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KTM 990 Super Duke/R Repair Manual

KTM 990 Super Duke/R
447 pages
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950/990 ADVENTURE
990 SUPER DUKE/R
950/990 SUPERMOTO/R
950 SUPER ENDURO
REPARATURANLEITUNG
MANUALE DI RIPARAZIONE
MANUEL DE RÉPARATION
MANUAL DE REPARACIÓN
ART.NR.: 3.206.056-E
REPAIRMANUAL2003-2008

Table of Contents

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KTM 990 Super Duke/R Specifications

General IconGeneral
Displacement999cc
Transmission6-speed
LubricationForced oil lubrication with 2 oil pumps
ABSOptional
Front Tire120/70 ZR17
StarterElectric
Engine TypeV-Twin, 4-stroke
Bore x Stroke101 mm x 62.4 mm
Compression Ratio11.5:1
Power120 hp (89.5 kW) @ 9000 rpm
Torque100 Nm @ 7000 rpm
CoolingLiquid cooled
Front SuspensionWP 48mm upside-down fork, adjustable
Rear SuspensionWP monoshock
Front BrakeDual 320 mm discs, 4-piston calipers
Rear BrakeSingle 240 mm disc, 2-piston caliper
Rear Tire180/55 ZR 17
Dry Weight186 kg
Fuel Capacity18.5 liters

Summary

GENERAL INFORMATION

ECU Software Update/Mapping

Guidance on downloading and updating ECU software and mapping.

REMOVING AND REFITTING ENGINE

950 ADVENTURE ENGINE REMOVAL AND REFITTING

Detailed steps for removing and refitting the engine for the 950 Adventure model.

990 ADVENTURE ENGINE REMOVAL AND REFITTING

Detailed steps for removing and refitting the engine for the 990 Adventure model.

990 SUPER DUKE ENGINE DISMOUNTING AND MOUNTING

Procedure for dismounting and mounting the engine on the 990 Super Duke.

950 SUPERMOTO/R ENGINE DISMOUNTING/MOUNTING

Steps for dismounting and mounting the engine for 950 Supermoto/R models.

990 SUPERMOTO ENGINE REMOVING AND REFITTING

Detailed procedure for removing and refitting the engine for the 990 Supermoto.

DISASSEMBLING THE ENGINE

SERVICING INDIVIDUAL COMPONENTS

REPLACING MAIN BEARINGS AND CONROD BEARINGS

Procedures for replacing main and conrod bearings, including measurements.

ELECTRICAL SYSTEM

Ignition system, ECU 950 Adventure

Details on the ignition system and ECU for the 950 Adventure.

ABS SYSTEM 990 ADVENTURE

Procedures for checking ABS fuses, fault memory, and sensors.

FUEL SYSTEM

INJECTION SYSTEM PROCEDURES

Procedures for throttle body, fuel pump, and fuel filter work.

TROUBLE SHOOTING

ENGINE DOES NOT START

Troubleshooting guide for engine start issues and potential causes.

ENGINE DOES NOT HAVE ENOUGH POWER

Troubleshooting steps for lack of engine power.

ENGINE GETS TOO HOT

Common causes and solutions for engine overheating.

ERROR CODES

Table of diagnostic trouble codes, their descriptions, and engine behavior effects.

CHASSIS

REPLACING THE ABS UNIT

Steps for replacing the ABS unit and its components.

TECHNICAL SPECIFICATIONS

TOLERANCES AND FITTING CLEARANCE

Specified values and tolerance limits for engine and chassis components.

TIGHTENING TORQUES – ENGINE

List of engine component tightening torques with specifications.

TIGHTENING TORQUES – CHASSIS

List of chassis component tightening torques with specifications.

PERIODIC MAINTENANCE SCHEDULE

950 ADVENTURE MAINTENANCE

Periodic maintenance schedule for the 950 Adventure model.

990 SUPER DUKE/R MAINTENANCE

Periodic maintenance schedule for the 990 Super Duke/R models.

990 ADVENTURE MAINTENANCE

Periodic maintenance schedule for 990 Adventure models.

LUBRICATION AND MAINTENANCE WORK - ENGINE

Procedures for engine oil and filter changes, and cleaning oil screens.

WIRING DIAGRAMS

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