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KTM 990 Super Duke 2003-2006 Service Repair Workshop Manual

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The 990 Super Duke, produced from 2003 to 2006, is a naked sportbike renowned for its aggressive styling and potent performance, powered by a liquid-cooled, four-stroke V-Twin engine displacing approximately...
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Tipo: Motorcycle
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SKU: 151395
KTM 990 Super Duke 2003-2006 Service Repair Workshop Manual
The 990 Super Duke, produced from 2003 to 2006, is a naked sportbike renowned for its aggressive styling and potent performance, powered by a liquid-cooled, four-stroke V-Twin engine displacing approximately 999 cc. Building on a strong off-road heritage and a 'Ready to Race' philosophy, this Austrian-manufactured machine established the Super Duke as a benchmark in its class, offering typically 100-115 horsepower and around 90-95 Nm of torque. Its engineering quality is evident in its robust LC8 chassis, fully adjustable suspension, and powerful braking system, making it a favored choice for riders seeking an exhilarating street experience. This comprehensive Service Repair Workshop Manual in English provides detailed guidance for the maintenance and repair of the 990 Super Duke (2003-2006 models). It covers all essential systems, including the engine, transmission, fuel system, electrical components, suspension, and frame, offering step-by-step instructions, diagnostic procedures, and technical specifications such as torque values and fluid capacities. Designed for owners with basic mechanical skills and service professionals alike, this manual ensures accurate and efficient upkeep, enabling owners to maintain their vehicle's performance and reliability while facilitating cost-effective repairs.
🏷️ Basic Information
Identification
Make:
KTM
Model:
990 Super Duke
Year:
2003-2006
Codes
Chassis Code:
LC8
👋 Introduction
Market Position
Target Audience:
KTM 990 Super Duke owners with basic mechanical skills, independent service professionals, and authorized dealer service departments
Competitive Analysis
Value Proposition:
Provides dealership-level repair and maintenance information, enabling cost savings on routine services and repairs
Key Features
Content Quality:
Accurate, clear, and concise text with diagrams, illustrations, and wiring schematics
Instruction Style:
Step-by-step instructions, easy-to-follow directions
Completeness:
Complete and intact, no missing or corrupt parts/pages
Manufacturer Origin:
Written by the manufacturers (KTM)
📋 Manual Details
Coverage Areas
Primary Coverage:
Service, Repair, Workshop
Specific Models Covered:
KTM 990 Super Duke (2003, 2004, 2005, 2006 models)
Page Count
Estimated Page Count:
Comprehensive (specific number not provided, but implied to be extensive)
Manual Type
Type:
Service Repair Workshop Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
Engine specifications, engine removal/installation, internal engine components, lubrication, cooling system
Transmission:
Transmission overhaul, internal components, servicing
Drivetrain:
Drive chain maintenance, sprocket replacement
Fuel System:
Fuel system diagnostics, components, servicing
Electrical System:
Complete electrical system, wiring schematics, diagnostics, troubleshooting
Suspension:
Front and rear shock absorber servicing, adjustments, and overhaul
Steering System:
Steering system maintenance and repair
Bodywork:
Body panel removal, installation, and repair
Intake Exhaust:
Intake and exhaust system maintenance and service
Frame Chassis:
Frame inspection, analysis, and related component servicing
Procedures Included
Maintenance:
Routine maintenance, periodic checks and adjustments, lubrication schedules
Repair:
Step-by-step repair instructions for all major components and systems
Troubleshooting:
Specific fault codes and diagnostic procedures for electrical issues
Diagnostics:
Diagnostic procedures and fault finding techniques
Technical Data:
Specifications, torque values, clearances, fluid capacities
Technical Depth
Depth:
Comprehensive (mechanic-level detail, suitable for full rebuilds and advanced diagnostics)
Diagrams Illustrations:
Detailed diagrams, illustrations, and exploded views for all components
📊 Manual Specifications
File Format
Readability:
Viewable on PC, Mac, phones, and ebook readers
Print Quality
Printability:
Yes, individual pages printable
Binding Type
Binding:
N/A (Digital PDF format)
Paper Type
Paper Type:
N/A (Digital PDF format)
Software Requirements
Reader Required:
Adobe PDF Reader
Compatibility
Operating Systems:
All Versions of Windows AND Mac
⚙️ Engine Specifications
Primary Engine
Engine Type:
V-Twin, Four-stroke, Liquid-cooled
Engine Type
Engine Displacement:
999 cc (exact figure for the 2003-2006 models is implied by the '990' designation)
Performance
Horsepower Range:
Typically around 100-115 hp (specific figures would be detailed in the manual)
Torque Range:
Typically around 90-95 Nm (specific figures would be detailed in the manual)
Fuel System
Fuel Delivery:
Fuel Injection (likely Keihin or similar)
Lubrication
Oil Type Recommendation:
Specific grade and type detailed in manual (e.g., SAE 10W-50, JASO MA)
Cooling System
Coolant Type Recommendation:
Specific type and mixture ratio detailed in manual (typically ethylene glycol based)
Engine Components
Valve Train:
DOHC, 4 valves per cylinder (details on valve clearances and adjustment procedures included)
🔧 Transmission
Standard
Transmission Type:
6-speed manual
Features
Clutch Type:
Hydraulic wet multi-plate clutch (details on adjustment and replacement included)
Gear Ratios
Gear Ratios:
Specific ratios for each gear are detailed in the manual
Fluid Requirements
Transmission Oil Type:
Specific grade and specification detailed in the manual (often shared with engine oil or specific transmission oil)
📐 Dimensions
Exterior
Bike Type:
Naked Sportbike / Hyper-naked
Weights
Dry Weight Approx:
Around 180-190 kg (specific figures for various configurations are in the manual)
🛡️ Safety Features
Active Features
Braking System:
Dual front disc brakes with multi-piston calipers, single rear disc brake (specifics on pad replacement, bleeding, and caliper service included)
Suspension Adjustability:
Fully adjustable front forks and rear shock absorber (details on adjustments for various riding conditions are in the manual)
💡 Technology Features
Infotainment
Features:
Basic instrumentation (tachometer, speedometer, LCD display for basic info). No advanced infotainment systems.
Driver Assistance
Features:
ABS was optional or not available on early models. No advanced rider aids like traction control.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000-7,500 km or annually (specifics in manual)
Valve Check Interval:
Typically every 10,000-15,000 km (specifics in manual)
Chain Maintenance Interval:
Lubrication and adjustment every 500-1,000 km, or as needed based on conditions (detailed in manual)
Fluid Specifications
Engine Oil Capacity:
Approximately 2.5-3.0 liters (specific figure in manual, including filter)
Coolant Capacity:
Approximately 1.5-2.0 liters (specific figure in manual)
Brake Fluid Type:
DOT 4 (specifics in manual)
Known Issues
Common Wear Items:
Clutch wear, fuel pump issues (early models), voltage regulator/rectifier failures, chain and sprocket wear are common on performance motorcycles of this era.
Typical Repairs:
Regular engine tuning, brake system maintenance, suspension servicing, and electrical system checks.
📚 Vehicle History
Brand Heritage
Brand Focus:
KTM is renowned for its 'Ready to Race' philosophy and off-road prowess, extending to its street motorcycles with a focus on performance and aggressive styling.
Model Evolution
Super Duke Lineage:
The 990 Super Duke represented a significant step for KTM in the street motorcycle segment, building on the success of the LC8 engine platform and establishing the Super Duke as a benchmark for naked sportbike performance.
Production
Manufacturing Country:
Austria
🏆 Awards & Recognition
Recognitions
Market Reception:
The 990 Super Duke was generally well-received for its raw power, agile handling, and distinctive styling, often praised by motorcycle journalists for its performance capabilities.
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