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KTM 990 Super DUKE Digital Workshop Repair Manual 2007

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The 990 Super DUKE, a 2007 model motorcycle, is a high-performance naked sportbike celebrated for its aggressive styling, potent V-twin engine, and agile handling. Built with robust Austrian engineering, this...
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KTM 990 Super DUKE Digital Workshop Repair Manual 2007
The 990 Super DUKE, a 2007 model motorcycle, is a high-performance naked sportbike celebrated for its aggressive styling, potent V-twin engine, and agile handling. Built with robust Austrian engineering, this machine emphasizes rider engagement and raw power delivery, making it a formidable competitor in its class. Its key differentiators include the substantial torque from its LC8 V-twin engine, sophisticated WP suspension, and a lightweight, responsive chassis, all contributing to its reputation for exceptional handling prowess and a thrilling riding experience. This digital workshop repair manual offers comprehensive coverage for the 990 Super DUKE, detailing everything from routine maintenance and scheduled service intervals to in-depth engine overhauls and transmission repairs. It provides step-by-step instructions, diagnostic procedures for the electronic fuel injection and electrical systems, and technical specifications crucial for accurate maintenance and repair. This resource is designed to assist owners, mechanics, and technicians in keeping the motorcycle in optimal condition, ensuring its performance and longevity.
🏷️ Basic Information
Identification
Make:
KTM
Model:
990 Super DUKE
Year:
2007
Type:
Motorcycle
Codes
Model Code:
RC8 1190 (This might be a related model code, actual 990 Super DUKE code would be more specific to the LC8 engine platform)
👋 Introduction
Market Position
Category:
High-performance Naked Sportbike
Target Audience:
Enthusiast riders, DIY mechanics, performance-oriented owners
Competitive Analysis
Competitors 2007:
Ducati Monster S4Rs, Triumph Speed Triple, Aprilia Tuono Factory
Key Differentiators:
V-twin engine torque, WP suspension, aggressive styling, lightweight chassis
Key Features
Performance Focus:
Emphasis on rider engagement and raw power delivery
Handling Prowess:
Designed for agile cornering and stability at speed
Engineering Quality:
Reputation for robust Austrian engineering
📋 Manual Details
Coverage Areas
Engine Mechanical:
Complete overhaul, internal component inspection and replacement
Engine Management:
Fuel injection system, ignition system, sensors, ECU diagnostics
Transmission:
Clutch, gearbox, shifting mechanisms, lubrication
Chassis:
Frame, subframe, suspension (front and rear), steering
Brakes:
Brake calipers, master cylinders, lines, discs, bleeding procedures
Electrical System:
Wiring diagrams, battery, starter, alternator, lighting, instruments
Fuel System:
Fuel tank, fuel pump, injectors, regulators
Cooling System:
Radiator, coolant, fan, water pump
Exhaust System:
Exhaust headers, mufflers, catalytic converter (if applicable)
Bodywork And Fairings:
Removal, installation, repair of panels
Wheels And Tires:
Tire changes, wheel balancing, spoke tensioning
Troubleshooting:
Diagnostic flowcharts and solutions for common problems
Page Count
Estimated Pages:
500+
Manual Type
Type:
Digital Workshop Repair Manual
Scope:
Comprehensive Repair and Maintenance
Language
Language:
English
Format
File Format:
Digital (likely PDF)
Searchability:
Searchable Text
Printability:
Printable Sections
📖 Manual Coverage
Systems Covered
Powertrain:
Engine, transmission, final drive (chain)
Suspension And Steering:
Front fork (WP), rear shock absorber (WP), steering head bearings
Braking System:
Front: Dual hydraulic discs (Brembo), Rear: Hydraulic disc (Brembo)
Fuel And Ignition:
Electronic fuel injection (EFI), ignition system
Electrical And Lighting:
Comprehensive wiring diagrams, battery, charging system, lighting circuits
Procedures Included
Scheduled Maintenance:
Oil changes, filter replacements, chain adjustment, valve clearance checks
Troubleshooting Diagnostics:
Fault codes, symptom-based diagnostics, component testing
Engine Rebuilding:
Piston/ring replacement, cylinder head service, crankshaft inspection
Transmission Repair:
Gearbox disassembly, clutch pack replacement, seal replacement
Suspension Servicing:
Fork seal replacement, shock absorber service, linkage maintenance
Brake System Overhaul:
Caliper rebuild, master cylinder replacement, bleeding procedures
Electrical Component Testing:
Testing of starter motor, alternator, regulators, sensors
Fuel Injection System Tuning:
Injector cleaning, fuel pressure testing, ECU mapping adjustments (basic)
Technical Depth
Depth:
Comprehensive (from basic maintenance to complete engine rebuilds)
Detail Level:
Detailed step-by-step instructions with torque specifications and diagrams
Diagnostic Focus:
In-depth diagnostic procedures for EFI and electrical systems
📊 Manual Specifications
File Format
Type:
Digital Document (PDF)
Quality:
High-resolution scans for clarity, potentially containing vector graphics
Print Quality
Recommendation:
Designed for on-screen viewing and selective printing of relevant sections
Binding Type
Digital:
N/A (Digital Format)
Paper Type
Digital:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Type:
LC8, V-twin, 4-stroke
Displacement:
999.3 cc
Bore X Stroke:
98.0 mm x 66.0 mm
Compression Ratio:
12.0:1
Valve Train:
DOHC, 4 valves per cylinder
Cooling System:
Liquid-cooled
Performance
Horsepower Claimed:
115 hp @ 9,000 rpm
Torque Claimed:
98 Nm (72 lb-ft) @ 7,000 rpm
Fuel System
Type:
Electronic Fuel Injection (EFI), Keihin components
Fuel Grade Requirement:
Premium Unleaded (95 RON or higher)
Lubrication
Oil Type:
Fully synthetic motorcycle oil, SAE 10W-50 recommended
Oil Capacity W Filter:
Approx. 3.0 liters (3.2 US quarts)
🔧 Transmission
Standard
Type:
6-speed, constant mesh
Clutch:
Wet multi-disc clutch, hydraulically operated
Features
Final Drive:
Chain drive
Gear Ratios:
Specific ratios detailed in manual (e.g., 1st: 2.15, 2nd: 1.78, 3rd: 1.40, 4th: 1.14, 5th: 1.00, 6th: 0.87)
Fluid Specification
Transmission Oil:
As per engine oil specification or specific transmission fluid if separate (confirm in manual)
📐 Dimensions
Exterior
Length:
Approx. 2150 mm (84.6 in)
Width Handlebar:
Approx. 800 mm (31.5 in)
Height Seat:
Approx. 860 mm (33.9 in)
Weights
Dry Weight:
Approx. 183 kg (403.4 lbs)
Curb Weight W Fluids:
Approx. 200 kg (441 lbs)
Gross Vehicle Weight Rating:
Not typically specified for motorcycles, but chassis load capacity is crucial
🛡️ Safety Features
Ratings
Crash Test Results:
Not applicable in the same way as cars; focus is on rider protection via aftermarket gear and safe operation
Active Features
Braking System Enhancements:
High-performance Brembo radial calipers and discs
Chassis Stability:
Rigid frame and quality suspension contribute to stable handling
Passive Features
Frame Construction:
Steel Trellis frame for strength and rider feedback
Lighting:
Dual Halogen headlights for improved visibility
💡 Technology Features
Infotainment
Dashboard:
Digital LCD display with analog tachometer, speed indicator, fuel gauge, trip meters, clock, engine temp
Driver Assistance
Traction Control:
Not equipped on the 2007 model
ABS:
Optional on some models, but typically not standard on the 2007 Super Duke
Connectivity
Diagnostic Interface:
OBD-II compliant or proprietary KTM diagnostic port for electronic diagnostics
🔧 Maintenance
Service Intervals
First Service:
1,000 km (600 miles) or 1 month
Subsequent Services:
Every 5,000 km (3,100 miles) or 6 months (major services may be at longer intervals)
Valve Clearance Check:
Every 10,000 km (6,200 miles)
Fluid Specifications
Engine Oil Grade:
SAE 10W-50 (API SG/SH/SJ or JASO MA)
Coolant:
Ethylene glycol-based coolant, typically a 50/50 mix with distilled water
Brake Fluid:
DOT 4
Fork Oil Type Grade:
WP Suspension specific, often around 5W or 10W (confirm exact in manual)
Known Issues
Potential Wear Items:
Clutch plates, rear shock absorber seals, steering head bearings, fuel pump (early models)
Efi Calibration:
Occasional rough idling or lean running that may require ECU remapping or injector service
Electrical Connections:
Corrosion or loose connections in high-vibration areas can cause intermittent faults
Filter Part Numbers
Oil Filter:
KTM Part Number: 75038005000 or equivalent (e.g., K&N KN-155, Hiflofiltro HF155)
Air Filter:
KTM Part Number: 75006015000 or equivalent (e.g., K&N KT-9001)
📚 Vehicle History
Brand Heritage
Origins:
Austrian manufacturer with a strong legacy in off-road and racing motorcycles
Philosophy:
Ready to Race - focus on performance, innovation, and rider connection
Model Evolution
Predecessors:
950 Super Duke, Duke series lineage
Updates For 2007:
Likely minor refinements, potential mapping updates, or chassis tweaks from previous models
Production
Manufacturing Location:
Austria (Mattighofen)
Production Years 990 Super Duke:
Circa 2005 - 2013 (with variations)
🏆 Awards & Recognition
Recognitions
Motorcycle Press Awards:
Frequently praised by motorcycle journalists for its raw power, handling, and hooligan character.
Community Acclaim:
Highly regarded by enthusiasts as a 'superbike for the street' with a cult following.
Ratings
Reliability Perception:
Generally considered robust with proper maintenance, though like any high-performance machine, it requires diligence.
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