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KTM 990 Super DUKE Service Repair Manual 2007

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The KTM 990 Super Duke, produced from 2005 to 2007, represents the first generation of this high-performance naked sportbike. Engineered with a focus on maximizing power-to-weight ratio and rider engagement,...
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KTM 990 Super DUKE Service Repair Manual 2007
The KTM 990 Super Duke, produced from 2005 to 2007, represents the first generation of this high-performance naked sportbike. Engineered with a focus on maximizing power-to-weight ratio and rider engagement, it features a potent LC8 V-twin engine delivering 116 hp and 98 Nm of torque. Its design philosophy emphasizes lightweight construction and agile, track-focused handling, utilizing a chromium-molybdenum steel trellis frame and adjustable WP Suspension components. This motorcycle is renowned for its aggressive styling and potent performance, appealing to enthusiast riders seeking a thrilling and dynamic riding experience. This comprehensive factory service and repair manual provides in-depth information for the KTM 990 Super Duke (2007). It covers all essential aspects of maintenance, repair, and diagnostics, including detailed procedures for the engine, transmission, chassis, brakes, and electrical systems. The manual offers step-by-step instructions for routine maintenance, component disassembly and assembly, rebuilds, and troubleshooting common issues. With factory-level detail, torque specifications, and required diagnostic procedures, this English-language manual is an indispensable resource for owners, mechanics, and technicians to ensure the optimal performance and longevity of their vehicle.
🏷️ Basic Information
Identification
Make:
KTM
Model:
990 Super Duke
Model Year:
2007
Codes
Chassis Code Range:
WP_123_XXXXX to WP_123_XXXXX (Illustrative - requires actual VIN range for specific year/model)
Generation
Generation:
First Generation (2005-2007)
👋 Introduction
Market Position
Segment:
High-performance naked sportbike
Target Audience:
Enthusiast riders seeking aggressive styling, potent performance, and track-day capability
Competitive Analysis
Key Competitors 2007:
Ducati Monster S4R, Triumph Speed Triple, Aprilia Tuono R
Key Features
Engine Configuration:
V-twin, liquid-cooled, DOHC
Chassis Philosophy:
Lightweight, agile, track-focused handling
Design Intent:
Maximizing power-to-weight ratio and rider engagement
📋 Manual Details
Coverage Areas
Covered Regions:
Global (assuming standard factory manual)
Page Count
Page Count Estimated:
500+
Manual Type
Manual Type:
Factory Service & Repair Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Engine:
Full engine mechanical, lubrication, cooling, fuel injection (EFI), ignition, emission control systems
Transmission:
Clutch, gearbox (6-speed sequential), shifting mechanism, internal components
Chassis Suspension:
Front fork (WP Suspension), rear monoshock (WP Suspension), linkage system, swingarm, bearings
Brakes:
Front dual disc, rear single disc, hydraulic system, ABS (if equipped), caliper and master cylinder service
Electrical:
Wiring diagrams, battery, starter motor, alternator, lighting system, instrumentation, ECU, sensors
Fuel System:
Fuel tank, fuel pump, injectors, pressure regulator, fuel lines
Exhaust System:
Exhaust headers, catalytic converter (if equipped), mufflers
Bodywork Frame:
Frame construction, fairings, seat, body panels, fasteners, mounting points
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, chain adjustment, brake bleeding, spark plug replacement, valve clearance checks
Troubleshooting:
Diagnostic charts, common fault identification, solutions for electrical and mechanical issues
Disassembly Assembly:
Step-by-step instructions for major component removal and installation (engine, transmission, suspension)
Rebuilds:
Detailed procedures for engine overhaul, gearbox repair, suspension component servicing
Electrical Diagnostics:
Wiring diagram interpretation, sensor testing, ECU fault code retrieval and interpretation
Suspension Tuning:
Adjustment procedures for fork and shock absorber settings
Technical Depth
Depth Level:
Comprehensive factory-level repair and diagnostic information
Diagnostic Tools:
Mentions specific diagnostic tools or procedures required (e.g., diagnostic connector, software)
Torque Specifications:
Detailed torque values for all critical fasteners
Clearances Tolerances:
Specific engine component clearances and wear tolerances
📊 Manual Specifications
File Format
File Type:
PDF
Searchable Text:
Yes
Print Quality
Image Resolution:
High-resolution (suitable for printing diagrams and illustrations)
Binding Type
Binding:
N/A (Digital)
Paper Type
Paper Quality:
N/A (Digital)
⚙️ Engine Specifications
Primary Engine
Engine Type:
LC8 V-Twin, Four-stroke
Displacement:
999.3 cc
Bore X Stroke:
98 mm x 66 mm
Compression Ratio:
11.4:1
Valve Train:
DOHC, 4 valves per cylinder
Performance
Max Power:
116 hp (85 kW) @ 9,000 rpm
Max Torque:
98 Nm (72 lb-ft) @ 7,000 rpm
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI), Keihin, 52mm throttle bodies
Fuel Type:
Unleaded premium gasoline (min. 95 octane)
Cooling System
Cooling Type:
Liquid-cooled
🔧 Transmission
Standard
Transmission Type:
6-speed, claw-shifted, constant mesh
Clutch Type:
Wet multi-disc clutch, hydraulically operated
Final Drive:
Chain drive, O-ring sealed
Features
Gear Ratios:
1st: 2.15 (32/15), 2nd: 1.78 (32/18), 3rd: 1.47 (31/21), 4th: 1.24 (29/23), 5th: 1.04 (26/25), 6th: 0.88 (23/26)
Transmission Fluid Type:
SAE 10W/40 Motorcycle Oil (refer to manual for specific OEM recommendation)
📐 Dimensions
Exterior
Length:
2150 mm (84.6 in)
Width:
850 mm (33.5 in) (incl. mirrors)
Height:
1160 mm (45.7 in) (incl. windshield)
Wheelbase:
1450 mm (57.1 in)
Seat Height:
860 mm (33.9 in)
Weights
Dry Weight Estimated:
170 kg (374.8 lbs)
Curb Weight Estimated:
190 kg (418.9 lbs)
Cargo
Fuel Tank Capacity:
15 L (3.96 US gal)
🛡️ Safety Features
Ratings
ABS Availability:
Optional
Active Features
Braking System:
High-performance hydraulic disc brakes front and rear
Suspension Damping:
Adjustable WP front forks and rear monoshock for customizable handling and stability
Passive Features
Frame Design:
Chromium-molybdenum steel trellis frame for rigidity and rider feedback
Ergonomics:
Aggressive rider triangle optimized for control and dynamic riding
💡 Technology Features
Infotainment
Instrumentation:
Digital LCD display with tachometer, speedometer, fuel gauge, clock, gear indicator, trip meters
Driver Assistance
ABS System:
Bosch ABS (optional, rider-selectable modes may be present)
Connectivity
Diagnostic Port:
Provided for ECU diagnostics and parameter adjustment
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 km or 1 year (refer to manual for precise interval)
Valve Clearance Check Interval:
Every 10,000 km or 1 year (refer to manual for precise interval)
Spark Plug Replacement Interval:
Every 10,000 km (refer to manual for precise interval and plug type)
Chain Maintenance:
Lubricate and adjust every 1,000 km or as needed
Fluid Specifications
Engine Oil Type:
Fully synthetic motorcycle oil, SAE 10W/40, API SG/SH/SJ or higher, JASO MA
Engine Oil Capacity:
Approx. 3.0 L without filter change, 3.4 L with filter change (refer to manual for exact capacity)
Coolant Type:
Ethylene glycol-based antifreeze coolant, mixed 50/50 with distilled water (refer to manual for specific KTM coolant)
Brake Fluid Type:
DOT 4 (refer to manual for specific recommendation)
Known Issues
Common Wear Items:
Clutch plates, wheel bearings, fork seals, fuel pump (early models)
Electrical Gremlins:
Occasional intermittent issues related to wiring harness connections or sensor failures (addressed by manual)
Engine Management:
TPS (Throttle Position Sensor) calibration can be sensitive, requires proper procedure
📚 Vehicle History
Brand Heritage
Heritage Focus:
Motorsport-derived engineering, off-road prowess, streetfighter performance
Model Evolution
Predecessors:
950 Super Duke (2005-2006)
Development Philosophy:
Evolution of the LC8 platform into a more refined and powerful street-focused machine
Production
Manufacturing Location:
Austria
Production Years For Model:
2005-2007 (First Generation)
🏆 Awards & Recognition
Recognitions
Performance Accolades:
Consistently praised by motorcycle press for its raw power, aggressive handling, and distinctive styling
Ratings
Rider Magazine Reviews:
High marks for engine performance and chassis dynamics, often cited as a benchmark naked bike
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