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KTM 990 Super Duke 2004 Service Repair Manual

$16.99
$16.99
The 990 Super Duke, a 2004 model, stands as a pinnacle of naked sportbike engineering, characterized by its potent LC8 V-Twin engine and a minimalist, aggressive design. Built in Austria,...
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Tipo: Motorcycle
Proveedor:
Ktm
SKU: 149039
Etiquetas: 2004 990 Super Duke KTM Misc Motorcycle Motorcycles
KTM 990 Super Duke 2004 Service Repair Manual
The 990 Super Duke, a 2004 model, stands as a pinnacle of naked sportbike engineering, characterized by its potent LC8 V-Twin engine and a minimalist, aggressive design. Built in Austria, this machine was engineered for enthusiasts seeking raw performance and exhilarating handling, featuring advanced WP suspension and powerful Brembo brakes. Its rider-focused ergonomics and striking aesthetics positioned it as a formidable competitor in its class, embodying a renowned 'Ready to Race' philosophy and contributing significantly to the brand's growing reputation in the street motorcycle market. This comprehensive service repair manual in English provides detailed guidance for the maintenance and repair of the 990 Super Duke. It covers essential areas including engine, transmission, chassis, brakes, and electrical systems, offering step-by-step procedures for routine maintenance, troubleshooting, and complex diagnostics. The manual is designed to assist owners, mechanics, and technicians in preserving the vehicle's performance, ensuring its reliability, and facilitating effective repairs through its extensive technical information and clear instructions.
🏷️ Basic Information
Identification
Make:
KTM
Model:
990 Super Duke
Year:
2004
Codes
Engine Code:
LC8 V-Twin
👋 Introduction
Market Position
Positioning:
The KTM 990 Super Duke 2004 was positioned as a high-performance, naked sportbike known for its aggressive styling, powerful engine, and agile handling. It competed in the super-naked segment against rivals like Ducati Monster and Triumph Speed Triple.
Competitive Analysis
Key Competitors:
Ducati Monster S4R, Triumph Speed Triple, Aprilia Tuono RSV 1000 R.
Key Features
Features:
Dominant LC8 V-Twin engine, minimalist design, advanced WP suspension, powerful Brembo brakes, rider-focused ergonomics.
📋 Manual Details
Coverage Areas
Primary Coverage:
Service and Repair
Secondary Coverage:
Maintenance, Troubleshooting, Diagnostics
Page Count
Estimated Page Count:
Extensive (Specific count not provided, but typical for a complete service manual)
Manual Type
Type:
Service Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine:
Engine disassembly, assembly, tuning, lubrication, cooling system, fuel injection system, ignition system, emission control system.
Transmission:
Clutch operation, gearbox, shift mechanism, lubrication.
Chassis:
Frame, swingarm, rear suspension (monoshock), front suspension (upside-down forks), steering system.
Brakes:
Front and rear brake systems (dual disc front, single disc rear), hydraulic components, bleeding procedures, pad replacement.
Electrical:
Wiring diagrams, battery, charging system, lighting, ignition, starter motor, instrument panel, sensors, ECU.
Bodywork:
Fairings, fuel tank, seat, fenders, exhaust system.
Procedures Included
Maintenance:
Regular scheduled maintenance, oil changes, filter replacements, chain adjustment, spark plug replacement, brake fluid flush, coolant service.
Repair:
Detailed step-by-step repair instructions for all major and minor components, component overhaul procedures.
Troubleshooting:
Diagnostic flowcharts and procedures for identifying and resolving common issues and malfunctions.
Technical Depth
Depth:
Comprehensive: Covers everything from basic user maintenance to complete engine rebuilds and complex electrical diagnostics. Designed for professional technicians, indicating a high level of detail.
📊 Manual Specifications
File Format
Format:
PDF
Print Quality
Quality:
Digital (High resolution for clear viewing and printing)
Binding Type
Type:
N/A (Digital Download)
Paper Type
Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Configuration:
V-Twin, 4-stroke, Liquid-cooled
Displacement:
999 cc (61.0 cu in)
Bore X Stroke:
98 mm x 66 mm (3.86 x 2.60 in)
Compression Ratio:
12.5:1
Performance
Horsepower:
Approx. 120-125 hp (90-93 kW) at 9000 rpm
Torque:
Approx. 99-100 Nm (73-74 lb-ft) at 7000 rpm
Fuel System
Induction:
Fuel Injection (Multi-point)
Fuel Type:
Unleaded Premium (95 RON recommended)
Lubrication
Oil Type:
Fully synthetic motorcycle oil, e.g., Motorex Power Synth 4T SAE 10W/50 or equivalent.
Cooling
System:
Liquid-cooled
Coolant Type:
Ethylene glycol-based antifreeze mixture, e.g., Motorex Coolant M3.0 or equivalent.
🔧 Transmission
Standard
Type:
6-speed sequential manual gearbox
Features
Clutch Type:
Wet multi-plate clutch, hydraulically operated
Final Drive:
Chain drive
Fluid Type
Gearbox Oil:
SAE 75W/90 or SAE 80W/90 GL-4 gear oil.
📐 Dimensions
Exterior
Length:
Approx. 2110 mm (83.1 in)
Width:
Approx. 840 mm (33.1 in) (excluding mirrors)
Height:
Approx. 1130 mm (44.5 in) (to handlebar grips)
Seat Height:
Approx. 850 mm (33.5 in)
Weights
Dry Weight:
Approx. 183 kg (403.4 lbs)
Wet Weight:
Approx. 205 kg (452 lbs) (fully fueled)
Maximum Load:
Approx. 200 kg (441 lbs)
Cargo
Storage:
Minimal, typically no integrated cargo storage on naked bikes of this era.
🛡️ Safety Features
Ratings
Crash Test Results:
N/A (Motorcycles are not typically rated by NHTSA or Euro NCAP in the same way as cars)
Active Features
Braking System:
Dual 320mm front discs with Brembo 4-piston radial calipers, Single 240mm rear disc with Brembo 2-piston caliper.
Suspension:
WP 48mm USD front forks (fully adjustable), WP monoshock rear suspension (fully adjustable).
Passive Features
Lighting:
Halogen headlight, LED taillight, turn signals.
Ergonomics:
Aggressive but upright riding position for control and rider engagement.
💡 Technology Features
Infotainment
System:
Basic instrumentation: Analog tachometer, digital speedometer, odometer, trip meters, engine temperature gauge, clock. No infotainment system in the modern sense.
Driver Assistance
Features:
No electronic rider aids like ABS or traction control standard on this early model. Focus is on mechanical feedback and rider input.
Connectivity
Features:
N/A
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000-7,500 km (3,000-4,500 miles) or annually, whichever comes first (refer to manual for exact recommendation).
Major Service Interval:
Major engine inspection, valve clearance check, spark plug replacement usually around 15,000-20,000 km (9,000-12,500 miles).
Fluid Specifications
Brake Fluid:
DOT 4 or DOT 5.1
Coolant Capacity:
Approx. 2.2 liters (refer to manual for precise capacity)
Known Issues
Common Problems:
Early models may have had minor issues with the fuel pump or voltage regulator. Some owners reported a snatchy throttle response at low RPMs, often addressed with ECU remapping or tuning. Check for any recalls or service bulletins specific to the 2004 model.
Maintenance Points:
Regular chain lubrication and adjustment, checking coolant levels, inspecting brake pads, verifying tire pressures are critical for longevity and performance.
📚 Vehicle History
Brand Heritage
Heritage:
KTM, founded in Austria in 1934, has a strong heritage in off-road and racing motorcycles, known for its 'Ready to Race' philosophy.
Model Evolution
Evolution:
The 990 Super Duke represented KTM's entry and significant impact on the super-naked motorcycle segment, building on the success of the smaller 640 Duke. It was an evolution of their LC8 V-twin engine platform, initially developed for adventure bikes.
Production
Production Years:
2004-2007 for the first generation 990 Super Duke. The platform evolved into the 990 Super Duke R.
Manufacturing Location:
Austria
🏆 Awards & Recognition
Recognitions
Industry Accolades:
While specific awards for the 2004 model year are not widely publicized, the 990 Super Duke series generally received critical acclaim for its performance, handling, and character, establishing KTM as a serious contender in the street motorcycle market.
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