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maintenance work on chassis and engine

1. lus 45 Rebound damping of shock absorber llus 22 Removing and remounting the seat llle 41 Replacing the brake and tail light bulbs 68 Replacing the flasher bulbs llle 69 Replacing the headlight lamps 0000s 66 Running inthe LC8 engine cee eee es 24 Se TOE aana a atau na sec Sieg cabaret wpa anes ease E 17 __ HEAD WORD INDEX gt tg Serial number locations 0 0 00 es 6 setting options in the display leen 10 SD 48 dard tea ius a We ondre tet nae onde bet nae ah ae Seat tee ee 18 SMANERIAINS esaet ed ie Giese m aa dipsa a odi cit dvds 9 29 Shock absorber s preload adjuster lll 22 SIG SEWN auras atas o ach ule a es du ca eie Cod ui b pte ddl a a 19 Spring preload of the fork nuuanu a ee ee 20 SLANE ON Ge dace niti ctr cae Qva d oe tet ddp aves bah iv aac Eade ae 29 Starting the engine i c4 nsa naa 4 aa lea Ee Cn a 28 Stopping and parking ssa dy dome e eds J o ee o edt us 32 scu aang Ghar ain ore en erie eee brent eae ae 89 Storage compartment 0 0 ee ee ee 17 Switching off the ABS 2 208 aue do e id ed 0 Sw Big wi Mie a e a 31 TACO ITI GEO eraa lt aai abro e e Ale a oro ed xs Be ek 15 Technical specifications chassis llle 90 Technical specifications engine eee eee ees 94 Tires air pressure uacua x xr des of RICE sape x e ace dd 59 TOOIPSOL a ici scatet s Eta er BER Be ag
2. Check coolant level Check fuel lines for leaks Check all control elements for smooth running Check brake performance Treat exposed metal components except for the braking and exhaust systems with wax based anti corrosion agents Treat ignition steering lock and light switch with contact spray e VAIN NAN NURA UN CNOA AND ENGIN AQ CAUTION When cleaning the motorcycle do not use a high pressure cleaning unit if possible otherwise water will penetrate the bearings elec tric connectors etc Do not use toothed washers or spring washers with the engine fastening screws as these work into the frame parts and keep working loose Instead use self locking nuts If you unscrew any screwed connections with self locking nuts they must be replaced when mounting If no self locking nuts are avail able apply Loctite 243 to the thread The screws and nuts must be replaced if the thread is damaged All screws and nuts must be tightened to the specified torque figures using a torque wrench If screws or nuts are not adequately tight ened they can become loose and cause the motorcycle to go out of control while you drive Tightening the screws and nuts too tightly can damage the thread and components Let your motorcycle cool down before beginning any maintenance work in order to avoid getting burned Dispose of oil grease filters fuels cleaning agents etc according to your local regulations
3. Excessively tensioned spokes may rupture due to local overloading The spokes must be tensioned to 5 Nm 1 Nm Battery The battery is located in the underride protection 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 bat tery 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 Y WARNING ee Never operate the motorcycle with a run down battery or without the battery This can dam age the electronic components or safety equipment in either caseand the motorcycle will no longer be roadworthy CAUTION Do not remove the locking strip 1 otherwise the battery will be damaged V TA AND ENGIN Demounting and mounting the battery The battery does not need to be demounted unless the motorcycle is being immobilized To demount the battery remove the screws 1 and fold the underride protection 2 down Remove the screws 3 and tilt the battery cover 4 to the front First disconnect the neg ative pole and then the positive pole Remove the battery cover and remove the battery together with the battery case Recharge the battery before and after storage Storage temperature O 35 C 32 95 F To mount place the battery and battery case in the battery compartment and mount the bat tery cover First connect the positive
4. 8 Bic ad Scie oe Saas Sa ee ae She Gs alee PTT 8 setting options in the display llle 10 Cooling liquid temperature display 12 NCIC ALO 210810 ORO REC RERO CL TT RECTO ID RT os 13 ABS warning lamp models with ABS antilock brake system eee RI 14 ABS button models with ABS antilock brake system 14 DHT ots sinha aaa wien to aa aie Ss oh Sa oh nee ae 15 feinihitoinMrsrr MED 15 Combination switch iux do Swe SS Ae Slew as ee a we 16 Emergency OFF tip switch starter tip switch 16 Storage compartment zac dcos yw ae RO w Sea ace ROS 17 diis s PIE Rr 17 s mrs APER TRORENER DURER PRENNE 17 Fel X aS dudar i e oa e ape Ao de A paf eR t d 18 SERAIS ISSUE V eto Sta neat Pe te NL UO 18 SIC Siad ui aa suse Gag Gh ated n ne avg i anc Ro ACA nak aha AE a hee 19 CONST Sta kom Ae oe oir un CR wines eme GG we ER HERR SS 19 Foot brake pedal llle 19 Compression damping of fork 0 000 ee eee eee 20 Rebound damping of fork llle 20 Spring preload of the fork Damping action during compression of shock absorber Rebound damping of shock absorber Shock absorber s preload adjuster Baggage carrier plate Grips Footrests Alarm system GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE Instructions for initial operation Running in the LC8 engine Accessories and payload DRIVING INSTRUCTIONS Check the following before each start Starting the engine Start
5. Tire type and size can be found in the technical specifications and in the homologation certificate ire 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 TN WARNING eee Do not mount tires which have not been approved by KTM Other tires could have adverse effects on the way your motorcycle rides Models with ABS antilock brake system do not mount wheels with a different rim diam eter The ABS function can no longer be guaranteed Models with ABS The ABS is designed to be used with the tires authorized by KTM and works best with these tires The ABS function cannot be guaranteed if other tires are used Use tires of the same brand and type for the front and rear wheels For your own safety replace damaged tires immediately Worn tires can have a negative effect on how your motorcycle performs especially on wet surfaces If air pressure is too low abnormal wear and overheating of the tire can r
6. A TA AND ENGIN To mount the front wheel lift the wheel into the fork slightly pull one brake caliper out and push the tire in between the brake calipers Insert the brake disks in the brake calipers and mount the axle passage Mount the collar screw 1 and tighten slightly Tighten the clamp screws 2 on the right fork leg axle passage in the direction of travel tighten to prevent the axle passage from turning and tighten the collar nut to 60 Nm Loosen the clamp screws on the right fork leg axle passage take the motorcycle off the stand actuate the front wheel brake and vigorously compress the fork several times to align the fork legs Now you can tighten the clamp screws on both fork leg axle passages to 15 Nm AN WARNING m f you do not have a torque wrench to mount the wheel have the torques corrected by an authorized KTM workshop as soon as possible A loose axle passage can cause the motorcycle s handling performance to become instable After mounting the front wheel keep operating the hand brake until the pressure point returns Always keep the brake disks free from oil and grease otherwise the braking effect will be significantly reduced TA AND ENGIN Dismounting and mounting the rear wheel NOTE FOR MODELS WITH ABS ANTILOCK BRAKE SYSTEM The ABS sensor 6 can be removed to make it easier to dismount and mount the rear wheel Loosen the HH screw 7 and pull out the ABS sensor When remounting app
7. 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 CLOCK mode press the MODE button TRIP F eee pr ecc ec c c c c c 0c0 6060 96 e e eec cc c 0 00 00000000 Setting options in the display 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 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 st
8. or foot brake pedal feels spongy too much play this is an indication that something is wrong with the brake sys tem Don t ride your motorcycle anymore without first having the brake system looked over by a KTM dealer gt d JN Stopping and parking Apply the brakes fully and put the engine into neutral To stop the engine switch off the ignition Park the motorcycle on a firm surface and lock AN WARNING OO 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 motorcycle and take care to park it where pedestrians are not likely to touch it and get burned Never park your motorcycle in places where there exist fire hazards due to dry grass or other easily flammable materials CAUTION Always take out the ignition key when parking your motorcycle so that it cannot be used by unauthorized persons INFORMATION ABOUT THE SIDE STAND Use your foot to push the side stand forward as far as possible and lean your motorcycle to the side Make sure that your motorcycle is standing safely on solid ground Just in case you can also put in a gear CAUTION The side stand is dimensioned for the weight
9. 15 mm and carefully tilt to the side Disconnect the fuel lines disconnect the connector for the fuel pump and the pickup cable fuel level and set down the tank Remove the lower screw 2 on the right tank Remove the HH screws and take off the bat tery cover 3 Remove the drain plug 4 on the oil tank and allow the oil to drain into a receptacle Remove the screws 5 and tilt the oil return valve 6 to the side m TA AND ENGIN Carefully pull the oil screen 7 out of the oil tank Thoroughly clean the drain plugs the cover and both oil screens Clean all rubber seal rings and check for damage Replace if necessary Mount the oil drain plug on the engine with a new seal ring and tighten to 20 Nm Slide the oil screen 8 into the guides in the oil pump housing with the TOP mark facing va up Make sure the form ring is in place and mount the cap 9 Tighten the screws to 10 Nm V A TA AND ENGIN o0 Insert a new oil filter 1 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 CAUTION 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 2 and carefully slide the oil screen into the oil tank
10. 9 Grips p The passenger can hold on to both grab handles 1 Footrests The passenger footrests 2 fold up Alarm system An alarm system can be retrofitted Ask your authorized KTM shop for details AND WA NERKA Instructions for initial operation 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 hand brake lever and foot brake lever to your most comfortable position The motorcycle is equipped with 2 three way catalysts Leaded fuel will destroy the catalytic converters Please use unleaded fuel only Get used to handling the motorcycle on an empty parking lot before starting on a longer drive Also try to drive as slowly as possible and in standing position to improve your feeling for the vehicle Do not drive along off road tracks which go beyond your abitily and experience Hold the handlebars with both hands and leave your feet on the foot rests while driv ing 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 th
11. Gi s Se eg hes te en ated ir te ae eee f 41 Trouble shooting x scar aot n COR a ace SCORE e eR Aedes wick 83 JN VIER INFURIVIA Sticker positions ap A ap Fe a under seat cD on frame tube R S E on frame tube R S JN VIER INFURMATIUN FUR A UN 1 EAVP 2 Type label USA 2 Type label CAN 4 Fuel level 5 Before you go for the first ride 6 Vehicle emission 7 Noise emission 8 Technical information 9 Exhaust system JN VIER INFURMALIUN FUR A UN 90 REPORTING SAFETY DEFECTS If you believe that your vehicle has a defect which could cause an accident resulting in injury or death you should immediately inform the National Highway Traffic Safety Administration NHTSA in addition to notifying KTM North America Inc If NHTSA receives similar complaints it may open an investigation and if it finds that a safety defect exists in a group of vehicles it may order a recall and remady cam paign However NHTSA cannot become involved in individual problems between you your dealer or KTM North America Inc To contact NHTSA you may either call the Auto Safety Hotline toll free at 1 800 424 9393 or visit the website www nhtsa dot gov or write to NHTSA U S Department of Transportation 400 7th Street Southwest Washington D C 20590 You can also obtain other information about motor vehicle safety from the Hotline NOISE EMISSION WARRANTY KTM Sportmotorcycle AG warrants that this exhaust system at
12. S 265 mm 10 4 in Front brake Disk brake 2 perforated brake disks 300 mm 11 8 in floating brake calipers and brake disks Rear brake Disk brake perforated brake disk 240 mm 9 5 in floating brake calipers and brake disks ABS antilock brake system ADVENTURE Brembo Bosch with 2 independent brake circuits ADVENTURE S Authorized front tires Pirelli MT90 90 90 21 M C 54V Up to a max of 160 kph 100 mph Continental TKC80 90 90 21 M C 54S TT M S Air pressure front road driver only 2 4 bar 34 psi road with passenger 2 4 bar 34 psi Authorized rear tires Pirelli MT90 150 70 18 M C 70V Up to a max of 160 kph 100 mph Continental TKC80 150 70B18 M C 70Q TT M S Air pressure rear road driver only 2 6 bar 37 psi road with passenger 2 8 bar 40 psi Fuel tank capacity 19 5 liters 5 1 USgal 4 liters 1 USgal reserve Gear ratio rear wheel 17 42 Chain 525 HV 5 8 x 5 16 X ring 118 rolls Lighting high beam H3 12V 55W socket PK22s low beam H7 12V 55W socket PX26d USA high beam low beam H4 12V 60 55 W socket P43t position light front rear 12V 5W socket W2 1x9 5d indicator lamps LED stoplight 12V 21W socket BA15s further tire releases are available on the Internet at www ktm com CHASSIS 990 ADVENTURE 990 ADVENTURE S Lighting flasher 12V 10W socket BA15s licens plate illumination 12V 5W socket W2 1x9 5d Battery maintenance free battery 12V 11 2 A
13. Should the warning light still be on off after 1500 meters 1 mile stop immediately switch off the engine and look for other possible causes The cooling fan on the radiator is not working The cooling fan must be running when the cooling liquid temperature is 120 C 248 F and the ignition is on If the fan is not working and there appears to be sufficient cool ing liquid the only thing you can do is to drive on to your nearest authorized KTM work shop 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 lt 4 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 elim inated You will damage the engine if you continue to drive when the cooling liquid tem perature warning lamp is on Excessive use of the clutch at slow speed TA AND ENGIN 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 protec tion this mixture also provides great corrosion protection which is why it must not be replaced by pure water CAUTION Forthe cooling system use only high grade antifreezer
14. Under no circumstances may used oil be disposed of in the sewage system or in the open countryside 1 liter used oil contaminates 1 000 000 liters water TA AND ENGIN Removing and remounting the seat Insert the ignition key in the seat lock and turn in a counterclockwise direction to unlock the seat Lift the back of the seat and pull off towards the rear To remount fit the nose 1 of the seat in the front lower the back while pushing towards the front Both noses 2 should fit into the frame Insert the catch bolts 3 in the lock hous ing and push the seat down in the back until you hear the catch bolts snap into place Check whether the seat is correctly mounted CAUTION If not correctly mounted the seat can slip while you are driving and cause you to lose con trol of your motorcycle Tool set The tool set 4 and an extension piece 5 for some of the wrenches in the tool set are located in the pocket under the seat The 990 Adventure S model without ABS has an additional storage compartment under the cover 6 TA AND ENGIN Adjusting the spring preload on the fork The fork spring preload can be adjusted by turning the adjusting screws 4 wrench size 24 mm 5 mm 0 2 in 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 adjus
15. WARNING eee If you don t happen to have a torque wrench at hand make sure you have the tighten ing 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 pressure point returns t is very important to keep the brake disk free from oil and grease otherwise the brak ing effect would be strongly reduced TIRES AIR PRESSURE ront rear Road 2 4 bar 2 6 bar driver only 34psi 37psi Road with 2 4 bar 2 8 bar passenger 34psi 4Opsi maximum 2 4 bar 2 8 bar payload 34psi 40psi TA AND ENGIN 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 AN WARNING eee Only use tires authorized by KTM to guarantee driving safety and maximum handling performance tire releases are available on the Internet at www ktm com Other tires can have an adverse effect on the vehicle handling e g wobbling at high speeds and the stopping distance Do not exceed the respective maximum speed for tires designed with a speed index of less than V 240 kph 150 miles h A sticker showing the maximum speed must be affixed to the motorcycle within the driver s field of vision
16. WM ace tare ar a ce Sprig x Mae setter gaan Get a Getty dh doer seca th ahd a 95 SUUS MFETETARETRRITIICLTLTOTTI OT ia ae IT 75 PUG CAS sk wre ihe oh ard ida ai a RUP AR a ale wes Sos ade 17 Foot brake pedal dew tus mods arie n eo L1 oC ap a RC o0 19 as 19 S CSU Seah de sit tae ERE ERSCEERQIUCUTTTLINTLILU LIEU 23 UN ce diro pour eu buds ees i ane ames Geena ane eee nan dne etr ue pec 34 Fel TOS 3e ces vaste arp Deinem actin theses Sy tan nat Me ecdee ey atq AA ut eras ek 18 Fuses for individual current consumers 65 General informations about KTM disc brakes 50 General tips and warnings for starting the motorcycle 24 Cu sak decid hd he a iat ey unnamed e ation a anderen ede tone ee 23 Hand brake lever su uota e ge xe E n dede RR wR Skee OC EMON LOCC DT 15 Important information ac eth t sow RR t a Shue aya eB a elu la abe 2 dI WNRECCCEETTCESTTTTTIOOSTTTTLS E e a a AAE a 4 HAEMOST 99 mete ah aa DNA 13 Instructions for initial operation 00 eee aa 24 ARI goI9 UO RIO RENT UR konnen a a a ne aka a 1 JUMO STAN of tinge aaraa x cod e qa Aaa A ar ER a A 63 MaN ISO orya Saas AAA A a DA DA 64 Maintenance work on chassis and engine Ln 40 Multi functional digital speedometer 8 Operation instruments 0 2 0 00 ee es 7 Periodic maintenance schedule 002s 36 Rebound damping of fork wisi scans athe cab e ada SE n Fn 20 Rebound damping of shock absorber
17. a fuse allowed to be repaired An inexpert treatment could damage the whole electrical installation Spare 25 and 40 ampere fuses are located next to the fuse box in the storage compartment in front of the seat V TA AND ENGIN Fuses for individual current consumers A fuse box with additional fuses is mounted in the storage compartment to separately pro tect the current consumers against short circuits The current consumers and the corresponding fuse capacities are listed on the cover of the fuse box 1 Spare 10 15 25 and 40 ampere fuses 2 are also located next to the stor age compartment Replace a blown fuse only with an equivalent one Visit an authorized KTM workshop if the new fuse blows again CAUTION Under no circumstances is a stronger fuse allowed to be set in or a fuse allowed to be repaired An inexpert treatment could damage the whole electrical installation The ACC 1 CLOCK and ACC 2 fuses 3 are designed for accessory equipment with a max imum current consumption of 10 amperes each The respective connectors for this equip ment are provided under the headlight cover For more information contact an authorized KTM workshop NOTE FOR MODELS WITH ABS The ABS OPTIONAL fuse 4 is the fuse for the ABS VAINIENAN NURA UN GHA AND ENGIN 5E Replacing the headlight lamps N Remove the 5 screws on the left and right and take off both side covers 1 Use a screw SN driver to detach the re
18. joint for safety reasons Always have the chain replaced in an authorized KTM workshop where the service technicans have the required riveting tool Never mount a normal chain joint Also check sprockets and chain guides for wear and replace if necessary Checking the chain for wear To check the chain for wear proceed as follows Switch the transmission to idle and put a load of approx 15 kilograms 33 Ibs 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 max 272 mm parts of the chain Replace the chain if any X rings are missing e 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 TA AND ENGIN i General informations about KTM disc brakes BRAKE CALIPERS The brake calipers of this series float This means that the brake calipers are not solidly attached to the caliper support Thus the brake pads are always in optimum contact with the brake disc Secure the screws of the caliper support with Loctite 243 and tighten to 25 Nm AN WARNING eee For safety reasons always have maintenance work and repairs to the brake system performed by an authorized KTM workshop QW BRAKE PADS Your
19. life of your engine VIULUR ART Wear suitable clothing when driving a motorcycle Clever KTM drivers always wear a helmet boots gloves and a jacket regardless of whether driving all day or just for a short trip The protective cloth ing 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 necessary operating temper ature Maximum road grip is assured when the tires are warm The front and rear wheel are allowed to be fitted only with tires that have the same profile type NERA 9 AND WB ART The tires must be designed for a maxi mum speed of 240 kph speed symbol V and must be authorized by KTM Do not exceed the respective maximum speed for tires designed with a speed index of less than V 240 kph A sticker showing the maximum speed must be affixed to the motorcycle within the dri ver s field of vision New wheels have a smooth surface which means that they must be run in to achieve full grip For this purpose ride the motor cycle carefully at moderate speed during the first 200 kilometers with new tires tilting the vehicle at different angles so that
20. pole then the negative pole to the battery to avoid a short circuit Fold the battery cover up and fasten with 2 screws Fold the underride protec tion up apply Loctite 243 screw retainer to both screws mount the screws and tighten to 25 Nm 19 ft Ibs WARNING eee If electrolyte sulphuric acid leaks from the battery proceed with great care The elec trolyte can cause severe burns In the case of skin contact rinse thoroughly with water In the case of contact with the eyes thoroughly rinse eyes with water for at least 15 min utes Immediately consult a doctor The battery is a closed model but can nevertheless emit explosive gases Avoid sparks and open fire near the battery Defective batteries must be stored out of the reach of children Ensure proper disposal of discarded batteries The screws on the underride protection must be secured with loctite 243 to prevent them from becoming loose CAUTION Never disconnect the battery while the engine is running This will destroy the rectifier regulator STORAGE If the motorcycle is being immobilized for longer periods of time remove and charge the battery Storage temperature O 35 C 32 95 F avoid direct sunlight Charge the battery every 3 months TA AND CNUGIN Charging the battery The battery does not need to be dismounted to charge Remove the screws 1 and the engine cover 2 Remove the red protection cover and connect th
21. put at higher speeds Most motorcycle engines also use the same oil to lubricate the trans 32 F 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 5W 40 10W 50 mation on the can KTM recommends Motorex Power Synt 4T in the 10W 50O 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 motorcycle place the motorcycle on a level surface not on the side stand Turn off the engine unscrew the oil dipstick 5 and wipe off with a cloth Screw the oil dip stick all the way back in and back out again The oil level should fall between the lower end of the oil dipstick MIN and the MAX mark The oil capacity between the MIN and MAX mark is O 5 liters 0 13 USgal Add more engine oil if necessary and check the engine for leakage CAUTION 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 TA AND ENGIN Changing the engine oil and the oil filter cleaning the oil screen CAUTION You may only change the engine oil yoursel
22. sim ply pull the clutch lever and start It is not necessary to switch the gear to NEUTRAL Stop immediately if the Fl indicator lamp lights up while driving The Fl indicator lamp will start blinking as soon as the transmission is in neutral The rhythm of the blinking lamp will let you determine the two digit blink code e g Blink code 34 FI blinks 3x long 4x short pause Blink code 06 FI blinks 6x short pause The blink code will indicate which compo nent is defective see Troubleshooting This makes it possible to pinpoint the defect if a diagnostic tool is unavailable ART MM Avoid abrupt load changes while riding around bends and on wet or slippery ground Otherwise you might easily lose control over your motorcycle Jn NG INSIR JN ART While riding your motorcycle never switch the ignition lock to positions amp And amp Do not try to change the settings of the multi functional Speedometer while driv ing 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 grab handle on the baggage car rier during the ride and keep his feet on the passenger footrests Regularly make sure that the baggage and cases are tightly fastened After falling with the motorcycle check all functions thoroughly before starting up operations again Abent handlebar must always be replaced Never
23. the distance between the clutch lever and the handlebar Turning the adjusting screw clockwise increases the distance between the clutch lever and the handlebar CAUTION Adjustment of the clutch lever position is only possible within certain limits Only turn the adjusting screw manually and never apply excessive force Checking the oil level of the hydraulic clutch To check the oil level in the master cylinder of the clutch remove the cover For this pur pose remove screws 2 and cover 3 together with the rubber boot 4 The oil level in the horizontal standing master cylinder should be 4 mm below the upper edge If necessary add SAE 10 biodegradable hydraulic oil Motorex clutch fluid 75 available from your authorized KTM workshop CAUTION KTM uses biodegradable hydraulic mineral oil to actuate the hydraulic clutch Do not mix this oil with any other hydraulic oil Always use original KTM hydraulic oil available from your authorized KTM workshop to make sure your clutch operates smoothly Never refill with brake fluid Engine oil JASO T903 MA 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 TEMPERATURE car engines require long changing intervals motorcycle engines require a higher power out oc
24. the rear wheel 58 Tires air pressure llle en 59 Checking spoke tension llle 60 Ballo es aadoue sia JO RUP RC a a UE CA ROR ILC OPE ele BIN 61 Demounting and mounting the battery 62 Charging the battery leen 63 J UIEDID S EIE 22 8 dna i o De eo e o he e e nahe eie Prae E A 63 ManmUse apt wink helara E Gace Bos Gane os GL DE 64 ABS fuses models with ABS antilock brake system 64 Fuses for individual current consumers 65 Replacing the headlight lamps less 66 Adjusting the headlight range ee eee 68 Replacing the brake and tail light bulbs 68 INDEX gt gt h h h s5 Replacing the flasher bulbs Cooling system Checking the cooling liquid level in the compensating tank 71 Checking the cooling liquid level in the radiator 2 Bleeding the cooling system lll 73 Changing the original position of the clutch lever 4 Checking the oil level of the hydraulic clutch 74 EDANE PON 2 qud ts seers ep dv gear ten Gear ge dci dep de atr i si 75 Checking the engine oil level Changing the engine oil and the oil filter cleaning the oil screen 1 1 ee es 76 Activating the ignition curve for low octane fuel 82 TROUBLE SHOOTING s tea cea detta ark v aero ae eo 83 CEEAMING a Set tt Sic an asa ate op aiv ded
25. the right engine cover Replace the ABS OPTIONAL fuse Check the ABS sensors for a tight fit and the cable for dam age visit an authorized KTM workshop Visit an authorized KTM workshop Visit an authorized KTM workshop Refuel Replace fuse FUEL PUMP Check engine oil level when the engine is warm correct if necessary Use thicker engine oil see chapter Engine oil Replace bulb Replace fuse H L BEAM POSITION TROUBLE CAUSE REMEDY Flasher lights brake light horn and multi functional digital speedometer fail Time is not displayed or not cor rectly displayed The battery is discharged Bulb burned out Blown fuse Blown fuse thus no continuous power supply The ignition power consumer has n t been switched off The battery isn t charged by the generator Replace bulb Replace fuse HORN BRAKELIGHT SPEEDO Replace fuse ACC 1 CLOCK and set the clock Recharge the battery according to the relevant instructions Voltage regulator and generator should be checked by an authorized KTM workshop No values are visible in the multi functional digital speedometer display Blown fuse Replace fuse HORN BRAKELIGHT SPEEDO The speed indication on the multifunctional digital speedometer is not working Pickup cable is damaged or con tacts on the cable connector have oxidized Check the pickup cable for damage visit an authorized KTM workshop The blink code Fl indicator lamp i
26. try to straighten the handlebar because this will cause it to lose its sta bility CAUTION 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 temperature indicator lights up If the red oil pressure warning lamp lights up while driving the oil pressure is too low to adequately lubricate the engine Stop immediately and switch off the engine if you continue to drive engine damage will occur within a short period of time Check the engine oil level or con tact an authorized KTM workshop Never have the throttle wide open when changing down to a lower gear The engine will overspeed damaging the valves In addition the rear wheel blocks so that the motorcycle can easily get out of control Never use your motorcycle without an air filter Otherwise dust and dirt may enter the engine and cause increased wear Stop immediately if a perceptible power loss occurs while driving due to a defec tive ignition caused by a cylinder misfir ing or breaking down If the unburned fuel air mixture reaches the catalytic con verter it will ignite and the resulting heat will destroy the catalytic converter and the adjoining components the red coolant warnin
27. you will not need to brake so much and the brakes will not overheat Switching off the ABS The ABS can be switched off when driving off road with a special driving technique when you want the wheels to lock up To switch off the ABS stop the motorcycle and press the ABS button for at least 3 sec onds with the engine running Let go of the ABS button as soon as the ABS warning lamp starts blinking fast The ABS warning lamp will blink slowly to indicate that the ABS Is switched off To switch the ABS on again stop and switch off the ignition The ABS will be active again when you switch on the ignition ART NN Do not try to switch the ABS on or off while driving Your attention will be distracted from the traffic and it may cause you to lose con trol of the motorcycle ART MN Applies to all models with and without ABS In the rain or after the motorcycle has been washed braking action may be delayed due to wet brake discs First the brakes must be braked dry On salt sprayed or dirty roads brake action may be delayed as well First the brakes must be braked clean Remember that the stopping distance will be longer if you are carrying a pas senger or baggage When you brake the brake discs brake pads brake caliper and brake fluid heat up The hotter these parts get the weaker the braking effect In extreme cases the entire braking system can fail f the resistance in the hand brake lever
28. 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 Slide back the protective covers on the handlebar mounted instruments so that any water that may have sweeped into this parts of the motorcycle is allowed to evaporate 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 amp Shine The exhaust pipes can be polished with a chrome care product The mufflers are made of stainless steel and should be treated with a suitable care product Clean the windshield with plenty of water and a soft sponge Chemical cleansers will corrode the plastic 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 pa
29. 0 km or once a year every 15000 km or every 2 years 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 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 done by KTM autorized workshops is not a substitute of care and checks done by the rider 990 ADVENTURE 2007 ADDITIONAL SERVICE WORK TO BE PERFORMED UNDER A SEPARATE ORDER at least once a year every 15000 km or every 2 years Perform complete fork maintenance 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 990 ADVENTURE 2007 VITAL CHECKS AND CARE PROCEDURES TO CONDUCTED BY THE OWNER OR THE MECHANIC after every every 1000 km cleaning or after off road use Check oil level 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 Clean chain Lubricate chain Check chain tension Check tire pressure and wear
30. 12 35 2nd gear 15 32 3rd gear 18 30 Ath gear 20 27 5th gear 24 27 oth gear 26 27 ENGINE 990 LC8 Mixture preparation EFI electronic fuel injection Ignition system breakerless transistorized electronic ignition system with digital ignition advance Ignition timing Map controlled via TPS Generator 12V 450W at 6000 rpm Spark plug NGK DCPR 8 E Electrode distance 0 8 mm Cooling system liquid cooled permanent circulation of cooling liquid through water pump Cooling liquid 2 1 liters 50 antifreeze 50 distilled water at least 25 C starting aid 0 9 kW electric starter 91 Premium 95 87 TEMPERATURE PON Pump Octane Number 0 C CLC Cost of Living Council 32 F RON Research Octane Number ROZ Research Oktan Zahl MON Motor Octane Number 9W A0 10W 50 Engine oil Only use fully synthetic engine oils that meet the JASO MA quality requirements see infor mation on the can KTM recommends Motorex Power Synt 4T in the 10W 5O viscosity for temperatures over 0 C 32 F or 5W 40 for temperatures under 0 C 32 F ABS button models with ABS antilock brake system 14 ABS fuses models with ABS antilock brake system 64 ABS warning lamp models with ABS antilock brake system 14 Accessories and payload a 25 Activating the ignition curve for low octane fuel 82 Adjusting compression damping of fork 004 42 Adjusting of free travel
31. 25x1 5 Collar nut for swing arm bolt M19x1 5 AH screw shock absorber top M14x1 5 AH bolt shock absorber bottom M14x1 5 80 Nm AH bolt for top of brake hose guide M6 Loctite 243 8 Nm HH bolts on front brake caliper M8 Loctite 243 25 Nm HH bolts on footbrake cylinder M6 Loctite 243 10 Nm Collar bolt front brake disks M6 Loctite 243 14 Nm AH bearing bolt for foot brake pedal M8 Loctite 243 25 Nm HH bolts on foot brake pedal surface M5 Loctite 243 6 Nm AH bolts on subframe M10x1 25 Loctite 243 45 Nm AH bolts on back of footrest support M8 Loctite 243 25 Nm AH bolts on tank cover M5 5 Nm M5 HH bolt on fuel level indicator 3 Nm HH bolts fuel taps M 6 AH bolts on tank mounting M8 25 Nm 6 Nm TIGHTENING TORQUES CHASSIS Exhaust nuts on manifold evenly do not bend sheet metal HH bolts on exhaust suspension Spoke nipple HH nuts on rear sprocket bolts M10x1 25 Loctite 243 12 Nm 5 Nm x 1 Nm Loctite 243 50 Nm Hexagon nut on engine sprocket M20x1 5 Engine carrier bolts Loctite 243 sheet retainer 100 Nm 45 Nm HH bolts for side stand bracket engine Loctite 243 45 Nm HH bolts side stand bracket side stand console HH bolts side stand mounting Loctite 243 25 Nm Loctite 243 35 Nm HH bolt spring retainer side stand HH bolt side stand switch M6 Loctite 243 25 Nm Loctite 243 10 Nm HH bolts for underride protection M8 Loctite 243 25 Nm Dr
32. Motorex Anti Freeze Using low ergrade antifreeze agents can cause corrosion and coolant foaming More antifreeze must be added if you plan to travel to a region where temperatures are expected to drop below 25 C 13 F Pressure induced by heating of the cooling liquid in the cooling system is controlled by a valve in the radiator cap 4 a water temperature rising up to 125 C 257 F is 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 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 6 sating tank is empty also check the cooling liquid level in the radiator Have the cooling system checked by an authorized KTM workshop TA AND ENGIN Checking the cooling liquid level in the radiator Remove the 5 screws and the right cover 1 disconnect the flasher cable and tank ventilation AN WARNING OOOO If possible always check level of cooling liquid when engine is cold If you have to open the radiator cap when engi
33. NITION Remove the engine cowl and replace the main fuse Check ignition lock and emergency OFF switch contact an authorized KTM workshop Contact an authorized KTM workshop A gear is engaged The engine cranks only with pulled clutch lever A gear is engaged and the side stand is still folded down Defect safe starting system Shift the transmission to neutral Shift the transmission to neutral Contact an authorized KTM workshop Engine cranks with gear Defect safe starting system engaged Engine cranks but doesn t start Operating error Contact an authorized KTM workshop Pay attention to starting off information see driving instructions TROUBLE CAUSE REMEDY Engine cranks but doesn t start Engine will not reach full power Engine overheats Blown fuse for the fuel pump Clutch not attached to the fuel line The plug and socket connector on the wiring harness is oxidized Error in the injection system A gear is engaged and the side stand is folded down Air filter fuel filter heavily soiled Error in the injection system The ignition curve for 80 octane is activated Insufficient cooling liquid Radiator fins are extremely dirty Foam forms in cooling system Radiator hose is kinked or damaged Blown fan fuse Replace the FUEL PUMP fuse Connect the clutch to the fuel line Remove the panel and fuel tank clean the plug and socket connector and spray with contact spra
34. NUA JL 990 ADVENTURE 990 ADVENTURE S ART NR 3 211 149 EN INTRODUCTION gt L A a 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 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 KTM may stop manufacturing certain models without previous notice KTM shall not be held liable for any deviations of availability and or ability to deliver illustrations descriptions printing and or other errors The illustrated models partly contain extra equip ment which is not applied to standard models 2006 by KTM SPORTMOTORCYCLE AG Mattighofen AUSTRIA All rights reserved Reprint also in extracts with written allowance of KTM SPORTMOTORCYCLE AG Mattighofen only COMSUMER INFORMATION FOR AUSTRALIA ONLY Tampering with noise control system prohibited Owners are warned th
35. Position the oil return valve 3 mount the screws and tighten to 10 Nm Mount the battery cover and tighten the screws to 25 Nm Mount the lower screw on the right tank and tighten to 25 Nm Attach the left tank to the upper bracket Connect the fuel lines and connector for the fuel pump and the pickup cable fuel level Fasten the tank with 3 screws and tighten the screws to 25 Nm Open both fuel taps and the connecting line A TA AND ENGIN Add 2 5 liters 0 7 USgal of fully synthetic engine oil meeting the JASO MA standard e g Motorex Power Synt 4T and mount the oil dipstick Start the engine allow to run warm for 4 minutes and switch off the engine Remove the oil dipstick and add engine oil up to the MAX mark approx 0 5 liters 0 13 USgal Check the engine and the oil tank for oil leakage Apply Loctite 243 to the thread of the 4 screws mount the underride protection and tighten the screws to 25 Nm CAUTION The screws on the underride protection must be secured with loctite 243 to prevent them from becoming loose Connect the turn signal cable and the tank vent hose and mount the left panel Mount the storage compartment cover V A TA AND ENGIN Activating the ignition curve for low octane fuel If you are traveling to a country where fuel having at least 95 octane RON is not available you can easily activate the corresponding ignition curve A plug and socket connection 1 on a brown black cabl
36. ad Shas aired mob fe seks Sedan Aides 88 CONSERVATION FOR WINTER OPERATION 88 SFORA aa desea ederent ote oe ta ren Pt UR ax dedi in ah aedi died elem eue Hae ies 89 TECHNICAL SPECIFICATIONS CHASSIS 90 TECHNICAL SPECIFICATIONS ENGINE 94 Sine PP HET 95 HEAD WORD INDEX 3 2 dercanaiy at cic dodo c dade eec tn 96 CONSUMER INFORMATION FOR USA ONLY 98 JN Chassis number The chassis number is located on the right side of the steering head tube and on the type label Write this number into the relevant area on page 1 Engine number engine type The engine number and engine type are embossed in the engine case near the shift lever Write this number into the relevant area on page 1 Foe n JN Clutch lever The clutch lever 1 is located on the left side of the handlebar The adjusting screw A is used to change the original position of the clutch lever see maintenance work on chassis and engine The clutch is hydraulically actuated and adjusts itself automatically Hand brake lever The hand brake lever 2 is mounted on the handlebars on the right and actuates the front wheel brake The adjusting screw B can be used to change the basic position of the hand brake lever see Maintenance ES 1 71 71 ws s LL o me DBDBDS Multi functional digital speedometer The universal instrument is divided into 3 parts Use the MODE and SET 1 button to change t
37. ain plug on oil tank M12x1 5 HH collar screw for front ABS sensor 25 Nm 6 Nm Special screw for rear ABS sensor Nut for plug socket Other bolts on chassis Loctite 243 8 Nm 4 Nm Other collar nuts on chassis ENGINE Design 990 LC8 Liquid cooled 2 cylinder 4 stroke engine with 75 V arrangement with balancer shaft and electric starter Displacement Bore Stroke Compression ratio 999 cc 101 62 4 mm 11 5 1 Fuel Valve timing unleaded fuel with at least RON 95 USA Premium PON 91 RON 80 94 for other ignition curve 4 valves controlled over bucket tappet and 2 camshafts camshaft drive with gears chain Valve diameter Intake 38 mm Exhaust 33 mm Valve clearance cold Crankcase bearing Intake 0 10 0 15 mm Exhaust 0 25 0 30 mm Friction bearings 2 main bearings 1 supporting bearing Conrod bearing Piston pin bearing Friction bearing Dual fuel bearing Piston Light alloy forged Piston rings Engine lubrication l 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 Engine oil Quantity of engine oil Primary drive SAE 10W 50 Motorex Power Synt AT approx 3 0 liters during oil filter change straight toothed spur wheels 35 67 Clutch Transmission Multi disc clutch in oil bath 6 speed claw shifted Gear ratio lst gear
38. all frequently used items To open turn the quick release 1 approx 180 in a counterclockwise direction and lift the cover To lock close the cover insert the quick release in the dolly and turn 180 in a clock wise direction Filler caps The 990 Adventure has 2 separate fuel tanks Both filler caps 2 can be locked and are equipped with a tank vent system To open insert the ignition key turn 45 in a clockwise direction and fold up the filler cap The ignition key can be pulled out to open the other filler cap Simply press on the filler cap to close Seat lock The seat is unlocked by inserting the ignition key in the lock 3 on the side and turning the key in a counterclockwise direction See Maintenance Work to remove and remount the seat p g B qu 9 Fuel taps Both fuel taps 1 must be open when the motorcycle is running The level in the fuel tanks is equalized by means of a connecting hose Only close the fuel taps to remove the tanks 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 JN INS IKUMLEN 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 instru
39. all sections are properly roughened Tires will not display their full grip char acteristics until they are properly run in Wheels with a different rim diameter or other rim width may not be mounted oth erwise the vehicle handling will no longer AINIIN D D Jh AR N Observe the traffic regulations drive defensively and trying to look ahead as far as possible so that any hazards can be recognized as early as possible The faster you drive the more sensitive your motorcycle will be to crosswind and changing road conditions Your motorcy cle can easily go out of control at high speeds Choose your driving speed according to the conditions and your driving skills Drive carefully on unknown roads or on unfamiliar trials Renew the vizor on your helmet or the glass of your goggles on time so as to ensure optimum vision in any situation When light shines directly on scratched visor or goggles the operator will be blinded Never leave your motorcycle without super vision if the engine is running MU TUR Never drive faster than 130 kph 80 mph if your motorcycle is loaded with cases or other baggage They will impair the motorcycle s handling at higher speeds and can easily cause it to go out of control If you have cases mounted do not exceed the manufacturer s recommended maxi mum payload Fasten the baggage close to the center of the motorcycle and distribute the weight evenly on the front and rear wheels and on the l
40. at the hand brake lever 53 Adjusting rebound damping of fork 200000 0 42 Adjusting the fork and shock absorber 42 Adjusting the headlight range 2 eee ee ees 68 Adjusting the preload of the shock absorber 46 Adjusting the spring preload on the fork 04 43 PAC SVSLORT sp saris ated Son eran Sew SERRE BERN eS Olea deo as 23 Baggage carrier plate e a a a a A 22 PANGI ae poaae ra aa eb aa co a Moo e o An cn ot oo els 61 Bleeding the cooling system 0 eee ee ees 73 Braking models with ABS antilock brake system 30 Braking models without ABS antilock brake system 30 Breathing the fork legs 2 es 46 Cemer iMd MMERTETSTITTITOETTTTIOTOT erica on vam Shes 19 Chain maintenance Changing the engine oil and the oil filter cleaning the oil screen aunan ee 76 Changing the original position of the clutch lever Charging the battery Chassis NUMDE es cs dme Sep e oe Gt EOD Site Sat aE an oh at ana um Pan 6 Check the following before each start lll 26 Checking of brake fluid level front brake 53 Checking rear brake fluid level leen 54 Checking Spoke tension c ng Ue eed wal wr Wain Sie Ca 60 HEAD WORD INDEX gt I 96 Checking the chain for wear leen 49 Checking the chain tension llle 47 Checking the cooling liquid level in the co
41. at the law may prohibit a The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorpo rated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use and b the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person In accordance with the international quality management ISO 9001 standard KTM uses quality assurance processes that lead to the highest possible product quality INTENDED PURPOSE The KTM 990 Adventure is designed to resist the usual wear and tear of normal use on roads and easy terrain unpaved roads OWNER S MANUAL Carefully read the entire Owner s Manual before you start riding your motorcycle even if this will take a little time It contains use ful tips and information on the best way to handle the motorcycle and how to protect yourself from injuries The Manual also con tains important information on service and maintenance In your own interest pay particular attention to the information marked as follows ADT i C Ignoring these instructions can endanger your body and Ignoring these instructions could cause damage to parts your life of your motorcycle or that the motor cycle is not road safe anymore The Owner s Manual corresponded to the latest information available for this mod
42. ckly which saves money 1000 km or or once a year every 2 years Check actuating cables for damage smooth operation and kink less arrangement adjust and lubricate Check fluid level of the clutch master cylinder Check air filter renew if necessary clean air filter box Check cables for damage and kink less arrangement Check headlamp adjustment ADD ON PARTS Check electrical system for function low high beams stop light turn indicators headlamp flasher tell tale lamps ABS warning lamp speedometer illumination horn side stand switch clutch switch emergency off switch Make sure all bolts and nuts are tight Check brake fluid level lining thickness and brake discs Change brake fluid 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 the ABS fault memory using the KTM diagnostics tool Check shock absorber and fork for leaks and proper operation Clean fork dust sleeves 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 shock absorber 1st Service 990 ADVENTURE 2007 after A clean motorcycle can be checked more quickly which saves money 1000 km Check spoke tension and rim joint Check tire condition and inflation pressure every 750
43. contact a ktm workshop Maximum period for continuous starting 5 seconds Wait at least 5 seconds before try ing 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 Co os Jn NG INSIR JN IF THE ENGINE IS DOES NOT CRANK WHEN YOU ACTUATE THE STARTER TIP SWITCH whether you accelerated while starting the transmission is switched to idle Check if the emergency OFF switch is on Check if the ignition is on the headlight is on the light is switched off when actuating the starter button f this is not the case the battery is dis charged fthe lights are on proceed as described in the Trouble shooting section or contact a KTM dealer IF THE ENGINE CRANKS BUT DOES NOT START WHEN YOU ACTUATE THE STARTER TIP SWITCH whether you accelerated while starting whether the Fl indicator lamp is blinking if yes check Troubleshooting Blink codes table Check if sufficient fuel is in the tank f 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 NOTE This motorcycle is equipped with a safety start ing system The engine can only be sta
44. ctions n Center stand The bike is equipped with a side stand and a center stand 2 Foot brake pedal The foot brake pedal 3 is located in front of the right footrest Its basic position can be adjusted to your seat position see maintenance work ye gt g 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 under the cap 1 on the lower end of the fork legs More information is provided in the chapter Adjusting the fork and shock absorber Rebound damping of fork The fork s damping action during rebound travel rebound damping can also be adjusted This allows you adjust the damping behavior to match your driving style and the payload The adjusting screws 3 are located on the upper end of the fork legs More information is provided in the chapter Adjusting the fork and shock absorber Spring preload of the fork The fork s preload can be adjusted by means of the adjusting screws 4 More information is provided in the chapter Adjusting the fork and shock absorber Foe n Damping action during compression of shock absorher 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 st
45. cycle and remove Slightly depress the bulb turn it approx 30 counterclockwise and pull it out of the socket To mount the lamp reverse the worksteps indicated above VAIN NAN NURA UN CNOA AND ENGIN i 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 lt 41 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 CAUTION The temperature indicator 2 will begin to blink and the red cooling liquid temperature warn ing lamp 3 will light up when the cooling liquid reaches approx 120 C 248 F having exceeded the normal operating temperature Possible causes Slow riding with large loads at a higher air temperature If possible increase your running speed so that more air can blow through the radiators
46. diately 990 ADVENTURE 2007 A clean motorcycle can be checked more quickly which saves money FUEL INJECTION Change engine oil and oil filter Clean oil screens of engine and oil tank 1st Service after 1000 km every 7500 km or once a year every 15000 km or every 2 years Clean magnetic drain plugs of engine and oil tank Check oil lines for damage and kink less arrangement Renew spark plugs Check and adjust valve clearance 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 Clean the oil jet for the clutch lubrication Check rubber boots for cracks or leaks Check fault memory with the KTM diagnosis tool Perform a status check of neutral clutch 2nd 3rd gear and side stand switch using the KTM diagnosis tool Make sure the fuel hose hoses on the vacuum sensors SAS hoses and vent hoses are run correctly and check for damage 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 ADD ON PARTS Check cooling system for leaks and antifreeze protection Check radiator fan for proper operation Check exhaust system for leaks and correct fitment 1st Service every every 990 ADVENTURE 2007 after 7500 km 15000 km A clean motorcycle can be checked more qui
47. e Motorex DOT 5 1 brake fluid when you refill or change the brake fluid DOT 5 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 Brake fluid DOT 5 1 is a poly ethylene glycol based fluid amber colored and can be mixed with DOT 4 brake fluid Do not in any event use DOT 5 brake fluid It is based on silicone oil and is dyed purple KTM motorcycle gaskets and brake hoses are not designed for DOT 5 brake fluid Brake fluid is exposed to a high thermal load and absorbs moisture from the air which low ers the boiling point The brake fluid should therefore be changed at the prescribed intervals AN WARNING eee 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 1 with the brake pads The brake disk should not be thinner than 4 5 mm 0 18 in at the weakest point A Check the wear at several points WARNING OOOO Brake disks that are less than 4 5 mm 0 18 in thick are a safety hazard Have worn brake disks replaced immediately TA AND ENGIN ABS ANTILOCK BRAKE SYSTEM 990 ADVENTURE The ABS is a safety system that prevents the wheels from locking when driving straight ahead without the influence of lateral forces The ABS unit 1 consisting of a hydraulic unit an electronic control un
48. e charging device with the positive terminal post at screw 3 and the negative terminal post at screw 4 Charge the battery as specified in the following table Do not exceed the amperage and charging times Quick charges with high amperages will have an adverse effect on the battery s service life BATTERY CHARGE normal 1 1 amperes 5 max 10 hrs max 14 4 volts quick 5 5 amperes max 1 hr max 14 4 volts To charge the battery while mounted always use the KTM battery charger Item no 58429074000 to ensure that the electric system is not damaged by excess voltage Always remove the battery if using other battery chargers You can also use this charging device to test the off load voltage and startability of the battery and generator It is impossible to over charge the battery with this device 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 CAUTION Do not remove the locking strip otherwise the battery will be damaged 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 discon nect the battery Provide adequate ventilation when charging the battery in a clo
49. e is located near the upper shock absorber holder If the two connectors are connected to each other the ignition curve for fuel having at least 95 octane RON is activated If you disconnect the plug and socket connection the ignition curve for fuel having 80 94 octane RON is activated Although this causes the engine to lose some of its power out put it prevents poor glow ignitions and engine damage CAUTION If fuel having at least RON 95 USA Premium PON 91 is not available the ignition curve for 80 94 octane RON must be activated to prevent engine damage TROUBLE SHOOTING gt 1 7g 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 Discharged battery Blown fuse IGNITION Main fuse is blown Defect ignition lock or emergency OFF switch Defect safe starting system Turn on the ignition switch the gear to neutral and switch the emergency OFF switch on do not accelerate while starting the engine Recharge the battery and investigate the causes for discharg ing contact an authorized KTM workshop Replace fuse IG
50. e motor cycle and always use ORIGINAL KTM AINIIN Jn ARIIN SPARE PARTS Spare parts from other manufacturers can impair the safety of the motorcycle 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 Pay attention to running in procedure Running in the LC8 engine Even finely machined surfaces of engine parts have rougher surfaces than parts that slide on each other for a long time Therefore every engine must be run in For this reason do not demand maximum performance from the engine for the first 1000 kilometers 620 miles The vehicle must be run in at low changing performance level for the first 1000 km 620 miles The maximum number of revolutions per minute must not go exceed 6500 rpm Once you have run your engine in for 1000 km you may push it to its 9500 rpm limit i e up to the black zone indicated in the tachometer Exceeding the above listed rotations as well as pushing high rpm when the engine is cold will have an adverse effect on the
51. ect 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 l FUEL Check the fuel quantity in the tanks 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 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 CABLES Check sm
52. eft and right Baggage must be securely and adequately fastenend loose baggage will significantly impair driving safety A high payload will change the motorcy cle s handling and considerably increase the braking distance adapt your driving speed accordingly Never exceed the maximum permissible laden weight and the axle weights The maximum permissible laden weight is made up of the following components Accessories and payload Motorcycle ready for operation and tank Accessory parts and baggage can signifi full cantly decrease a motorcycle s driving stabil Luggage ity Please observe the following warnings Driver and passenger with protective clothing and helmet 7N WARNING RN Never drive faster than 130 kph 80 mph be safe For models equipped with ABS antilock brake system the ABS func tion is no longer guaranteed Models with ABS The ABS is designed to be used with the tires authorized by KTM and works best with these tires The ABS function cannot be guaranteed if other tires are used Models with ABS an incorrect tire pres sure will have an adverse effect on the ABS control and driving stability and will increase the stopping distance if you have mounted accessory parts on your motorcycle Accessory parts can sig nificantly impair the motorcycle s han dling especially in the maximum speed range Check the following before each start When you start the motorcycle must be in perf
53. el series at the time it was printed Minor devia tions resulting from enhancements to the motorcycle design cannot be entirely precluded The Owner s Manual is an integral part of the motorcycle and must be handed over to the new owner when the motorcycle is sold SERVICE Observance of the service maintenance and operating instructions for the engine and chassis specified in the Owner s Manual is a prerequisite for faultless operation and the avoidance of premature wear Please observe the prescribed breaking in periods inspec tion intervals and service intervals Strict observance will significantly prolong the service life of your motorcycle Use of the motorcycle under extreme conditions e g on extremely muddy and wet terrain can lead to higher than average wear on components such as the drive train or the brakes In this case it may become necessary to service or replace wear parts before the service limit specified in the maintenance schedule has been reached WARRANTY The service work specified in the Lubrication and Maintenance Schedule must be performed by an authorized KTM workshop This is the only place that has the qualified technicians and the special tools required for the 990 Adventure Be sure to have the workshop verify all service work carried out in the service manual to avoid losing your right to claim under the warranty The warranty or guarantee shall become void for damage and consequential damage caused by manipulatio
54. er hand can result in the chain jumping off the chain wheels If this happens the chain could also block the rear wheel or damage the engine In either case the operator is likely to lose control of the motorcycle VAIN NAN NURA UN CNOA AND ENGIN Ag Correct chain tension Loosen collar nut 1 loosen counter nuts 2 and turn right and left adjusting screws 3 va equally far Tighten counter nuts 2 Before tightening the wheel spindle verify that the chain adjusters 4 are sitting close to the adjusting screws and that the rear wheel has been aligned with the front wheel Tighten collar nut 1 with 90 Nm ZN WARNING ere If you don t happen to have a torque wrench at hand make sure you have the tightening torque corrected by a KTM dealer as soon as possible A loose axle may lead to an unstable driving behavior of your motorcycle VAIN NAN NURA UN CNOA AND ENGIN AG Chain maintenance Maintenance of the X ring chain is reduced to a minimum Rinse off any heavy dirt with plenty of water Residual used grease must be removed prior to lubrication Motorex Chain Clean 611 After drying use a chain spray specially designed for X ring chains Motorex Chainlube 622 A 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 motor cycle could easily get out of control The chain does not have a chain
55. esult ZN WARNING Models with ABS an incorrect tire pressure will have an adverse effect on the ABS con trol and driving stability and will increase the stopping distance New wheels have a smooth surface which means that they must be run in to achieve full grip For this purpose ride the motorcycle carefully at moderate speed during the first 200 kilometers 125 miles with new tires tilting the vehicle at different angles so that all sections are properly roughened Tires will not display their full grip character istics until they are properly run in For reasons of safety it is recommended to exchange the valve insert whenever a new tire is mounted Checking spoke tension The correct spoke tension is very important for the stability of the wheels and thus for rid ing safety A loose spoke causes the wheel to become unbalanced and before long other spokes will have come loose Check spoke tension especially on a new motorcycle in reg ular intervals For checking tap on each spoke with the blade of a screw driver see illus tration A clear tone must be the result Dull tones indicate loose spokes If necessary have the spokes retightened and the wheel centered by a KTM dealer TN WARNING Oe If you continue to drive with loose spokes the spokes can tear and lead to an instable handling performance Torn spokes can damage the air hose The loss of air can easily cause the motorcycle to go out of control
56. f after the warranty period has expired The war ranty will become void if you change the oil yourself during the warranty period NOTE The LC8 engine has a dry sump lubrication system The engine oil is pumped from the oil sump in the engine case to the oil tank The engine oil must also be drained from the oil tank during an oil change Since many parts must be demounted for an oil change we recommend having the engine oil changed by an authorized KTM workshop During the guaranty period the oil change must be performed by an authorized KTM mechanic Otherwise the guarantee will become void The engine oil change is to be carried out when the engine is still warm Y WARNING eee An engine having been run warm and the engine oil in it is very hot do not burn yourself Place the motorcycle on a level surface Remove the 4 screws take off the underride pro tection and place a receptacle for the used oil under the engine Remove the oil drain plug 1 take off the cap 2 and pull the oil sieve out of the engine case with a pair of pliers Remove the oil filter cover 3 and pull the oil filter out of the engine case with circlip pli ers upside down TA AND ENGIN Remove the 6 screws and the cover 4 Remove the 5 screws take off the left panel 5 and disconnect the turn signal cable Close both fuel taps 6 on the connecting line VAIN NAN NURA UN CONA AND ENGIN y Remove the 3 screws 1 lift the tank approx
57. g lamp lights up when the coolant temperature has reached 120 c 248 F possible causes for the increase in tem perature low driving velocity and high load sit uation in high air temperatures level of coolant in the system is insuf ficient fan at radiator is not running improper use of the clutch while driv ing at low velocities Let the engine cool down Meanwhile check whether any cooling liquid is leak ing out of the motorcycle Check the cool ing liquid level in the radiator not only in the compensating tank CAUTION SCALDING HAZARD Do not drive on until there is sufficient liquid in the col ing system n the event that while riding on your motorcycle you notice any unusual oper ation related noise stop immediately turn the engine off and contact an author ized KTM dealer Braking models without ABS antilock brake system 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 Braking models with ABS antilock brake sy
58. ght up when the cooling liquid has reached a tempera ture of approx 120 C 248 F The orange warning light 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 Trouble shoot ing Foe n JN ABS warning lamp models with ABS antilock brake system The ABS warning lamp 1 must light up when the ignition is switched on and go out at a speed of approx 5 KPH after you drive off If it stays on or lights up while driving the ABS Is defective The ABS is no longer active and the wheels can lock when braking NOTE The brake system will still function but ABS control will no longer be active Continue to drive carefully and have the ABS checked at an authorized KTM workshop NOTE The ABS warning lamp can also light up if there is a large deviation between the speed of the front and rear wheel in extreme driving situations e g during a wheelie
59. h Steering head angle 63 4 Wheel base 1570 mm 61 8 in Seat height unloaded ADVENTURE 860 mm 33 8 in ADVENTURE S 915 mm 36 in Ground clearance unloaded ADVENTURE 261 mm 10 3 in ADVENTURE S 316 mm 12 4 in Dry weight ADVENTURE 209 kg 461 Ibs ADVENTURE S 207 kg 457 Ibs Max axle load rear 250 kg 552 Ibs BASIC SETTING SHOCK ABSORBER 990 ADVENTURE S BASIC SETTING SHOCK ABSORBER 990 ADVENTURE BASIC SETTING FORK 990 ADVENTURE 990 ADVENTURE S Driving Sport Volle Nutzlast T9 Basic Setting ci Driving Sport Driving Sport Compression adjuster Low Speed clicks Compression adjuster Low Speed clicks m 3 Driving Comfort Basic Setting m N Driving Comfort t Maximum Payload S Driving Comfort Basic Setting Maximum Payload Compression adjuster clicks Compression adjuster High Speed turns Compression adjuster High Speed turns Rebound adjuster clicks 23 Rebound adjuster clicks Rebound adjuster clicks Spring preload turns 5 Spring preload turns Spring preload turns TIGHTENING TORQUES CHASSIS HH clamp bolts on top triple clamp M8 20 Nm HH clamp bolts for steering stem M8 20 Nm AH bolt for handlebar mount M10 20 Nm Collar bolts for handlebar clamps M8 20 Nm HH clamp bolts on fork leg axle passages M8 Collar screw on front wheel spindle M24x1 5 Collar nut wheel spindle rear M
60. he display and the basic settings in the display Display 2 shows all of the information that may be of interest to you 5 display modes can be selected with the MODE button The indicator lamps 3 provide additional information on the motorcycle s running condition Display TEST When you switch on the ignition all of the display elements will light up for 1 second for the function test WS wheel size The display will change and show the diameter of the front wheel in inches for 1 second WS wheel size Then the CLOCK mode will be displayed or the mode that was active when the ignition was switched off pomum 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 Im 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 y TRIP 1 The TRIP 1 mode shows the speed the temperature of the cooling liquid and the trip odo meter 1 To switch to the next display mode press the MODE button T 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 eec 0 0 00000000009 ee ee ppp pp yar TRIP F
61. he owner may become subject to penal ties under state and local ordinances CONSUMER RIGHTS Limited Warranty claims should be directed to an authorized KTM dealer If you are not satisfied please contact KTM North America Inc Customer Relations 1119 Milan Avenue Amherst Ohio 44001 Your rights may vary please refer to the applicable state laws o KTM Group Partner 10 2006 FOTO MITTERBAUER
62. icks that cor responds to the respective type of shock absorber 990 Adventure 15 clicks 990 AdventureS 15 clicks AN WARNING OOOO The damping unit of the shock absorber is filled with high compression nitrogen Never try to take the shock absorber apart or to do any maintenance work yourself Severe injuries could be the result Never unscrew the black screw connection 5 15mm TA AND ENGIN 4 Adjusting the preload of the shock absorber The baggage and passenger put the main load on the shock absorber To guarantee maxi mum handling performance the preload of the shock absorber must be adapted to the load The preload is hydraulically adjusted by turning the hand wheel 1 Turning in a clockwise direction will increase the preload turning in a counterclockwise direction will reduce the preload Our pragmatical values are provided in the table Basic settings for the shock absorber to help you to make the necessary adjustments STANDARD ADJUSTMENT Turn the hand wheel in a counterclockwise direction up to the stop Turn the hand wheel 6 turns in a clockwise direction Breathing the fork legs Breath the fork legs regularly see Maintenance Schedule To breath place the motorcycle on the side stand and briefly remove the bleeder screws 2 to allow any overpressure to escape from the fork CAUTION Excessive pressure in the interior of the fork can cause leaks in the fork If your fork is leak
63. ight up during this time and the engine cannot be started NOTE FOR MODELS WITH ABS The ABS warning lamp 5 must light up when the ignition is switched on Switch transmission to idle green indicator lamp N 3 lights up Do not accelerate operate starter button 6 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 6 The oil pressure warning lamp 4 should go out as soon as the engine is running 7 Take the motorcycle off of the main stand or side stand NN WARNING OOOO Do not start the engine and allow it to idle in a closed room Exhaust fumes are poison ous and can cause loss of consciousness and death Always provide adequate ventila tion 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 caseand the motorcy cle will no longer be roadworthy CAUTION If you accelerate while starting the engine management will not inject any fuel and the engine will not start Do not accelerate while starting If the oil pressure warning lamp does not go out as soon as the engine is running imme diately 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
64. ing it is recommended to open the breather plugs before having the seals replaced TA AND ENGIN Cleaning the dust sleeves of the telescopic fork The dust protection bellows 3 are to remove dust and coarse dirt particles from the fork tube However after some time dirt may also get in behind the dust protection bellows If this dirt is not removed the oil sealing rings located behind it may start to leak Use a screwdriver to lever the dust protection bellows out of the outer tubes and slide them downward Clean dust protection bellows outer tubes and fork tubes thoroughly and oil them thor oughly with Universal oil spray Motorex Joker 440 or engine oil Then push dust protec tion bellows into the outer tubes by hand Y WARNING OOOO No oil may reach the front tire or the brake disks since this would considerably reduce the tire s road grip and the braking effect of the front brake Checking the chain tension Place the motorcycle on the side stand and switch the transmission to idle Press the chain upwards under the lower chainguard screw 4 The difference to the sagging chain should be 35 40 mm 1 37 1 57 in TN WARNING Oe 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 oth
65. ing in a clockwise direction will increase the damping turning counterclockwise will decrease the damping STANDARD ADJUSTMENT LOW SPEED turn the adjusting screw 1 to the limit in a clockwise direction using a screwdriver unscrew the respective number of clicks for the specific type of shock absorber in a coun terclockwise direction 990 Adventure 20 clicks 990 AdventureS 20 clicks A TA AND ENGIN STANDARD ADJUSTMENT HIGH SPEED Turn the adjusting screw in a clockwise direction up to the stop with a socket wrench wrench size 17 mm Turn the adjusting screw in a counterclockwise direction the number of turns specified for the respective type of shock absorber 990 Adventure 1 5 turns 990 Adventure S 1 5 turns Y WARNING EORR The damping unit of the shock absorber is filled with high compression nitrogen Never try to take the shock absorber apart or to do anymaintenance work yourself Severe injuries could be the result Never unscrew the black screw connection 24mm Rebound damping of shock absorher By using the adjusting screw 4 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 the adjusting screw clockwise to the stop then turn the adjusting screw counterclockwise counting the number of cl
66. ing off Shifting Riding Braking models without ABS antilock brake system Braking models with ABS antilock brake system Switching off the ABS Stopping and parking Fuel PERIODIC MAINTENANCE SCHEDULE MAINTENANCE WORK ON CHASSIS AND ENGINE Removing and remounting the seat Tool set Adjusting the fork and shock absorber Adjusting compression damping of fork Adjusting rebound damping of fork INDEX 4 Adjusting the spring preload on the fork 43 Compression damping of shock absorber 44 Rebound damping of shock absorber 45 Adjusting the preload of the shock absorber 46 Breathing the fork legs ees 46 Cleaning the dust sleeves of the telescopic fork 47 Checking the chain tension 0 00 cee eee ee ees 47 Correct chain tension 2 s scans est oso im he ecd o mr Bae rt tie se oe 48 Chain maintenance acu acea Reed ROSSO RD ROS RN OA SUR 49 Checking the chain for wear 0 00 cee eee eee 49 General informations about KTM disc brakes 50 Adjusting of free travel at the hand brake lever 53 Checking of brake fluid level front brake 53 Checking the front brake pads ees 53 Checking rear brake fluid level llle 54 Checking the rear brake pads llle 54 Dismounting and mounting the front wheel 56 Dismounting and mounting
67. inted parts with a mild paint care product JN XVAILIUN FUR WIN X UPERALIUN 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 ZS mDMNMN Keep anti corrosion agent from getting into contact with the brake discs for otherwise this will significantly reduce the braking power CAUTION After rides on salted roads clean motorcycle thoroughly with cold water and let it dry well STORAGE gt s 88 Should you desire to make a pause over a longer space of time please observe the following instructions Drive the tanks empty to be able to fill up with fresh fuel when starting the motorcycle up again Clean motorcycle thoroughly see chapter CLEANING Change engine oil and oil filter old engine oil contains aggressive contaminations Check antifreezer and amount of cooling liquid Correct tire pressure Disassemble and charge battery see chapter BATTERY Jack up the motorcycle if possible so the wheels do not touch the ground The storage place should be dry and not subject to excessive temperature fluctuations Cover the motorcycle with an air permeated tarpaulin
68. it and the electric pump motor is located under the seat Sensors 2 on the front and rear wheel send pulses to the control unit to indicate how fast the wheel is turning The KTM 990 Adventure ABS operates with two independent brake circuits front and rear wheel brake During normal service the brake system works just like a conventional brake without the ABS The ABS control phase sets in when the control unit detects that one of the wheels is starting to lock It releases the pressure in the respective brake circuit and prevents the wheel from locking You can feel the control function as a slight pulsing in the brake lever The ABS warning lamp 3 must light up when the ignition is switched on and go out at a speed of approx 5 KPH after you drive off If it stays on or lights up while driving the ABS is defective see Troubleshooting The ABS can be switched off with the ABS button 4 see Driving Instructions ZN WARNING Do not mount wheels with a different rim diameter The ABS function can no longer be guaranteed Do not carry out any chassis modifications that extend or shorten the spring travel oth erwise the proper functioning of the ABS cannot be warranted The ABS is designed to be used with the tires authorized by KTM and works best with these tires The ABS function cannot be guaranteed if other tires are used Maximum ABS control can no longer be guaranteed if the tire pressure is inco
69. ly Loctite 243 screw retainer to the thread mount the screw and tighten to 8 Nm Set the motorcycle on the center stand to keep the rear wheel from touching the ground Unscrew the collar nut 1 remove the chain tensioner 2 hold on to the rear wheel while you pull out the axle passage 3 Push the rear wheel as far to the front as possible take the chain off of the rear sprocket and lay it on the rear sprocket guard Carefully lift the rear wheel out of the swing arm CAUTION Do not operate the rear brake when the rear wheel has been dismounted When you lay the wheel down make sure the brake disk and for models with ABS the ABS sensor wheel are not 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 Models with ABS when you dismount and mount the rear wheel make sure that you do not damage the ABS sensor 6 and do not bend the ABS sensor wheel Before remounting the rear wheel clean and grease the bearing surface of the bushings 4 and the shaft seal ring 5 The rear wheel is remounted in reverse order Pay attention to the same mounting position of the axle passage and the chain tensioner and make sure the noses A point to the front Before tightening the collar nut to 90 Nm push the rear wheel forwards so that the chain tensioners lie on the tension screws AN
70. motorcycle is equipped with sintered brake pads in the front and rear and homologated accordingly They guarantee maximum braking performance Front brake pads Toshiba TT 2172 HH Rear brake pads Toshiba TT 2701 HH NN WARNING eee 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 dif ferent brake pads than those provided with the original equipment it cannot be war ranted 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 war ranty will be void Models with ABS antilock brake system The ABS is designed to be used with the orig inal brake pads The ABS function cannot be guaranteed if other brake pads are used 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 BRAKE FLUID We recommend that you us
71. mpensating tank 71 Checking the cooling liquid level in the radiator 2 Checking the engine oil level eene 75 Checking the front brake pads llle 53 Checking the oil level of the hydraulic clutch 74 Checking the rear brake pads eee eee eee 54 SCIT a a ae aele a a Se BORG dad OA one ds Rasa 88 Cleaning the dust sleeves of the telescopic fork 47 eredi tale tie ote ase cenatire PG E ice sa ie a inbrat bie Gata 7 Combination switch asana aaa atin epa rn de td cras 16 Compression damping of fork 000 eee eee eee 20 Compression damping of shock absorber 44 Conservation for winter operation 0 00 e eee e eee 88 Consumer information for USA only 000 0 es 98 Cooling liquid temperature display s 12 Coone SVSEOETTE ia So Sinn uscito aps tc Ue op th ae duod api edo oon ae Seo ties 70 Correct chain TENSION 2 23 oce ard da Re ce Eo calce ee RAS e 48 Damping action during compression of shock absorber 21 Demounting and mounting the battery 62 Dismounting and mounting the front wheel 56 Dismounting and mounting the rear wheel 58 DIDIT aeania e aR AE I aA A da aAa Aa ra Tr 8 Driving MStruUCtONS aise amea dicas oe Suk a Benge dl a ee 26 Emergency OFF tip switch starter tip switch 16 Engine number engine type 00 eee eee eee 6 Zune
72. ndicates which component is affected by an error This allows the error to be identified if no diagnosis tool is available The rhythm of the blinking lamp will let you determine the two digit blink code e g Blink code 34 FI blinks 3x long 4x short pause Blink code O6 FI blinks 6x short pause BLINK CODE SIGNAL COMPONENT ERROR DESCRIPTION ENGINE Malfunction Stalls Output signal too low high Continues to run Output signal too low high Continues to run O O O O l 2 Pulse generator 6 Throttle sensor Sensor for 2nd throttle valve 9 1 Intake manifold air pressure for sensor rear cylinder Intake manifold air pressure sensor for front cylinder Output signal too low high Continues to run Output signal too low high Continues to run The blink code indicates which component is affected by an error This allows the error to be identified if no diagnosis tool is available BLINK CODE SIGNAL COMPONENT ERROR DESCRIPTION ENGINE Coolant temperature sensor Output signal too low high Continues to run 13 Air temperature sensor Output signal too low high Continues to run 14 Ambient air pressure sensor Output signal too low high Continues to run Tilt angle sensor Output signal too low high Lambda probe for rear cylinder Malfunction Lambda probe for front cylinder Malfunction Continues to run Control unit voltage supply Malfunction Side stand switch Short circuit to ground Contin
73. ne is hot use a rag to cover the cap and open slowly to release pres sure Carefully remove the radiator cap 2 with a rag turning in a counterclockwise direction 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 may leak Have the cooling system checked by an authorized KTM workshop CAUTION If more than 1 liter 0 26 USgal of cooling liquid needs to be added the cooling system must be bled TA AND ENUIM Bleeding the cooling system Remove the 5 screws and the left cover 3 disconnect the flasher cable and tank ventilation Remove the bleeder screw 4 on the left side of the radiator To be able to completely bleed the cooling system raise the motorcycle approx 5O cm in the front Add cooling liquid until it runs out of the discharge opening without bubbles and immedi ately mount the screw to prevent more air from getting into the radiator Completely fill the radiator with cooling liquid Connect the flasher cable and tank ventilation Mount the cover Take a short ride and check the cooling liquid level again A TA AND ENGIN Changing the original position of the clutch lever The adjusting screw 1 can be used for individual adjustment of the original position of the clutch lever thus allowing adjustment to an optimal position for every hand size Turning the adjusting screw counterclockwise reduces
74. ns or conversions to the motorcycle AUTOMOTIVE FLUIDS The fuels lubricants and liquids specified in the Owner s Manual or automotive fluids with equivalent specifications must be used in accordance with the maintenance schedule SPARE PARTS ACCESSORIES For your own safety only use spare parts and accessories approved by KTM KTM shall not assume any liability for other products or consequential damage resulting from the use of such products ENVIRONMENT 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 Enjoy driving your motorcycle KTM SPORTMOTORCYCLE AG 5230 MATTIGHOFEN AUSTRIA INTRODUCTION soir aca doc Kon etd ctn BR 29 0 900 8 Er cone we et l IMPORTANT INFORMATION 5 5 2 ttr i dct SC Ca 2 SERIAL NUMBER LOCATIONS lesser IR 6 Chassis NUMDET aara TITSTTETOTTCRITI OTT T 6 Engine number engine type eee ee ee 6 OPERATION INSTRUMENTS 3 ut unload oder ta aire 2a ane tance 9s 7 Crate MEVE aa Eoaea a a ec aries a ee ete 7 Hand brake lever ce ee ee Multi functional digital speedometer
75. o the connector support to check all of the bulbs for proper func tioning before you remount the headlight VAIN NAN NUR TA AND ENGIN 5g 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 TO CHECK Make a mark on a light wall behind a level surface at a height of 830 mm 32 7 in 990 Adventure S or 790 mm 31 1 in 990 Adventure respectively Position your motorcycle loaded ready for the trip baggage driver passenger 10 meters away from the wall and switch on the low beam The light dark cut off line should be at the mark Replacing the brake and tail light bulbs Remove the hexagon nuts 2 on the bottom of the fender and pull the tail light off towards the rear BRAKE LIGHT BULB Turn the lamp socket 3 approximately 30 counterclockwise and pull it out of the tail light housing 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 TAIL LIGHT BULBS Pull the socket 4 out of the housing and pull the bulb out of the socket V A TA AND ENGIN 59 Replacing the flasher bulbs Remove the screw on the back of the turn signal carefully fold the lens 5 towards the motor
76. of the motorcycle only If you are sitting on the motorbike and thus apply an additional load onto the side stand you may cause damage to the side stand or the engine case and your motorbike may fall over NOTE REGARDING THE CENTER STAND We advise the following procedure to place the motorcycle on the center stand as effortlessly as possible a press main stand to ground using foot b put your weight on the stand stabilizer and pull the motorcycle back by the footrest sup port see illustration Make sure that the ground is solid and that your motorcycle is standing securely CAUTION The center stand is designed to hold the weight of the motorcycle only By sitting on the motorcycle you will put additional weight on the center stand possibly causing the cen ter stand or frame to be damaged or the motorcycle to fall down Do NOT pull the motorcycle back on the center stand by holding the hand wheel 2 on the shock absorber adjustment it could cause the shock absorber to leak but use the footrest bracket 1 Fuel In the condition at delivery the LC8 engine requires unleaded fuel with at least RON 95 USA Premium PON 91 If using lower octane fuel it is easy to change over to the pre programmed ignition curve for 80 94 octane RON see activating the ignition curve for low octane fuel After refueling it will take approx 8 minutes for the fuel warning lamp to switch off and for TRIP F to automatically
77. omponents of the brake pad will rub against the brake disc imparing the braking effect and destroying the brake disc VAIN NAN NURA UN CNOA AND ENGIN B Dismounting and mounting the front wheel Jack the motorcycle up at the underride protection until the front wheel no longer touches the ground Loosen the collar screw 1 and the clamp screws 2 at both fork leg axle passages Unscrew the collar screw approx 8 turns pressing your hand against the collar screw to push the axle passage out of the fork leg and remove the collar screw Hold the front wheel and pull out the axle passage Slightly pull one brake caliper out and take the front wheel off the fork Take the left 3 and right distance bushing out of the shaft seal rings Do not operate the hand brake when the front wheel has been dismounted When you lay the wheel down make sure the brake disks and for models with ABS the ABS sensor wheel are not damaged Models with ABS when you dismount and mount the front wheel make sure that you do not damage the ABS sensor 5 and do not bend the ABS sensor wheel Before remounting the front wheel clean and grease the shaft seal rings 4 and the bear ing surface A of the distance bushings and mount the distance bushings wide distance bushing in the left shaft seal ring Slightly push back the brake pads with a screwdriver Set up the front wheel facing in the running direction see arrow B on the tire mU V
78. ooth operation of the throttle cables COOLING FLUID Check the level of cooling fluid when the engine is cold ELECTRICAL SYSTEM start the engine and check the headlight taillight brake light turn signal indicator lamps and horn for proper functioning CHECK OIL LEVEL Insufficient oil results in premature wear and consequently to engine damage BAGGAGE PAYLOAD Never exceed the maximum total weight 430 kg 949 Ibs and the motorcycle s wheel loads The maximum total weight is comprised of the motorcycle in a running condition and refueled 232 kg 512 Ibs 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 Y WARNING eee Never drive faster than 130 kph 80 mph if your motorcycle is loaded with cases or other baggage They will impair the motorcycle s handling at higher speeds and can easily cause it to go out of control 10 REAR MIRROR Sit on the motorcycle and check the adjustment of the rear mirror gt d JN Starting the engine 1 Switch on emergency OFF switch 1 2 Switch on ignition turn ignition key 2 into position Q NOTE You will hear the operation of the fuel pump for approx 2 seconds after switch ing on the ignition The FI indicator lamp will also l
79. ops To return the trip meter 1 to zero switch on the ignition change to the TRIP 1 mode and i press the SET button te A 18 Lr of 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 BEM 120 C 248 F t p of approx 40 C 104 F When the upper bar lights up 120 C 248 F all of the bars will HMMM 110 C 230 F 1 EB 100 c 212 F BN 60 C 140 F BMP 50 C 122 F BM 40 C 104 F E me CAUTION Possible causes for an increase in temperature causing the red warning light for the cool ing 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 radiator is not running Improper use of the clutch when driving slowly EBEN 70 C 158 F D start to blink and the red warning lamp 2 will light up eT Indicator lamps Gm D 9 The green indicator lamp will blink in the blinker rhythm when the blinker is switched on NOTE The indicator lamp will blink faster 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 li
80. or blanket Do not use non air permeable materials as a possible humidity might not be able to escape and could cause corrosion CAUTION It would be very bad to let the engine run for a short time during the storage period The engine would not get warmed up enough and the thus developed steam would condense during the combustion process and cause the valves and exhaust to rust RE INITIATION AFTER TIME OF STORAGE Mount the charged battery regard polarity secure the screws on the underride protection with Loctite 243 Fill up tank with fresh fuel Check motorcycle as before each start see driving instructions Take a short careful test ride first NOTE Before you put your motorcycle away for the winter you have to check all parts for their function and wear Should any service jobs repairs or any refitting be necessary you should have them carried out during the off season lower workload at mechanics shops This way you can avoid the long waiting times at your mechanic at the beginning of the next biking season ALINIUA a ALIUNes CNA 90 990 ADVENTURE 990 ADVENTURE S Frame Tubular chrome molybdenum steel space frame Fork WP Up Side Down 4860 MXMA Multiadjuster Wheel travel front ADVENTURE 210 mm 8 3 in ADVENTURE S 265 mm 10 4 in Rear suspension WP Suspension Progressive Damping System shock absorber with hydraulic preload adjuster Wheel travel rear ADVENTURE 210 mm 8 3 in ADVENTURE
81. or if the rear wheel slips when accelerating on loose ground The ABS will no longer be active and the wheels can lock when braking To activate the ABS again stop and switch off the ignition If the warning lamp goes off again at a speed of approx 5 KPH after you drive off the ABS is active and fully operative ABS button models with ABS antilock brake system The ABS button 2 switches off the ABS To switch off the ABS stop the motorcycle and press the ABS button for at least 3 seconds with the engine running Let go of the ABS but ton as soon as the ABS warning lamp starts blinking fast The ABS warning lamp will blink slowly to indicate that the ABS is switched off To switch the ABS on again stop and switch off the ignition The ABS will be active again when you switch on the ignition Foe JN Tachometer The tachometer shows the engine speed in revolutions per minute Do not run the engine beyond the black mark at 9500 rpm The speed limiter will set in at 9600 rpm drastically reducing the engine power above this rotational speed When you switch on the ignition the indicating needle will move to the black mark and back again Ignition lock The ignition lock 1 has 3 switching positions VA Ignition off engine can t be started Ignition on engine can be started Ignition off handlebar blocked To switch the ignition to position amp turn the ignition key to position amp and firmly press it in
82. reset to O and return to the previous display mode NOTE Press the SET key for 2 seconds to immediately turn off the fuel warning lamp CAUTION Useunleaded fuel with at least RON 95 USA z Premium RON 91 If using lower octane fuel the ignition curve must be changed otherwise engine damage will occur This motorcycle is equipped with 2 catalytic converters Leaded fuel will destroy the cat alytic converters Please use unleaded fuel only The 990 Adventure has 2 tanks with 1 filler cap each Both filler caps can be locked and are equipped with a tank vent system To open insert the ignition key turn 45 in a clock Wise direction and fold up the filler cap The ignition key can be pulled out to open the other filler cap Simply press on the filler cap to close Fill the right tank first then the left tank see drawing for the maximum filling level If the right tank is filled up to the filler neck fuel may overflow when the motorcycle is parked on the side stand after refueling when the fuel becomes warm Y WARNING eee Gasoline is highly flammable and poisonous Extreme caution should be used when han dling gasoline Do not refuel the motorcycle near open flames or burning cigarettes Always switch off the engine before refuelling Be careful not to spill gasoline on the engine or exhaust pipe while the engine is hot Wipe up spills promptly If gasoline is swallowed or splashed in the eyes seek a doctor s advice imme
83. rrect VIF min 1mm TA AND ENGIN Adjusting of free travel at the hand brake lever Free travel at the hand brake lever may be readjusted by using adjusting screw 1 In this way the position of the point of pressure i e the resistance you feel on the hand brake lever when the brake pads are pressed against the brake disc can be adjusted for any hand size CAUTION At the hand brake lever free travel must at least be 3 mm 0 12 in Only then may the pis ton 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 of brake fluid level front brake The brake fluid reservoir is linked with the hand brake cylinder at the handlebar and the reservoir is provided with an inspection glass With the reservoir in a horizontal position the brake fluid level should not go below middle of the glass Y WARNING o f 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 Checking the front brake pads The brake pads can be inspected from below The linings must be at least 1 mm 0 04 in thick Y WARNING m At
84. rted 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 pulled The engine will stall if a gear is engaged and the clutch lever is released with the side stand folded down Starting off Pull the clutch lever and engage 1st gear Slowly release the clutch lever while you gen tly accelerate ART MN 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 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 Only accelerate to the extent that road and weather conditions allow Be especially care 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
85. sed 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 Jump starts are not recommended since they can damage the motorcycle s electronic system Main fuse The main fuse protects all of the motorcycle s current consumers The main fuse is located in the starter relay under the right engine cowl Remove the screws 1 and take off the engine cowl 2 AN WARNING eee Do not burn yourself on the hot exhaust pipe Lift the starter relay 3 out of the bracket remove the cap 4 and check the main fuse 5 A spare fuse 6 30 ampere is also plugged into the starter relay Replace a blown fuse only with an equivalent one Visit an authorized KTM workshop if the new fuse blows again CAUTION Under no circumstances Is a stronger fuse allowed to be set in or a fuse allowed to be repaired An inexpert treatment could damage the whole electrical installation ABS fuses models with ABS antilock brake system Two fuses for the ABS are located under the starter relay Remove the caps and check the fuses 7 and 8 Replace blown fuses with the same type of fuse Visit an authorized KTM workshop if the new fuse blows again CAUTION Under no circumstances Is a stronger fuse allowed to be set in or
86. stem Close throttle and apply the hand and foot brakes at the same time The ABS allows you to apply the full braking force during full braking and with poor road grip on sandy wet Jn NG INSIR JN or slippery surfaces without running a risk of having the wheels lock AN WARNING The ABS cannot prevent one or both wheels from losing the road grip if the motorcycle is banked during the braking procedure Although the wheel will not lock the centrifugal force will cause the wheel to lose traction and cause the motorcycle to crash despite the ABS The ABS cannot prevent one or both wheels from losing traction if braking the motorcycle on laterally sloping surfaces Although the wheel will not lock the lat eral force will cause the wheel to lose trac tion and cause the motorcycle to crash despite the ABS The ABS cannot prevent the rear wheel from locking on slippery surfaces due to the engine s braking effect The ABS cannot generally guarantee a shorter stopping distance in every situation Do not try to offset the added safety afforded by the ABS against a risky driv ing style When braking shift to a lower gear in accor dance with the speed Pull the clutch dur ing emergency braking or braking on slippery surfaces 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
87. taining tabs 2 tilt the windshield and headlight forward and pull the connector off the connector support Place the headlight on a soft pad to keep it from lt being damaged CAUTION Never touch the glass of the bulb with your fingers The glass of the bulb must remain absolutely free from grease Heat will otherwise cause the grease to evaporate and settle down on the NS NS reflector HIGH BEAM BULB A AE Remove the rubber cap 3 and pull off the connector 4 Detach the retaining clip and lt 3 remove the bulb Insert a new bulb see Technical specifications Chassis Lighting fit the retaining clip AE gt gt connect the connector and mount the rubber cap LOW BEAM BULB B Remove the rubber cap 5 and pull off the connector 6 Detach the retaining clip and remove the bulb When inserting the new bulb see Technical specifications Chassis Lighting make sure tab D is firmly seated in the socket recess lt p Fit the retaining clip connect the connector to the bulb and mount the rubber cap VAIN NAN NURA UN CONA AND ENGIN PARKING LIGHT BULB C Pull the bulb socket 7 out of the reflector and pull the bulb out of the bulb socket USA design The parking light E is located in the upper part of the headlight in the USA design Bulb F see Technical specifications Chassis Lighting with high and low beams is mounted in the lower part of the headlight Connect the connectors t
88. the time of sale meets all applicable U S EPA Federal noise standards This warranty extends to the first per son who buys this exhaust system for purposes other than resale and to all subsequent buyers Warranty claims should be directed to KTM North America Inc 1119 Milan Avenue Amherst Ohio 44001 Telephone 440 9853553 TAMPERING WARNING TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED FEDERAL LAW PROHIBITS THE FOLLOWING ACTS OR CAUSING THEREOF 1 The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 The use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW 1 Removal of or puncturing the muffler baffles header pipes or any other components which conducts exhaust gases 2 Removalor puncturing of any part of the intake system 3 Lack of proper maintenance 4 Replacing any moving part of the vehicle or parts of the exhaust or intake system with parts other than those specified by the manufacturer WARNING STATEMENT This product should be checked for repair or replacement if the motorcycle noise has increased significantly through use Otherwise t
89. their most worn point brake pad linings should not be thinner than 1 mm otherwise they could lead to brake failure For your own safety don t put off having your brake pads changed CAUTION 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 TA AND ENGIN Checking rear brake fluid level The brake fluid reservoir for the rear disk brake is combined with the foot brake cylinder and has an inspection window The brake fluid level should not drop below the MIN mark when the motorcycle is in a vertical position AN WARNING eee f 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 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 Y WARNING eee At their most worn point brake pad linings should not be thinner than 1 mm otherwise they could lead to brake failure For your own safety don t put off having your brake pads changed CAUTION If the brake pads are replaced too late so that the lining is partly or entirely worn away the steel c
90. tment although adjusting screw 3 will turn at the same time Make the same spring preload adjustments to both fork legs Generally if the preload is higher the rebound damping should also be set higher STANDARD ADJUSTMENT Turn the adjusting screw in a counterclockwise direction up to the stop and then 5 turns in a clockwise direction BASIC SETTING SHOCK ABSORBER 990 ADVENTURE S BASIC SETTING SHOCK ABSORBER 990 ADVENTURE Basic Setting Driving Comfort Basic Setting Driving Sport Maximum Payload N Driving Comfort ci Driving Sport c Maximum Payload N O1 N O rn O1 Compression adjuster Low Speed clicks N o Compression adjuster Low Speed clicks Compression adjuster High Speed turns 2 15 I1 Compression adjuster High Speed turns 2 15 1 Rebound adjuster clicks 20 15 10 10 Rebound adjuster clicks 20 15 10 Spring preload turns 6 6 10 18 Spring preload turns 6 6 10 12 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 EN 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 Turn
91. to the lock Turn the handlebar to the left then turn the ignition key to the left The ignition key can be withdrawn in position amp and f Socket for electric accessories A socket is provided in the cockpit for electric accessories e g GPS roadbook cell phone etc The socket has a 12V voltage and is protected by a 10 A fuse Do not plug power consumers with a higher requirement into this socket CAUTION Remember that electric accessories will run down the battery dD Ld Fe JN IN XU lV i Combination switch The rocker switch LIGHTS 1 actuates the high beam or low beam High beam light Z D Low beam light z D The light signal high beam is actuated with button 2 The indicator switch 3 returns to central position after actuation Press flasher switch towards switch housing to switch off the flasher be The horn is sounded with button 4 Emergency OFF tip switch starter tip switch The emergency off switch 5 is provided for emergency situations and should not be used to switch off the engine The engine is ready for operation in position ignition circuit and starter circuit are switched on The engine cannot be started in position amp ignition circuit and starter circuit are inter rupted G Use the starter tip switch 6 to operate the electric starter Foe n Foe V Storage compartment A storage compartment is located under the seat to hold sm
92. ues to run Injection nozzle for rear cylinder Malfunction Stalls Injection nozzle for front cylinder Malfunction Stalls Ignition coil for rear cylinder Malfunction Stalls Injection coil for front Malfunction Stalls Fuel pump relay Short circuit to ground positive Stalls Lambda probe heater for rear cylinder Short circuit to ground positive Continues to run Lambda probe heater for front cylinder Short circuit to ground positive Continues to run Idle control motor Malfunction Continues to run Purge valve for carbon canister Short circuit to ground positive Continues to run Secondary air valve Short circuit to ground positive or interruption Continues to run EEPROM error Malfunction Continues to run Vacuum hose for front cylinder is defective Malfunction Continues to run Vacuum hose for rear cylinder is defective Malfunction Continues to run Stepper motor for 2nd throttle valve Malfunction Continues to run CLEANING gt 988 Regular cleaning and paintwork care is part of the maintenance work and helps to maintain the value of your motorcycle CAUTION Never clean your motorcycle with a high pressured cleaner or a high pressured water jet The water could otherwise run into the electrical components connectors sheathed cables bearings etc and cause disturbings or lead to a premature destruction of these parts Before you wash
93. y Visit an authorized KTM workshop Switch to neutral gear Have the air filter fuel filter replaced at an authorized KTM workshop Visit an authorized KTM workshop Activate the ignition curve for 95 octane if fuel with at least RON 95 USA Premium PON 91 is being used Refill cooling liquid see maintenace work check cooling sys tem for leaks Clean radiator with water jet Replace cooling liquid use antifreezer with brand name Run the radiator hose correctly or replace Replace fuse FAN TROUBLE CAUSE REMEDY Engine overheats Fl lamp is blinking lights up ABS warning lamp lights up Engine stalls while driving High oil consumption Headlight and position light fail Defect fan or thermoswitch for fan Air in the cooling system Thermostat defective Error in the injection system see blink code Driving situation with extremely dif ferent wheel speeds Fuse is blown ABS sensor is loose or the cable damaged ABS sensor wheel is bent Error in the ABS No fuel Fuse for fuel pump has blown Engine oil level too high Engine oil too thin viscosity Bulb burned out Blown fuse Contact an authorized KTM workshop Bleed the cooling system see Maintenance work Have the thermostat checked opening temperature 75 C 167 F or replaced contact an authorized KTM workshop Visit an authorized KTM workshop Stop switch off the ignition start again Replace the ABS fuses under
94. yle and the payload The damping rate can be adjusted in the low and high speed range Dual Compression Control The designation low and high speed refers to the movement of the shock absorber and not to the motorcycle s driving speed The adjusting screw 1 for the low speed range can be adjusted with a screwdriver The adjusting screw 2 for the high speed range can be adjusted with a 17 mm socket wrench More information is provided in the chapter Adjusting the fork and shock absorber Foe JN 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 Shock absorber s preload adjuster The shock absorber s preload adjuster is infinitely variable by means of the hand wheel 2 This allows the shock absorber to be adapted to match your body weight and the payload The hand wheel can be swung out to make adjustments Baggage carrier plate The base plate for your choice of case system can be attached to the baggage carrier plate 3 7N WARNING Do not load more than 8 kg on the trunk carrier rack Observe the baggage manufacturer s instructions CD Oo p g B qu 9 9 p g

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