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KTM 990 Super Duke 2003-2007 Workshop Service Manual Repair

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The KTM 990 Super Duke, produced between 2003 and 2007, is a high-performance naked sportbike renowned for its aggressive styling and potent LC8 V-twin engine. This Austrian-manufactured machine offers a...
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KTM 990 Super Duke 2003-2007 Workshop Service Manual Repair
The KTM 990 Super Duke, produced between 2003 and 2007, is a high-performance naked sportbike renowned for its aggressive styling and potent LC8 V-twin engine. This Austrian-manufactured machine offers a thrilling riding experience, characterized by its powerful performance, estimated at 120-125 HP, and robust torque output. Its design emphasizes a no-compromise approach to speed and handling, featuring a chromium-molybdenum steel trellis frame, WP suspension components, and potent Brembo braking systems. This model represents KTM's strong entry into the street bike market, building upon their off-road heritage with a focus on raw power and rider engagement. This comprehensive workshop service manual provides detailed information for the KTM 990 Super Duke, covering all aspects from routine maintenance to complex repairs. It includes in-depth procedures for engine overhaul, transmission, chassis, brakes, and the electrical system, along with specific guidance on fuel and bodywork. The manual is designed for both professional technicians and experienced DIY mechanics, offering step-by-step instructions, diagnostic troubleshooting, and essential torque specifications. Its factory-originated content ensures the highest accuracy and completeness, enabling owners to maintain and repair their vehicle effectively, saving on labor costs and preserving performance.
🏷️ Basic Information
Identification
Make:
KTM
Model:
990 Super Duke
Year:
2003-2007
Codes
Engine Code Range:
LC8 V-twin
👋 Introduction
Market Position
Target Audience:
Professional technicians and experienced DIY mechanics
Value Proposition:
Enables owners to perform expert-level maintenance and repairs, saving on labor costs.
Competitive Analysis
Uniqueness:
Factory-originated information provides the highest accuracy and completeness for the 990 Super Duke model range.
Key Features
Features:
Includes detailed diagrams, step-by-step instructions, and troubleshooting information.
📋 Manual Details
Coverage Areas
Manual Type:
Workshop Service Manual / Repair Manual
Language:
English
Format:
PDF Download
Page Count
Estimated Page Count:
Hundreds (typical for comprehensive workshop manuals)
Delivery
Delivery Method:
Instant Download
Requirements
Software Requirements:
Adobe PDF Reader, WinRAR
Compatibility:
All Versions of Windows & Mac
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine overhaul, cylinder head, pistons, crankshaft, lubrication, cooling system, fuel injection system, ignition system
Transmission Drivetrain:
Gearbox, clutch, chain drive, final drive maintenance and repair
Chassis Suspension:
Frame, front fork (WP USD), rear shock absorber (WP Monoshock), swingarm, steering system
Brakes:
Front and rear brake system overhauls, hydraulic circuits, caliper and master cylinder service, disc inspection
Electrical System:
Wiring diagrams, starter system, charging system, lighting, ignition switch, fuses, battery maintenance
Fuel System:
Fuel pump, fuel injectors, fuel lines, fuel tank service
Bodywork Ergonomics:
Fairings, seat, fuel tank, handlebars, footpegs, body panel removal and installation
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, chain adjustment and lubrication, spark plug replacement, air filter cleaning/replacement
Diagnostic Troubleshooting:
Step-by-step troubleshooting guides for common and uncommon issues
Major Repairs:
Engine rebuilds, transmission overhauls, suspension component replacement, electrical system diagnostics and repair
Special Procedures:
Torque specifications for all fasteners, valve clearance adjustment, fuel injection system calibration
Technical Depth
Depth:
Comprehensive (from basic maintenance to full engine/component rebuilds)
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Printability:
Full Printable
Zoom Capabilities:
Zoom IN/OUT
Binding Type
Binding Style:
Digital (N/A for PDF download)
Paper Type
Paper Quality Indication:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
V-twin, four-stroke, liquid-cooled (LC8 engine)
Displacement:
999 cc (999 cubic centimeters)
Bore X Stroke:
101 mm x 62.4 mm
Compression Ratio:
12.3:1
Performance
Horsepower:
Approx. 120-125 HP @ 9,000 RPM (model dependent)
Torque:
Approx. 100-102 Nm @ 7,000 RPM (model dependent)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with twin throttle bodies per cylinder
Ignition System
Ignition Type:
Digital CDI
Cooling System
Cooling Method:
Liquid-cooled
Lubrication System
Oil Type Recommendation:
Refer to manual for specific grade (e.g., Motorex Power Synt 4T SAE 10W-50 or equivalent meeting API SG, JASO MA)
Engine Components
Valve Train:
DOHC, 4 valves per cylinder
🔧 Transmission
Standard
Transmission Type:
6-speed, sequential
Optional
Optional Transmission:
N/A (Standard 6-speed manual)
Features
Clutch Type:
Wet multi-disc clutch, hydraulically operated
Gear Ratios
Gear Ratios 1St:
Refer to manual for specific ratios
Gear Ratios 6Th:
Refer to manual for specific ratios
📐 Dimensions
Exterior
Length:
Approx. 2150 mm (model dependent)
Width:
Approx. 850 mm (model dependent)
Height:
Approx. 1160 mm (model dependent)
Weights
Dry Weight:
Approx. 196 kg (196 kilograms)
Wet Weight:
Approx. 208 kg (208 kilograms, including fluids)
Fuel Capacity
Fuel Tank Capacity:
15 Liters (3.96 US gallons)
🛡️ Safety Features
Ratings
Safety Certification:
CE, ADR (country specific)
Active Features
Braking System:
Dual 320mm discs front with 4-piston Brembo calipers, single 240mm disc rear with 2-piston Brembo caliper. Optional ABS on later models.
Lighting:
Halogen headlight, LED taillight and indicators
Passive Features
Frame Construction:
Chromium-molybdenum steel trellis frame
💡 Technology Features
Infotainment
Infotainment Features:
Basic instrumentation including speedometer, tachometer, odometer, trip meter, and warning lights. No advanced infotainment systems typical of modern vehicles.
Driver Assistance
Driver Assistance Systems:
Optional ABS (Anti-lock Braking System) on some later models of this generation. No other electronic rider aids.
Connectivity
Connectivity Features:
N/A (No Bluetooth, smartphone integration, or Wi-Fi connectivity)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000 - 7,500 km or annually. Refer to manual for precise interval and conditions.
Valve Clearance Check:
Approximately every 10,000 - 15,000 km. Manual will detail specific checks.
Chain Maintenance:
Regular cleaning, lubrication, and tension adjustment every 500-1000 km, or as needed.
Fluid Specifications
Engine Oil Capacity:
Approx. 3.0 - 3.5 Liters (check manual for exact capacity with filter change)
Coolant Type:
Ethylene glycol-based antifreeze mixture (e.g., Motorex Coolant M3.0)
Brake Fluid Type:
DOT 4
Clutch Fluid Type:
DOT 4 (if hydraulic clutch)
Fork Oil Type:
Refer to manual for specific grade and type (e.g., WP Suspension Fork Oil 5W)
Known Issues
Common Issues:
Potential for fuel pump issues, voltage regulator failure, occasional clutch slave cylinder leaks. Specific model year updates may address some concerns. Refer to manual for detailed troubleshooting.
Tire Specifications
Front Tire Size:
120/70ZR17
Rear Tire Size:
180/55ZR17
📚 Vehicle History
Brand Heritage
Brand Focus:
KTM is renowned for its off-road motorcycles, but has expanded significantly into street bikes, particularly performance-oriented models.
Model Evolution
Super Duke Lineage:
The 990 Super Duke represents a significant step for KTM into the naked sportbike segment, building on the aggressive styling and performance of its V-twin LC8 engine platform.
Production
Production Period:
2003-2007 (for this specific generation covered by the manual)
Manufacturing Location:
Austria
🏆 Awards & Recognition
Recognitions
Motorcycle Type Recognition:
Praised for its raw power, aggressive styling, and thrilling performance in the naked sportbike category by various motorcycle publications during its production run.
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