KTM 990 Super Duke 2003-2007 Factory Service Repair Manual

Name: KTM 990 Super Duke 2003-2007 Factory Service Repair Manual
Brand: Ktm
SKU: 145183
Price: 16.99 USD
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The KTM 990 Super Duke, produced from 2003 to 2007, is a high-performance naked sportbike renowned for its potent V-twin engine, aggressive styling, and sharp handling. Built in Austria, this...

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Tipo: Motorcycle

Proveedor:

Ktm

SKU: 145183

Etiquetas: 2003 2004 2005 2006 2007 990 990 Super Duke Agriculture Case KTM Motorcycle Tractors

Variantes de producto

Descripción

The KTM 990 Super Duke, produced from 2003 to 2007, is a high-performance naked sportbike renowned for its potent V-twin engine, aggressive styling, and sharp handling. Built in Austria, this model represents KTM's transition into premium street motorcycles, drawing from its off-road heritage to deliver a sporty and engaging riding experience. Positioned against competitors like the Ducati Monster and Triumph Speed Triple, the 990 Super Duke is distinguished by its powerful LC8 V-twin engine, offering approximately 115-120 HP and 93-98 Nm of torque, and a chassis designed for dynamic capability. This factory service repair manual provides comprehensive guidance for the KTM 990 Super Duke across its covered years. It details all major systems, including the engine, fuel system, cooling system, clutch, transmission, wheels, tires, brakes, suspension, steering, frame, and electrical system. The manual includes routine maintenance procedures, detailed diagnostics, step-by-step repair instructions, and even special techniques for part testing. This resource is invaluable for owners and technicians seeking to maintain, troubleshoot, and repair the motorcycle, potentially leading to significant savings on labor costs.

🏷️ Basic Information

Identification

Make:

KTM

Model:

990 Super Duke

Model Variant:

Super Duke

Years Covered:

2003, 2004, 2005, 2006, 2007

Vin Code:

N/A (Motorcycle specific codes vary)

Codes

Engine Code Format:

KTM typically uses a combination of letters and numbers indicating engine type and displacement.

👋 Introduction

Market Position

Motorcycle Segment:

High-performance naked sportbike.

Competitive Analysis

Key Competitors Era:

Ducati Monster series, Triumph Speed Triple, Aprilia Tuono.

Key Features

Unique Selling Points:

Known for its potent V-twin engine, aggressive styling, and sharp handling, positioning it as a premium performance motorcycle.

Manual Value Proposition

Cost Saving Potential:

Significant potential savings on labor costs (estimated $50-$60 per hour) by enabling DIY servicing and informed discussions with mechanics.

Manual Usability

User Friendliness:

Designed for ease of use, with step-by-step instructions, clear numbering, and quick navigation via a numbered table of contents and search functionality.

📋 Manual Details

Coverage Areas

Major Systems:

General Information, Fuel System, Cooling System, Engine Top End, Clutch, Engine Lubrication System, Engine Removal/Installation, Crankshaft/Transmission, Wheels/Tires, Final Drive, Brakes, Suspension, Steering, Frame, Electrical System, Appendix

Page Count

Estimated Page Count:

Hundreds of pages (precise number not specified, but indicative of comprehensive coverage)

Manual Type

Type:

Factory Service Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Detailed coverage of engine top end (cylinder head, valves, camshafts), clutch operation and overhaul, lubrication system, engine removal and installation procedures, crankshaft and transmission internals.

Fuel System:

Comprehensive information on fuel delivery, injectors, fuel pump, fuel filter, and fuel tank maintenance and diagnostics.

Cooling System:

Details on radiator, coolant flow, fan operation, water pump, and coolant pressure testing.

Electrical System:

Extensive coverage including detailed wiring diagrams, troubleshooting for electrical faults, battery, charging system, ignition system, lighting, and starter motor.

Chassis Components:

In-depth coverage of wheels, tires, final drive (chain and sprockets), braking system (hydraulic circuits, pads, discs, calipers), suspension (forks, rear shock, linkages), steering system, and frame integrity.

Procedures Included

Maintenance:

Routine maintenance, fluid changes, filter replacements, chain adjustment, brake pad inspection, tire pressure checks, and general inspection procedures.

Diagnostics:

Step-by-step troubleshooting guides for engine fault symptoms, electrical issues, fuel system problems, and chassis component malfunctions.

Repair:

Detailed instructions for component removal, disassembly, inspection, repair, reassembly, and installation for all major systems.

Tuning:

While not explicitly stated as 'tuning', the comprehensive nature implies procedures for maintaining optimal engine performance, which may include basic adjustments.

Special Techniques:

Includes 'secret techniques used by top mechanics' for part testing and diagnosis.

Technical Depth

Depth:

Factory-level diagnostic and repair procedures, covering everything from basic maintenance to complex component overhauls and electrical system tracing.

📊 Manual Specifications

File Format

File Format:

PDF

Print Quality

Printability:

Printable without restriction, allowing users to print individual pages or the entire manual.

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

Software Requirements

Software:

Adobe PDF Reader

Delivery Method

Delivery:

Immediate download link provided upon successful payment.

⚙️ Engine Specifications

Primary Engine

Engine Type:

V-twin, 4-stroke, Liquid-cooled

Displacement:

999 cc

Bore X Stroke:

98 mm x 66 mm (typical for this model)

Compression Ratio:

11.5:1 (typical for this model)

Performance

Horsepower:

Approx. 115-120 HP (at crankshaft, depending on specific tune/year)

Torque:

Approx. 93-98 Nm (at crankshaft, depending on specific tune/year)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI) with dual throttle bodies.

Fuel Type:

Unleaded Premium Gasoline (95 RON or higher)

Lubrication

Oil Type:

Semi-synthetic or fully synthetic motorcycle oil (e.g., Motul 5100 10W-50, or manufacturer-specified equivalent).

Oil Capacity:

Approximately 3.5 liters (with filter change, verify in manual).

🔧 Transmission

Standard

Type:

6-speed constant mesh sequential gearbox.

Features

Clutch Type:

Wet multi-plate clutch, hydraulically operated.

Final Drive:

O-ring sealed chain.

📐 Dimensions

Exterior

Length:

Approx. 2100 mm

Width:

Approx. 800 mm (excluding mirrors)

Height:

Approx. 1170 mm (at handlebars)

Weights

Dry Weight:

Approx. 180 kg

Wet Weight:

Approx. 196 kg (with all fluids)

Fuel Tank Capacity:

18 liters

🛡️ Safety Features

Ratings

Safety Certification:

N/A (Motorcycles typically do not have standardized crash test ratings like cars).

Active Features

Brakes Front:

Dual 320 mm discs with radial-mount 4-piston Brembo calipers.

Brakes Rear:

Single 240 mm disc with 2-piston Brembo caliper.

ABS:

Optional ABS available on later models within this range, or as an aftermarket fitment. Manual coverage should detail ABS system if equipped.

Passive Features

Lighting:

Halogen headlight, LED taillight and turn signals.

💡 Technology Features

Infotainment

Instrument Cluster:

Analog tachometer and digital speedometer, odometer, trip meter, fuel gauge, and warning lights.

Driver Assistance

ABS Availability:

As noted, ABS was often optional or introduced later in the model run.

Connectivity

Bike To Device:

None (Pre-modern connectivity era for motorcycles).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 5,000-7,500 km or annually, whichever comes first (refer to manual for exact interval).

Valve Clearance Check:

Typically every 10,000-15,000 km (critical for performance and longevity).

Chain Maintenance:

Regular cleaning, lubrication, and tension adjustment (e.g., every 500-1000 km).

Fluid Specifications

Coolant Type:

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

Brake Fluid Type:

DOT 4 or DOT 5.1 (verify in manual).

Clutch Fluid Type:

DOT 4 or DOT 5.1 (usually same as brake fluid).

Known Issues

Common Wear Items:

Clutch plates, fuel pump components, voltage regulator, and chain/sprockets are common wear items requiring periodic inspection and replacement.

Potential Electrical Faults:

Intermittent electrical issues can sometimes arise, often related to grounds or connectors; the manual's electrical diagrams are crucial for diagnosis.

Filter Part Numbers

Oil Filter:

Specific part number should be obtained from the manual or an OEM parts catalog (e.g., K&N KN-153 or equivalent).

📚 Vehicle History

Brand Heritage

Brand Focus:

KTM is renowned for its off-road heritage, transitioning to high-performance street motorcycles with a focus on sporty dynamics and rider engagement.

Model Evolution

Predecessor:

While not a direct predecessor in name, the 990 Super Duke built upon KTM's experience with V-twin engines and naked bike performance.

Key Innovations Era:

Introduction of the LC8 V-twin engine into a naked streetfighter platform, offering significant power and torque.

Production

Manufacturing Location:

Austria

🏆 Awards & Recognition

Recognitions

Industry Acclaim:

The 990 Super Duke was generally well-received for its performance and character, earning praise in motorcycle media for its dynamic capabilities and raw power.