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KTM 990 Super Duke 2003-2007 Service Repair Manual

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$16.99
The KTM 990 Super Duke, produced from 2003 to 2007, represents a pinnacle of naked sportbike engineering, renowned for its potent 999cc LC8 V-twin engine, delivering robust torque and exhilarating...
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Taper: Motorcycle
Distributeur:
Ktm
UGS: 146433
Mots clés: 2003 2004 2005 2006 2007 990 Super Duke KTM Misc Motorcycle Motorcycles
KTM 990 Super Duke 2003-2007 Service Repair Manual
The KTM 990 Super Duke, produced from 2003 to 2007, represents a pinnacle of naked sportbike engineering, renowned for its potent 999cc LC8 V-twin engine, delivering robust torque and exhilarating performance. This Austrian-manufactured machine is distinguished by its aggressive styling, high-quality WP suspension, and potent Brembo braking system, making it a formidable contender in its class. Engineered for discerning riders seeking a raw and engaging riding experience, the 990 Super Duke excels in both spirited road riding and track-day applications, embodying KTM's heritage of performance and innovation. This comprehensive Service Repair Manual provides detailed guidance for professional technicians and experienced DIY enthusiasts on the maintenance, repair, and troubleshooting of the KTM 990 Super Duke models from 2003 to 2007. It covers all essential systems, including the engine, fuel system, transmission, chassis, suspension, brakes, and electrical components, with step-by-step procedures for routine maintenance, diagnostics, and complete component rebuilds. The manual also includes critical technical specifications, torque values, fluid recommendations, and wiring diagrams, ensuring accurate and efficient servicing to keep the motorcycle in optimal condition.
🏷️ Basic Information
Identification
Make:
KTM
Model:
990 Super Duke
Years Covered:
2003, 2004, 2005, 2006, 2007
👋 Introduction
Market Position
Description:
The KTM 990 Super Duke was a flagship naked sportbike, known for its aggressive styling, powerful V-twin engine, and exceptional handling. Positioned as a premium performance machine for discerning riders.
Competitive Analysis
Competitors:
Competed against other high-performance naked bikes such as the Ducati Monster S4R, Triumph Speed Triple, and Aprilia Tuono V-Twin.
Key Features
Engine Type:
LC8 V-twin engine, renowned for its character and torque.
Handling And Suspension:
High-quality WP suspension components and aggressive chassis geometry.
Braking System:
Premium Brembo braking components offering superior stopping power.
📋 Manual Details
Identification
Product Name:
KTM 990 Super Duke 2003-2007 Service Repair Manual
Manual Type:
Service Repair Manual
Format:
PDF Download
Language:
English
Coverage
Prepared For:
Professional technicians and experienced DIY enthusiasts
📖 Manual Coverage
Systems Covered
Engine:
Complete engine disassembly, inspection, repair, and reassembly for the 990cc V-twin LC8 engine. Includes valve train, piston, connecting rod, crankshaft, cylinder head, and oil pump procedures.
Fuel System:
Fuel injection system components (throttle bodies, injectors, fuel pump, pressure regulator), fuel tank, and lines. Includes diagnostic procedures and adjustment specifications.
Transmission:
Gearbox inspection, repair, and maintenance. Includes clutch operation, gearbox internals, and shifting mechanism.
Chassis And Suspension:
Front fork (WP USD) overhaul, adjustment, and seal replacement. Rear shock absorber (WP) maintenance and settings. Swingarm, linkage, and bearing checks.
Brakes:
Front and rear brake system components, including calipers (Brembo radial-mount), master cylinders, brake lines, pads, discs, and ABS system (if equipped). Bleeding procedures and specifications.
Electrical System:
Wiring diagrams, component testing (ignition, lighting, starting system, charging system), fuse box layout, battery maintenance, and dashboard information.
Cooling System:
Radiator, coolant hoses, water pump, thermostat, and fan operation. Coolant type and capacity specifications.
Exhaust System:
Catalytic converter (if applicable), mufflers, and exhaust pipe maintenance and inspection.
Bodywork And Frame:
Frame inspection, fairing removal and installation, seat, fuel tank, and body panel components.
Procedures Included
Routine Maintenance:
Oil and filter change, air filter service, spark plug replacement, chain adjustment and lubrication, brake fluid flush, coolant flush.
Troubleshooting:
Diagnostic flowcharts for common issues related to engine performance, electrical faults, starting problems, and braking system anomalies.
Repair And Rebuild:
Detailed step-by-step instructions for engine internal rebuilds, suspension overhauls, brake system component replacement, and electrical system component repair.
Specifications And Tolerances:
Torque values for critical fasteners, valve clearances, piston ring gaps, bearing clearances, and fluid capacities. Includes engine tuning parameters.
Technical Depth
Depth:
Comprehensive: Covers all aspects from basic maintenance to complete engine and component rebuilds. Includes detailed diagrams, exploded views, and diagnostic information.
📊 Manual Specifications
File Details
File Type:
PDF
Searchable Text:
Likely included, enhancing ease of navigation and information retrieval.
Print Quality
Quality:
High resolution, suitable for printing individual pages or the entire manual.
Binding Type
Type:
Digital Download (N/A for print)
Paper Type
Type:
Digital Download (N/A for print)
⚙️ Engine Specifications
Primary Engine
Type:
Liquid-cooled, 4-stroke, 75° V-twin, DOHC, 4 valves per cylinder
Displacement:
999 cc
Bore X Stroke:
101 mm x 62.4 mm
Compression Ratio:
12.5:1
Performance
Horsepower:
Approx. 114 hp (84 kW) @ 9,000 rpm (varies slightly by year and market)
Torque:
Approx. 71 lb-ft (96 Nm) @ 7,000 rpm (varies slightly by year and market)
Fuel System
Induction:
Electronic fuel injection (throttle bodies by Keihin or Mikuni depending on year)
Fuel Type:
Unleaded premium gasoline (min. 95 RON)
🔧 Transmission
Standard
Type:
6-speed, claw shifted, constant mesh
Clutch:
Hydraulically operated, wet multi-disc clutch
Features
Final Drive:
X-ring chain
📐 Dimensions
Exterior
Length:
Approx. 2,150 mm (84.6 in)
Width:
Approx. 820 mm (32.3 in) (excluding mirrors)
Height:
Approx. 1,100 mm (43.3 in) (seat height varies)
Weights
Dry Weight:
Approx. 199 kg (439 lbs)
Wet Weight:
Approx. 217 kg (478 lbs) (fully fueled)
Fuel Tank Capacity:
18 liters (4.8 US gal)
🛡️ Safety Features
Ratings
ABS:
Optional on some models/markets, Brembo ABS system
Active Features
Braking:
Dual 320 mm front discs with radial-mount Brembo 4-piston calipers; Single 240 mm rear disc with Brembo 2-piston caliper.
Passive Features
Lighting:
Halogen headlights, LED taillight
💡 Technology Features
Infotainment
Dashboard:
Digital/analog hybrid instrument cluster displaying speed, RPM, fuel level, coolant temperature, odometer, trip meters, and warning lights.
Driver Assistance
ABS:
Optional Anti-lock Braking System available on some variants, enhancing safety.
Connectivity
Diagnostic Port:
Features a diagnostic connector for electronic fault finding and parameter adjustment using appropriate tools. The manual will detail its location and usage.
🔧 Maintenance
Service Intervals
Oil Change:
Every 5,000 - 7,500 km (3,000 - 4,500 miles) or annually.
Air Filter:
Inspect every 5,000 km (3,000 miles), clean/replace as needed.
Spark Plugs:
Replace every 10,000 - 15,000 km (6,000 - 9,000 miles).
Valve Clearance:
Check/adjust every 10,000 - 15,000 km (6,000 - 9,000 miles).
Brake Fluid Flush:
Every 2 years.
Fluid Specifications
Engine Oil:
SAE 10W-50, API SJ/SL or higher, JASO MA (e.g., Motorex Power Synt 4T 10W-50)
Coolant:
Mixture of distilled water and ethylene glycol-based coolant (e.g., Motorex Coolant M3.0). Capacity approx. 2.0 liters.
Brake Fluid:
DOT 4
Clutch Fluid:
DOT 4
Known Issues
Fuel Pump Reliability:
Early models sometimes experienced fuel pump failures. Troubleshooting guides in the manual will cover diagnostics.
Water Pump Seals:
Occasional leaks from the water pump seal; manual will detail replacement procedure.
Idle Control Issues:
Some models reported rough idling or stalling, potentially related to throttle body synchronization or TPS (Throttle Position Sensor) calibration. The manual provides guidance for these adjustments.
📚 Vehicle History
Brand Heritage
Origin:
KTM is an Austrian motorcycle manufacturer with a strong heritage in off-road racing, transitioning to high-performance street bikes with the LC8 engine platform.
Model Evolution
Introduction:
The 990 Super Duke was introduced in 2005 (though some earlier models may be referred to as 950 Super Duke, this manual specifically covers the 990cc variant, which began production in late 2004 for the 2005 model year, with the specified years covering its initial production run).
Production
Location:
Mattighofen, Austria
🏆 Awards & Recognition
Recognitions
Overall Reputation:
Consistently praised by motorcycle media for its raw performance, aggressive styling, and exceptional handling characteristics, earning it a strong enthusiast following.
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