User manual KTM 990 SUPER DUKE

[. . . ] 3211372en INTRODUCTION » We would like to congratulate you on your purchase of a KTM motorcycle. You are now the owner of a state-of-the-art sport motorcycle that guarantees to bring you lots of fun and enjoyment, provided that you clean and maintain it appropriately. Please insert the serial numbers of your motorcycle in the boxes below: Frame number Stamp of dealer 1 Engine number Key number All information contained is without obligation. KTM-Sportmotorcycle AG particularly reserves the right to modify any equipment, technical specifications, prices, colors, shapes, materials, services, service work, constructions, equipment and the like so as to adapt them to local conditions or to cancel any of the above items, all without previous announcement and without giving reasons. [. . . ] 15 kilograms (33 lbs) on the lower part of the chain (see illustration). Now measure the distance between 18 chain rollers on the upper part of the chain. The chain needs to be replaced when the distance is 272 mm (10. 70 in). Since chains do not always wear evenly, repeat the measurement at different parts of the chain. 272 mm 123 NOTE: If you mount a new chain, the sprockets should also be replaced. New chains wear faster if used on old used sprockets. MAINTENANCE WORK ON CHASSIS AND ENGINE » 1 2 LOCTITE 243 42 General information on KTM disk brakes BRAKE CALIPERS: The front brake calipers [1] have 4 brake pistons and are radially bolted to the fork legs. The front brake disks are designed as , , floating" brake disks, i. e. 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. The lateral balance ensures that the brake pads always have the best possible contact to the brake disk. For safety reasons, always have maintenance work and repairs to the brake system performed by an authorized KTM workshop. BRAKE PADS: Your motorcycle is equipped with sintered brake pads in the front and rear and homologated accordingly. Front brake pads: HAWK 7342-49 Rear brake pads: TOSHIBA TTH 38 GF Brake pads available in the accessory trade are often not authorized for operation of your KTM motorcycle in road traffic. The brake pads design and friction factor and therefore the braking power can deviate significantly from original KTM brake pads. If you use different brake pads than those provided with the original equipment, it cannot be warranted that they are authorized for use in road traffic. Your motorcycle will not longer comply with the regulations authorizing the use of vehicles for road traffic and the warranty will be void. BRAKE FLUID RESERVOIRS: The brake fluid reservoirs on the front and rear wheel brakes have been designed in such a way that even if the brake pads are worn it is not necessary to top up the brake fluid. There is no reason to remove the reservoir cap under normal conditions. If the brake fluid level drops below the minimum either the brake system has a leak or the brake pads are completely worn down. In this case, consult an authorized KTM dealer immediately. 3 MAINTENANCE WORK ON CHASSIS AND ENGINE » 43 BRAKE FLUID: We recommend that you use Motorex DOT 5. 1 brake fluid when you refill or change the brake fluid. 1 brake fluid has a wet boiling point of 180°C / 356°F (25°C / 45°F higher than DOT 4) and is safer for high performance applications. [. . . ] total load 990 SUPER DUKE / R 2009 maintenance-free battery 12V 11. 2 Ah Super Duke: 66. 1° 1450 ± 10 mm (57 ± 0. 4 in) Super Duke: 850 mm (33. 5 in) Super Duke: 140 mm (5. 5 in) 186 kg (410. 6 lbs) 180 kg (397. 3 lbs) 250 kg (551. 8 lbs) 387 kg (854. 2 lbs) Super Duke Super Duke R: 860 mm (33. 9 in) Super Duke R: 150 mm (5. 9 in) Super Duke R: 67. 3° 80 Super Duke Super Duke R Super Duke R Maximum Payload Maximum Payload Maximum Payload Driving Comfort Driving Comfort Basic Setting Basic Setting Basic Setting Basic Setting Driving Sport Driving Sport Driving Sport Driving Sport Race course Compression adjuster (clicks) Rebound adjuster (clicks) Spring preload (turns) Spring Air chamber length Fork oil 20 15 10 10 18 18 14 18 20 15 10 10 16 16 12 16 55555555 9. 5 N/mm 9. 5 N/mm 110 mm (4. 3 in) 80 mm (3. 5 in) SAE 5 (WP 4860. 0765) Compression adj. High Speed (turns) Rebound adjuster (clicks) Spring preload (mm) Spring 25 20 10 10 20 16 10 16 2 1. 5 1 1 2. 5 1. 5 1 1. 5 20 12 8 8 12 12 8 12 66665555 170/185 180/185 Race course BASIC SETTING FORK WP 4860 ROMA BASIC SETTING SHOCK ABSORBER WP 4618 BAVP Maximum Payload TECHNICAL SPECIFICATIONS ­ CHASSIS » TIGHTENING TORQUES ­ CHASSIS 2009 Collar bolt on front wheel spindle Collar nut wheel spindle rear AH bolt shock absorber top/bottom Collar nut for swing arm bolt AH bolts on subframe AH bolts on back of footrest support Engine carrier bolts HH clamp bolts on top triple clamp HH clamp bolts on bottom triple clamp HH screw for steering head HH clamp bolts on fork leg axle passages Collar bolts for handlebar clamps AH bolt for handlebar mount (Super Duke) AH bolt for handlebar mount (Super Duke R) HH clamp bolts for steering stem Collar bolt front/rear brake disk HH bolts on front brake caliper HH bolts on handbrake cylinder HH bolts on footbrake cylinder 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 HH bolts on foot brake pedal surface M24x1. 5 M25x1. 5 M14x1. 5 M19x1. 5 M8 M8 M10 M8 M8 M20x1. 5 M8 M8 M10 M10 M8 M8x1. 25 M10x1. 25 M6 M6 M8 M6 M8 M6 M6 M5 81 60 Nm 90 Nm 80 Nm 130 Nm Loctite 243 + 25 Nm Loctite 243 + 25 Nm 45 Nm 12 Nm 15 Nm 12 Nm 15 Nm 20 Nm 20 Nm 45 Nm 20 Nm Loctite 243 + 30 Nm Loctite 243 + 45 Nm 10 Nm Loctite 243 + 10 Nm Loctite 243 + 25 Nm Loctite 243 + 2 Nm Loctite 243 + 25 Nm Loctite 243 + 18 Nm Loctite 243 + 12 Nm Loctite 243 + 6 Nm TECHNICAL SPECIFICATIONS ­ CHASSIS » TIGHTENING TORQUES ­ CHASSIS 2009 AH bolts for side stand bracket - engine 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 Exhaust nuts on manifold Exhaust clamps Exhaust clamps for ball joint AH bolts on tank cover 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 HH nut for seat lock Jerk damper bolt - rear wheel Chainguard Chain sliding guard Front spoiler Taillight Screw, steering damper, fork leg clamp (Super Duke R) Screw, steering damper, top triple clamp (Super Duke R) Screw, steering damper, piston rod (Super Duke R) Screw, steering damper, clamp (Super Duke R) M10 M10 M10 M8 M4 M12x1. 5 M8 M8 M8 M5 M6 M6 M10 M6 M5 M19x1 M10x1. 25 M5 M5 M6 M6 M8 M8 M8 M6 82 Loctite 243 + 45 Nm Loctite 243 + 25 Nm Loctite 243 + 35 Nm Loctite 243 + 25 Nm Loctite 243 + 2 Nm 25 Nm evenly, do not bend sheet metal 8 Nm 35 Nm 5 Nm 6 Nm 6 Nm 15 Nm 6 Nm 4 Nm 8 Nm Loctite 243 + 50 Nm 5 Nm Loctite 243 + 6 Nm Loctite 243 + 10 Nm 8 Nm Loctite 243 + 10 Nm Loctite 243 + 10 Nm Loctite 243 + 10 Nm Loctite 243 + 4 Nm TECHNICAL SPECIFICATIONS ­ CHASSIS » TIGHTENING TORQUES ­ CHASSIS 2009 Other bolts on chassis M6 M8 M10 M6 M8 M10 83 10 Nm 25 Nm 45 Nm 15 Nm 30 Nm 50 Nm Other collar nuts on chassis TECHNICAL SPECIFICATIONS ­ ENGINE » ENGINE Design Displacement Bore / Stroke Compression ratio Fuel Valve timing Valve diameter Valve clearance, cold Crankcase bearing Conrod bearing Piston pin bearing Piston Piston rings Engine lubrication Engine oil Quantity of engine oil Primary drive Clutch Transmission Gear ratio 990 SUPER DUKE 2009 999 cc 101/62. 4 mm 11. 5:1 12. 2:1 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 Intake: 0. 10 - 0. 15 mm Friction bearing Dual-fuel bearing Light alloy ­ forged 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 Multi-disc clutch in oil bath 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 Intake: 41 mm Exhaust: 33 mm Exhaust: 0. 25 - 0. 30 mm 990 SUPER DUKE R 2009 84 Liquid-cooled, 2-cylinder 4-stroke engine with 75° V arrangement with balancer shaft and electric starter Friction bearings (2 main bearings / 1 supporting bearing) TECHNICAL SPECIFICATIONS ­ ENGINE » ENGINE Ignition system Ignition timing Map-controlled via TPS Spark plug Electrode distance Cooling system Cooling liquid Starting aid 990 SUPER DUKE 2009 Map-controlled via TPS 12V 450W at 6000 rpm NGK IR KR8DI 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 NGK LKAR8AI-9 990 SUPER DUKE R 2009 breakerless transistorized electronic ignition system with digital ignition advance 85 # JASO T903 MA TEMPERATUR 0°C 32°F * PON / CLC 87 91 Premium PON = CLC = RON = ROZ = MON = RON / ROZ 91 95 MON 83 87 Pump Octane Number Cost of Living Council Research Octane Number Research Oktan Zahl Motor Octane Number 5W/40 Engine oil 10W/50 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). HEAD WORD INDEX » Accessories and payload . [. . . ]