
Continues to run  
Continues to run  
Continues to run  
Sensor for 2nd throttle valve  
Intake manifold air pressure for sensor rear cylinder  
Intake manifold air pressure sensor for front cylinder  
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TROUBLESHOOTING »  
76  
The blink code indicates which component is affected by an error.  
This allows the error to be identified if no diagnosis tool is available.  
BLINK CODE  
12  
SIGNAL / COMPONENT  
ERROR DESCRIPTION  
Output signal too low /high  
Output signal too low /high  
Output signal too low /high  
Output signal too low /high  
Malfunction  
ENGINE  
Coolant temperature sensor  
Air temperature sensor  
Continues to run  
Continues to run  
Continues to run  
Continues to run  
Continues to run  
Continues to run  
Continues to run  
Continues to run  
Stalls  
13  
14  
Ambient air pressure sensor  
Tilt angle sensor  
15  
17  
Lambda probe for rear cylinder  
Lambda probe for front cylinder  
Control unit voltage supply  
Side stand switch  
18  
Malfunction  
24  
Malfunction  
25  
Short circuit to ground  
Malfunction  
33  
Injection nozzle for rear cylinder  
Injection nozzle for front cylinder  
Ignition coil for rear cylinder  
Injection coil for front  
34  
Malfunction  
Stalls  
37  
Malfunction  
Stalls  
38  
Malfunction  
Stalls  
41  
Fuel pump relay  
Short circuit to ground / positive  
Short circuit to ground / positive  
Short circuit to ground / positive  
Malfunction  
Stalls  
45  
Lambda probe heater for rear cylinder  
Lambda probe heater for front cylinder  
Idle control motor  
Continues to run  
Continues to run  
Continues to run  
Continues to run  
46  
49  
53  
Purge valve for carbon canister  
Secondary air valve  
Short circuit to ground / positive  
54  
Short circuit to ground / positive or interruption Continues to run  
65  
EEPROM error  
Malfunction  
Malfunction  
Malfunction  
Malfunction  
Continues to run  
Continues to run  
Continues to run  
Continues to run  
68  
Vacuum hose for front cylinder is defective  
Vacuum hose for rear cylinder is defective  
Stepper motor for 2nd throttle valve  
69  
72  
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CLEANING »  
77  
Regular cleaning 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 unapproach-  
able 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 and 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 con-  
nectors with contact spray.  
– Treat all of the painted parts with a mild paint care product (e.g. Motorex Moto Polish).  
CONSERVATION FOR WINTER OPERATION »  
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!  
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STORAGE »  
78  
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) and set the clock.  
– 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 con-  
versions 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.  
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TECHNICAL SPECIFICATIONS – CHASSIS »  
79  
CHASSIS  
990 SUPER DUKE  
Frame  
Tubular chrome-molybdenum-steel space frame  
WP Suspension – Up Side Down 4860 ROMA  
135 mm (5.3 in)  
Fork  
Spring travel front  
Rear suspension  
Spring travel rear  
Front brake  
Rear brake  
Tires, front  
WP Suspension 4618 BAVP  
160 mm (6.3 in)  
Disk brake, 2 perforated brake disks Ø 320 mm (12.6 in), fixed brake calipers  
Scheibenbremse, gelochte Bremsscheibe Ø 240 mm (9.4 in), Bremszange schwimmend gelagert  
120/70 ZR17 M/C 58W  
Air pressure  
Road, driver only...............................................2.4 bar (34 psi)  
Road, with passenger ........................................2.4 bar (34 psi)  
maximum payload.............................................2.4 bar (34 psi)  
Tires, rear  
180/55 ZR17 M/C 73W  
Air pressure  
Road, driver only...............................................2.4 bar (34 psi)  
Road, with passenger ........................................2.6 bar (37 psi)  
maximum payload.............................................2.6 bar (37 psi)  
Fuel tank capacity  
Gear ratio – rear wheel  
Chain  
15 liters (4 USgal), 4 liters (1 USgal) reserve  
17:38  
5/8 x 5/16” X-ring  
Lighting  
high beam .......................................................H3 12V 55W (socket PK22s)  
low beam ........................................................H7 12V 55W (socket PX26d)  
position light front ............................................12V 5W (socket W2,1x9,5d)  
indicator lamps ................................................LED  
position light rear..............................................12V 5W (socket W2,1x9,5d)  
stoplight .........................................................12V 21W (socket BA15s)  
flashers............................................................12V 10W (socket BA15s)  
licens plate illumination ...................................12V 5W (socket W2,1x9,5d)  
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TECHNICAL SPECIFICATIONS – CHASSIS »  
80  
CHASSIS  
990 SUPER DUKE  
Battery  
maintenance-free battery 12V 11.2 Ah  
66.5°  
Steering head angle  
Wheel base  
1438 ± 10 mm (56.6 ± 0.4 in)  
855 mm (33.6 in)  
Seat height, unloaded  
Ground clearance, unloaded  
Dry weight  
165 mm (6.5 in)  
184 kg (406.2 lbs)  
200 kg (441.5 lbs)  
220 kg (485.6 lbs)  
380 kg (838.8 lbs)  
Max. axle load, front  
Max. axle load, rear  
Max. total weight  
BASIC SETTING  
SHOCK ABSORBER WP 4618 BAVP  
990 SUPER DUKE  
BASIC SETTING  
FORK WP 4860 ROMA  
990 SUPER DUKE  
Compression adjuster Low Speed (clicks) 25 20 10 10  
Compression adjuster (clicks)  
Rebound adjuster (clicks)  
Spring preload (turns)  
Spring  
20 15 10 15  
Compression adjuster High Speed (turns) 2,5 2 2 1,5  
20 15 10 15  
Rebound adjuster (clicks)  
Spring preload  
Spring  
22 17 10 5  
6 mm (0.24 in)  
160/185  
5
5
5
6
9 N/mm  
Air chamber length  
Fork oil  
110 mm (4.3 in)  
SAE 5  
(WP 4860.0401)  
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TECHNICAL SPECIFICATIONS – CHASSIS »  
81  
TIGHTENING TORQUES – CHASSIS  
Collar bolt on front wheel spindle  
Collar nut wheel spindle rear  
M24x1.5  
60 Nm  
M25x1.5  
M14x1.5  
M19x1.5  
M8  
90 Nm  
80 Nm  
AH bolt shock absorber top/bottom  
Collar nut for swing arm bolt  
130 Nm  
AH bolts on subframe  
Loctite 243 + 25 Nm  
Loctite 243 + 25 Nm  
45 Nm  
AH bolts on back of footrest support  
Engine carrier bolts  
M8  
M10  
M8  
HH clamp bolts on top triple clamp  
HH clamp bolts on bottom triple clamp  
HH screw for steering head  
12 Nm  
M8  
15 Nm  
M20x1.5  
M8  
12 Nm  
HH clamp bolts on fork leg axle passages  
Collar bolts for handlebar clamps  
AH bolt for handlebar mount  
15 Nm  
M8  
20 Nm  
M10  
M8  
20 Nm  
HH clamp bolts for steering stem  
Collar bolt front/rear brake disk  
HH bolts on front brake caliper  
20 Nm  
M8x1.25  
M10x1.25  
M6  
Loctite 243 + 30 Nm  
Loctite 243 + 45 Nm  
10 Nm  
HH bolts on handbrake cylinder  
HH bolts on footbrake cylinder  
M6  
Loctite 243 + 10 Nm  
Loctite 243 + 25 Nm  
Loctite 243 + 10 Nm  
Loctite 243 + 25 Nm  
Loctite 243 + 18 Nm  
Loctite 243 + 12 Nm  
Loctite 243 + 6 Nm  
Loctite 243 + 45 Nm  
AH bearing bolt for foot brake pedal, shift lever  
HH screw on cover plate for foot brake lever/shift mechanism  
Relay for shift shaft (on connecting support)  
Relay for shift shaft (on shift shaft)  
Gearshift rod attachment  
M8  
M6  
M8  
M6  
M6  
HH bolts on foot brake pedal surface  
AH bolts for side stand bracket - engine  
M5  
M10  
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TECHNICAL SPECIFICATIONS – CHASSIS »  
82  
TIGHTENING TORQUES – CHASSIS  
HH bolts for side stand fixture - side stand bracket  
HH bolts for side stand mounting  
HH bolt for spring rest on side stand  
HH bolt for side stand switch  
Drain plug on oil tank  
M10  
M10  
M8  
Loctite 243 + 25 Nm  
Loctite 243 + 35 Nm  
Loctite 243 + 25 Nm  
M4  
Loctite 243 + 2 Nm  
M12x1.5  
M8  
20 Nm  
Exhaust nuts on manifold  
Exhaust clamps  
evenly, do not bend sheet metal  
M8  
8 Nm  
Exhaust clamps for ball joint  
AH bolts on tank cover  
M8  
35 Nm  
M5  
5 Nm  
HH bolts on tank mounting  
Collar screws for in-tank pump  
AH screw on arm for tank support  
Collar screw for gas pressure shock absorber  
Seat fixing plate  
M6  
6 Nm  
M6  
6 Nm  
M10  
M6  
15 Nm  
6 Nm  
M5  
4 Nm  
8 Nm  
HH nut for seat lock  
M19x1  
M10x1.25  
M5  
Jerk damper bolt - rear wheel  
Chainguard  
Loctite 243 + 50 Nm  
5 Nm  
Chain sliding guard  
M5  
5 Nm  
Front spoiler  
M6  
Loctite 243 + 10 Nm  
8 Nm  
Taillight  
M6  
Other bolts on chassis  
M6  
10 Nm  
25 Nm  
45 Nm  
M8  
M10  
Other collar nuts on chassis  
M6  
15 Nm  
30 Nm  
50 Nm  
M8  
M10  
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TECHNICAL SPECIFICATIONS – ENGINE »  
83  
ENGINE  
990 LC8  
Design  
Liquid-cooled, 2-cylinder 4-stroke engine with 75° V arrangement with balancer shaft and electric starter  
Displacement  
Bore / Stroke  
Compression ratio  
Fuel  
999 cc  
101/62.4 mm  
11.5:1  
unleaded fuel with at least RON 95 (USA: Premium RON 91) *  
4 valves controlled over bucket tappet and 2 camshafts, camshaft drive with gears/chain  
Intake: 38 mm Exhaust: 33 mm  
Valve timing  
Valve diameter  
Valve clearance, cold  
Crankcase bearing  
Conrod bearing  
Piston pin bearing  
Piston  
Intake: 0.10 - 0.15 mm Exhaust: 0.25 - 0.30 mm  
Friction bearings (2 main bearings / 1 supporting bearing)  
Friction bearing  
Dual-fuel bearing  
Light alloy – forged  
Piston rings  
Engine lubrication  
Engine oil  
1 compression ring, 1 taper face ring, 1 single-piece oil scraper ring with spiral-type expander  
Dry sump with 2 trochoidal pumps (pressure pump and suction pump)  
SAE 10W-50 (Motorex Power Synt 4T) #  
approx. 3 liters (0.8 USgal) during oil/filter change  
Straight-toothed spur wheels 35 : 67  
Quantity of engine oil  
Primary drive  
Clutch  
Multi-disc clutch in oil bath  
Transmission  
Gear ratio  
6-speed claw shifted  
1st gear 14:36  
2nd gear 16:30  
3rd gear 20:30  
4th gear 21:27  
5th gear 23:26  
6th gear 25:26  
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84  
TECHNICAL SPECIFICATIONS – ENGINE »  
ENGINE  
990 LC8  
Ignition system  
Ignition timing  
Map-controlled via TPS  
Spark plug  
breakerless transistorized electronic ignition system with digital ignition advance  
Map-controlled via TPS  
12V 450W at 6000 rpm  
NGK DCPR 8 E  
Electrode distance  
Cooling system  
Cooling liquid  
Starting aid  
0.8 mm  
liquid cooled, permanent circulation of cooling liquid through water pump  
2.1 liters (0.55 USgal), 50% antifreeze, 50% distilled water, at least –25° C  
electric starter  
PON / CLC  
87  
RON / ROZ  
91  
MON  
83  
#
*
JASO T903 MA  
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  
TEMPERATUR  
0°C  
32°F  
5W/40  
10W/50  
Engine oil  
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).  
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HEAD WORD INDEX »  
85  
Accessories and payload . . . . . . . . . . . . . . . . . . . . . . . . . . . .23  
Adjusting compression damping of fork . . . . . . . . . . . . . . . . .37  
Adjusting rebound damping of fork . . . . . . . . . . . . . . . . . . . .37  
Adjusting the basic position of the hand brake lever . . . . . . . .44  
Adjusting the fork and shock absorber . . . . . . . . . . . . . . . . .37  
Adjusting the handlebar tilt . . . . . . . . . . . . . . . . . . . . . . . . .65  
Adjusting the headlight range . . . . . . . . . . . . . . . . . . . . . . . .58  
Adjusting the spring preload on the fork . . . . . . . . . . . . . . . . .38  
Baggage loops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16  
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52  
Bleeding the cooling system . . . . . . . . . . . . . . . . . . . . . . . .62  
Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28  
Chain maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41  
Changing the basic position of the clutch lever . . . . . . . . . . .64  
Changing the basic position of the foot brake lever . . . . . . . . .46  
Changing the engine oil and the oil filter,  
Checking the rear brake pads . . . . . . . . . . . . . . . . . . . . . . . .47  
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77  
Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7  
Combination switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14  
Compression damping of fork . . . . . . . . . . . . . . . . . . . . . . . .19  
Compression damping of shock absorber . . . . . . . . . . . . . . . .38  
Conservation for winter operation . . . . . . . . . . . . . . . . . . . . .77  
Cooling liquid temperature display . . . . . . . . . . . . . . . . . . . .12  
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60  
Correcting the chain tension . . . . . . . . . . . . . . . . . . . . . . . .40  
Damping action during compression of shock absorber . . . . . .20  
Dismounting and mounting the rear wheel . . . . . . . . . . . . . . .50  
Dismounting and remounting the front wheel . . . . . . . . . . . .48  
Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8  
Driving instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24  
Emergency OFF tip switch, light switch, starter tip switch . . . .15  
Engine number, engine type . . . . . . . . . . . . . . . . . . . . . . . . . .6  
Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66  
Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84  
Filler cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15  
Foot brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18  
Footrests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19  
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30  
Fuses for individual power consumers . . . . . . . . . . . . . . . . . .56  
General information on KTM disk brakes . . . . . . . . . . . . . . . .42  
General tips and warnings for starting the motorcycle . . . . . . .22  
Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7  
Helmet lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17  
Holding strap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17  
Ignition lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14  
cleaning the oil screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68  
Charging the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54  
Chassis number, Type label . . . . . . . . . . . . . . . . . . . . . . . . . . .6  
Check the following before each start . . . . . . . . . . . . . . . . . .24  
Checking and adjusting the throttle cable play . . . . . . . . . . . .65  
Checking the chain for wear . . . . . . . . . . . . . . . . . . . . . . . . .41  
Checking the chain tension . . . . . . . . . . . . . . . . . . . . . . . . . .40  
Checking the cooling liquid level in the compensating tank . . .61  
Checking the cooling liquid level in the radiator . . . . . . . . . . .62  
Checking the engine oil level . . . . . . . . . . . . . . . . . . . . . . . .66  
Checking the front brake fluid level . . . . . . . . . . . . . . . . . . .44  
Checking the front brake pads . . . . . . . . . . . . . . . . . . . . . . . .45  
Checking the oil level of the hydraulic clutch . . . . . . . . . . . . .64  
Checking the rear brake fluid level . . . . . . . . . . . . . . . . . . . .46  
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HEAD WORD INDEX »  
86  
Important . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1  
Important limited warranty and limited guarantee information . .3  
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4  
Indicator lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13  
Instructions for initial operation . . . . . . . . . . . . . . . . . . . . . .22  
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2  
Jump start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54  
Main fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55  
Maintenance work on chassis and engine . . . . . . . . . . . . . . . .36  
Multi-functional digital speedometer . . . . . . . . . . . . . . . . . . .8  
Operation instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7  
Periodic maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32  
Rebound damping of fork . . . . . . . . . . . . . . . . . . . . . . . . . . .19  
Rebound damping of shock absorber . . . . . . . . . . . . . . . . . . .39  
Rebound damping of shock absorber . . . . . . . . . . . . . . . . . . .21  
Refilling engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67  
Refilling front brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . .44  
Refilling rear brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . .46  
Removing and remounting the battery . . . . . . . . . . . . . . . . . .53  
Replacing the brake light and taillight bulbs . . . . . . . . . . . . .58  
Replacing the flasher bulbs . . . . . . . . . . . . . . . . . . . . . . . . .59  
Replacing the headlight lamp . . . . . . . . . . . . . . . . . . . . . . .57  
Running in the LC8 engine . . . . . . . . . . . . . . . . . . . . . . . . . .22  
Seat lock, removing the seat . . . . . . . . . . . . . . . . . . . . . . . .16  
Serial number locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6  
Setting options in the display . . . . . . . . . . . . . . . . . . . . . . . .10  
Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18  
Shifting/Riding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27  
Side stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18  
Spring preload of the fork . . . . . . . . . . . . . . . . . . . . . . . . . . .20  
Starting off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27  
Starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26  
Starting up after immobilization . . . . . . . . . . . . . . . . . . . . . .78  
Stopping and parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29  
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78  
Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13  
Technical specifications – chassis . . . . . . . . . . . . . . . . . . . . .79  
Technical specifications – engine . . . . . . . . . . . . . . . . . . . . .83  
Tires, air pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51  
Tool set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17  
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72  
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87  
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88  
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10/2005  
FOTO: MITTERBAUER  
KTM Group Partner  
KTM Sportmotorcycle AG  
A–5230 Mattighofen  
www.ktm.at  
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