KTM 990 Super DUKE 2003-2007 Workshop Service Repair Manual

Name: KTM 990 Super DUKE 2003-2007 Workshop Service Repair Manual
Brand: Ktm
SKU: 153608
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Typ: Motorcycle

Anbieter:

Ktm

Art.-Nr: 153608

Stichworte: 2003 2004 2005 2006 2007 990 990 Super DUKE KTM Motorcycle Motorcycles

Produktvarianten

Beschreibung

The KTM 990 Super Duke is a high-performance naked sportbike produced from 2003 to 2007, known for its raucous LC8 V-twin engine and aggressive styling. This Austrian-engineered motorcycle offers a raw, engaging riding experience, characterized by its potent approximately 115-120 hp output and sharp handling, making it a formidable competitor in its segment. Designed for experienced riders, the 990 Super Duke delivers exhilarating performance on the street, embodying a potent blend of power and agility. This comprehensive workshop service repair manual provides complete vehicle service and repair information for the KTM 990 Super Duke models from 2003 to 2007. It covers all essential areas, including detailed engine disassembly and assembly, fuel system maintenance, electrical system diagnostics, chassis component servicing, and complete troubleshooting guidance. The manual is designed to assist owners, mechanics, and technicians in performing all necessary maintenance and repair procedures, ensuring the optimal performance and longevity of the motorcycle.

🏷️ Basic Information

Identification

Make:

KTM

Model:

990 Super Duke

Model Years Covered:

2003, 2004, 2005, 2006, 2007

Platform Code:

LC8 (V-Twin)

👋 Introduction

Market Position

Segment:

High-performance naked sportbike

Competitive Analysis

Rivals:

Ducati Monster S4R, Aprilia Tuono Factory, Triumph Speed Triple

Key Features

Design Philosophy:

Raucous V-twin power, aggressive styling, sharp handling

Target Audience

Rider Profile:

Experienced riders seeking a raw, engaging, and powerful street-focused motorcycle

📋 Manual Details

Coverage Areas

Coverage Scope:

Complete vehicle service and repair

Page Count

Estimated Page Count:

N/A (Digital Download)

Manual Type

Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Format:

PDF (Portable Document Format)

📖 Manual Coverage

Systems Covered

Engine:

Complete disassembly, assembly, servicing, and troubleshooting of the LC8 V-twin engine

Fuel System:

Fuel injection system (ECU, injectors, throttle bodies, fuel pump, lines)

Electrical System:

Wiring diagrams, ignition system, starting system, lighting, battery, ECU diagnostics

Chassis:

Frame, suspension (forks, rear shock), brakes (front and rear), wheels, steering

Engine Disassembly:

Detailed breakdown of engine components including cylinder heads, pistons, crankshaft, connecting rods, gearbox

Engine Assembly:

Step-by-step reassembly instructions with torque specifications and critical clearances

Servicing Individual Components:

In-depth servicing procedures for clutch, transmission, oil pump, water pump, starter motor

Procedures Included

Maintenance:

Periodic maintenance schedule, fluid changes, filter replacements, chain adjustment

Repair:

Step-by-step instructions for component removal, installation, and repair

Troubleshooting:

Diagnostic procedures for common issues and faults

Removing Refitting Engine:

Comprehensive guide on engine removal and installation from the chassis

Technical Depth

Depth:

Comprehensive, from basic maintenance to complete engine rebuilds and diagnostics

Diagnostic Capabilities:

Covers error codes and diagnostic procedures for the EFI system

Manual Completeness

Coverage Type:

Complete Service and Repair Manual

Technical Areas

Specific Chapters:

Service Informations, General Information, Engine Removal/Refitting, Engine Disassembly, Servicing Individual Components, Engine Assembly, Troubleshooting, Technical Specifications, Periodic Maintenance Schedule, Electrical/Injection, Fuel System, Chassis, Wiring Diagrams

📊 Manual Specifications

File Format

File Type:

PDF

Print Quality

Printability:

Full Printable

Zoom Functionality

Zoom:

YES (Zoom IN/OUT enabled)

Binding Type

Binding:

Digital Download (No physical binding)

Paper Type

Paper Quality:

N/A (Digital)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Liquid-cooled, four-stroke, 75° V-twin

Displacement:

999 cc

Performance

Horsepower Est:

Approx. 115-120 hp @ 9000 rpm

Torque Est:

Approx. 95-100 Nm @ 7000 rpm

Fuel System

Fuel Delivery:

Electronic fuel injection (EFI) with dual throttle bodies

Engine Internals

Bore X Stroke:

98 x 66 mm

Cooling System

Cooling Method:

Liquid Cooling

Engine Management

Ignition:

Digital ignition system (CDI)

🔧 Transmission

Standard

Type:

6-speed, claw-shifted

Optional

Transmission Options:

N/A (Single configuration)

Features

Clutch:

Hydraulically operated wet multi-disc clutch

Final Drive

Drive Type:

Chain drive

📐 Dimensions

Exterior

Length Est:

Approx. 2120 mm

Width Est:

Approx. 800 mm

Height Est:

Approx. 1130 mm

Weights

Dry Weight Est:

Approx. 195 kg

Wet Weight Est:

Approx. 215 kg (with fluids)

Wheels Tires

Front Tire Size:

120/70 ZR17

Rear Tire Size:

180/55 ZR17

Wheel Type:

Light alloy cast wheels

🛡️ Safety Features

Ratings

Safety Certifications:

N/A (Motorcycle specific safety features)

Active Features

Brakes Front:

Dual 320mm discs with 4-piston Brembo radial calipers

Brakes Rear:

Single 240mm disc with 2-piston Brembo caliper

Passive Features

Frame Design:

Chromium-molybdenum steel trellis frame

Lighting

Headlight Type:

Halogen

💡 Technology Features

Infotainment

Dashboard Display:

Digital LCD display with analog tachometer

Driver Assistance

ABS:

Not standard on 2003-2007 models. ABS became available on later Super Duke models.

Connectivity

Connectivity Features:

N/A (No modern connectivity features)

🔧 Maintenance

Service Intervals

Oil Change Interval:

Refer to manual (typically 5,000-7,500 km or annually)

Valve Clearance Interval:

Refer to manual (typically 10,000-15,000 km)

Fluid Specifications

Engine Oil Type:

Semi-synthetic or fully synthetic motorcycle oil, SAE 10W/40 or 20W/50 (API SG or higher, JASO MA certified)

Coolant Type:

Ethylene glycol-based antifreeze (e.g., Motorex Coolant M3.0 or equivalent)

Brake Fluid Type:

DOT 4

Clutch Fluid Type:

DOT 4 (Hydraulic clutch)

Known Issues

Common Problems:

Potential for stator failure, fuel pump issues, throttle body syncing problems, clutch slave cylinder leaks. Vibration at certain RPMs.

Filters

Oil Filter Part Number Example:

KTM Part #: 75038005000 (Example - confirm with manual)

Air Filter Part Number Example:

KTM Part #: 75006015000 (Example - confirm with manual)

📚 Vehicle History

Brand Heritage

Manufacturer Origin:

Austria

Model Evolution

Predecessor:

KTM 950 Supermoto (shared LC8 engine architecture)

Successor:

KTM 990 Super Duke R, KTM 1290 Super Duke series

Production

Production Period:

2003-2007

🏆 Awards & Recognition

Recognitions

Media Accolades:

Widely praised by motorcycle publications for its exhilarating performance and aggressive character.