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KTM 990 Super Duke 2005 Service Repair Manual

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The 2005 KTM 990 Super Duke is a high-performance naked sportbike, celebrated for its aggressive styling and potent performance derived from its LC8 V-Twin engine. Engineered with a focus on...
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KTM 990 Super Duke 2005 Service Repair Manual
The 2005 KTM 990 Super Duke is a high-performance naked sportbike, celebrated for its aggressive styling and potent performance derived from its LC8 V-Twin engine. Engineered with a focus on delivering an exhilarating riding experience, this model features a robust trellis frame and high-quality suspension components, ensuring exceptional handling and agility. Its minimalist, performance-oriented design, coupled with powerful dual front disc brakes, positions it as a formidable contender in its class. The 990 Super Duke embodies a 'Ready to Race' philosophy, offering riders a raw and engaging machine built for spirited street riding. This comprehensive service repair manual provides detailed information essential for the maintenance and repair of your 2005 KTM 990 Super Duke. It covers a wide range of systems, including engine mechanicals, fuel and ignition systems, cooling, transmission, chassis, suspension, brakes, and the electrical system. The manual offers step-by-step instructions for routine maintenance, troubleshooting common issues, and performing complex repairs, along with vital technical specifications and torque values. Designed for professional technicians and experienced enthusiasts, this English-language manual is an indispensable resource for ensuring the optimal performance and longevity of your motorcycle.
🏷️ Basic Information
Identification
Make:
KTM
Model:
990 Super Duke
Year:
2005
Market Segment:
Performance Naked Motorcycle
Codes
Chassis Code:
to be determined from manual content, typically found in VIN section
Engine Code:
LC8 V-Twin (specific variant for 990 Super Duke)
👋 Introduction
Market Position
Category:
High-performance naked sportbike
Target Demographic:
Riders seeking aggressive styling, potent performance, and cutting-edge technology in a street-focused package
Competitive Analysis
Key Rivals:
Ducati Monster series, Aprilia Tuono Factory, Triumph Speed Triple
Key Features
Engine Configuration:
V-twin, liquid-cooled, DOHC, 8 valves per cylinder
Frame Type:
Trellis frame
Suspension Type:
High-quality WP components (upside-down forks, adjustable monoshock)
Braking System:
Powerful dual front discs with radial-mount calipers
Styling:
Aggressive, minimalist, performance-oriented naked design
📋 Manual Details
Coverage Areas
Primary Focus:
Service and Repair
Intended Audience:
Professional Technicians and Experienced Enthusiasts
Page Count
Estimated Pages:
Likely 300-600 pages (typical for a comprehensive service manual)
Manual Type
Type:
Service Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine disassembly, assembly, overhaul, component inspection and replacement (pistons, rings, valves, camshafts, crankshaft, etc.)
Fuel System:
Fuel injection system (injectors, throttle body, fuel pump, pressure regulator), fuel tank, lines, and filters
Ignition System:
Ignition coils, spark plugs, ECU (Engine Control Unit) ignition timing parameters
Cooling System:
Radiator, cooling fan, water pump, coolant lines, thermostat, fluid specifications and bleeding procedures
Exhaust System:
Exhaust pipes, mufflers, catalytic converter (if applicable), sensor troubleshooting
Transmission Drivetrain:
Clutch operation, gearbox disassembly and assembly, gear shifting mechanisms, chain drive maintenance
Chassis Frame:
Frame inspection, alignment, component mounting points
Suspension Front:
Front fork disassembly, rebuild, oil levels, seal replacement, spring rates, damping adjustments
Suspension Rear:
Rear shock absorber inspection, servicing, linkage system lubrication and adjustment
Brakes Front:
Brake calipers, master cylinders, brake lines, pads, rotors, bleeding procedures, ABS system (if equipped)
Brakes Rear:
Rear brake caliper, master cylinder, brake line, pads, rotor, bleeding procedures
Wheels Tires:
Wheel bearing inspection and replacement, tire mounting and balancing, recommended tire pressures
Electrical System:
Wiring diagrams, battery, starter motor, alternator, lighting system, fuses, relays, ECU diagnostics
Instrumentation Controls:
Dashboard indicators, switches, controls operation and troubleshooting
Bodywork Fittings:
Fairing removal and installation, seat, fuel tank mounting, body panel repair and replacement
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, chain adjustment and lubrication, brake fluid checks, coolant checks
Troubleshooting:
Diagnostic charts for common symptoms, electrical system fault finding, engine performance issues
Repair Rebuild:
Step-by-step instructions for component removal, overhaul, and reinstallation
Diagnostics:
Information on reading diagnostic trouble codes (DTCs) and interpreting sensor data (if OBD-II equipped or similar)
Special Tools:
Identification and usage of specialized tools required for specific procedures
Torque Specifications:
Accurate torque values for all critical fasteners
Technical Depth
Depth:
Comprehensive, covering routine maintenance to complete engine and chassis rebuilds
Detail Level:
Detailed diagrams, exploded views, specifications, and step-by-step instructions
📊 Manual Specifications
File Format
Format:
PDF
Searchable:
Likely Yes (standard for professional PDF manuals)
Printable:
Yes
Print Quality
Resolution:
High resolution for clear diagrams and text
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, four-stroke, V-twin, DOHC, 8 valves
Displacement:
999 cc (999 cm³)
Bore X Stroke:
98.0 mm x 66.0 mm
Compression Ratio:
11.5:1
Performance
Horsepower Peak:
Approx. 115 hp (85.8 kW) @ 9,000 rpm (claimed)
Torque Peak:
Approx. 98 Nm (72.3 lb-ft) @ 7,000 rpm (claimed)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with dual throttle bodies
Fuel Type:
Unleaded Premium Gasoline (95 RON or higher recommended)
Lubrication System
Oil Type:
Fully synthetic motorcycle oil, API SG/SH/SJ or higher, JASO MA/MA2 specification (e.g., Motorex Power Synt 4T 10W/50 or equivalent)
Oil Capacity W Filter:
Approx. 3.0 liters (3.2 US qt)
Cooling System
Coolant Type:
Ethylene glycol-based coolant with corrosion inhibitors (e.g., Motorex Coolant M3.0 or equivalent)
Coolant Capacity:
Approx. 1.9 liters (2.0 US qt)
🔧 Transmission
Standard
Type:
6-speed, claw-shifted
Clutch Type:
Hydraulically operated, wet multi-plate clutch
Final Drive:
Chain drive
Gear Ratios:
Refer to manual for specific ratios (e.g., 1st: 2.235, 2nd: 1.579, 3rd: 1.294, 4th: 1.045, 5th: 0.913, 6th: 0.756)
Features
Transmission Oil Type:
SAE 75W/90, API GL-4 or GL-5 (typically shared engine/gearbox oil if wet clutch) - **Verify in Manual**
Transmission Oil Capacity:
Refer to manual, often same as engine oil capacity
📐 Dimensions
Exterior
Length:
Approx. 2,100 mm (82.7 in)
Width:
Approx. 800 mm (31.5 in) (excluding mirrors)
Height:
Approx. 1,100 mm (43.3 in) (to top of handlebars)
Seat Height:
Approx. 860 mm (33.9 in)
Weights
Dry Weight:
Approx. 183 kg (403.4 lbs)
Wet Weight Estimated:
Approx. 200 kg (441 lbs) (fully fueled and ready to ride)
Fuel Tank Capacity:
Approx. 15 liters (3.96 US gal)
Dimensions
Wheelbase:
Approx. 1,450 mm (57.1 in)
Ground Clearance:
Refer to manual for precise value, typically optimized for performance
🛡️ Safety Features
Ratings
Safety Certification:
CE, DOT (as applicable for respective markets)
Active Features
Brakes:
Dual 320mm front discs with 4-piston radial calipers, 240mm rear disc with 2-piston caliper
ABS Availability:
Optional (ABS model variant)
Passive Features
Lighting:
Halogen headlight, LED taillight
Mirrors:
Integrated handlebar mirrors
💡 Technology Features
Infotainment
Dashboard:
Analog tachometer with integrated LCD display for speed, odometer, trip meters, fuel level, and warning lights.
Driver Assistance
ABS:
Optional Anti-lock Braking System (ABS) available on certain models.
Connectivity
Diagnostic Ports:
Likely features a diagnostic connector for electronic fault diagnosis (refer to manual for location and type).
🔧 Maintenance
Service Intervals
First Service:
Typically 1,000 km (600 miles) or 1 month (whichever comes first) - Check Manual for specifics.
Oil Change Interval:
Every 5,000 - 10,000 km (3,000 - 6,000 miles) or 6-12 months, depending on riding conditions - Check Manual for specifics.
Valve Clearance Check:
Typically around 10,000 - 20,000 km (6,000 - 12,000 miles) - **Critical check, refer to manual.**
Chain Maintenance:
Regular cleaning and lubrication (e.g., every 500 km or after riding in wet/dirty conditions)
Fluid Specifications
Brake Fluid:
DOT 4
Coolant Type:
Ethylene glycol-based coolant with corrosion inhibitors (e.g., Motorex Coolant M3.0)
Engine Oil:
Fully synthetic motorcycle oil, API SG/SH/SJ or higher, JASO MA/MA2 (e.g., Motorex Power Synt 4T 10W/50)
Known Issues
Fuel Pump Reliability:
Some early models may have experienced fuel pump issues; refer to manual for testing and replacement procedures.
Regulator Rectifier:
Potential for early failure in some electrical charging systems; manual will detail testing.
Idle Control:
Some models might exhibit rough idling or stalling, potentially related to throttle body synchronization or sensor issues; manual will provide diagnostic steps.
Suspension Seals:
As with any performance motorcycle, front fork seals can wear; manual covers replacement.
📚 Vehicle History
Brand Heritage
Brand Focus:
KTM, known for its off-road prowess and aggressive performance motorcycles ('Ready to Race' philosophy)
Model Evolution
Lineage:
The 990 Super Duke marked KTM's significant entry into the large-displacement, high-performance naked sportbike segment, building upon the success of earlier Duke models.
Year Introduction:
The 990 Super Duke was introduced around 2005, replacing or evolving from the 950 Super Duke.
Production
Manufacturing Location:
Austria (KTM's primary manufacturing base)
🏆 Awards & Recognition
Recognitions
Motorcycle Reviews:
The KTM 990 Super Duke was generally well-received by the press for its performance, handling, and distinctive character, often praised for its raw power and aggressive riding experience.
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