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KTM 990 Super Duke 2007 Service Repair Manual

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The KTM 990 Super Duke, produced from 2005 to 2013, represents a pinnacle of naked sportbike engineering, particularly the 2007 model. This machine is powered by a formidable LC8 V-twin...
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Type: Motorcycle
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KTM 990 Super Duke 2007 Service Repair Manual
The KTM 990 Super Duke, produced from 2005 to 2013, represents a pinnacle of naked sportbike engineering, particularly the 2007 model. This machine is powered by a formidable LC8 V-twin engine, celebrated for its substantial torque and exhilarating performance, delivering approximately 118 horsepower. Its design prioritizes agility and rider engagement, featuring a lightweight trellis frame, advanced adjustable WP suspension, and powerful Brembo braking systems, with optional ABS for enhanced safety. Known for its aggressive styling and raw, unadulterated riding experience, the 990 Super Duke competed effectively with other high-performance naked bikes of its time, solidifying KTM's reputation for producing potent and exciting motorcycles. This comprehensive service and workshop manual provides detailed information essential for the maintenance and repair of your 2007 KTM 990 Super Duke. It covers all major systems, including the engine, transmission, clutch, chassis, suspension, braking system, fuel system, cooling system, electrical components, and bodywork. Within its pages, you will find step-by-step instructions for complete overhauls, routine maintenance, troubleshooting common issues, and detailed disassembly and assembly procedures. This manual is designed for both professional technicians and skilled DIY mechanics, empowering them with the knowledge to confidently maintain and repair the vehicle, ensuring its optimal performance and longevity.
🏷️ Basic Information
Identification
Make:
KTM
Model:
990 Super Duke
Year:
2007
Codes
Engine Code:
LC8 V-twin
👋 Introduction
Market Position
Positioning:
The KTM 990 Super Duke for 2007 was positioned as a flagship naked sportbike, renowned for its raw power, aggressive styling, and agile handling, appealing to performance-oriented riders.
Competitive Analysis
Competitors:
Competed with other high-performance naked bikes such as the Ducati Monster series, Aprilia Tuono, and Yamaha FZ1.
Key Features
Engine Type:
Powerful LC8 V-twin engine, known for its torquey delivery and high-revving nature.
Chassis Design:
Lightweight trellis frame, advanced suspension components, and strong braking system contributing to its renowned handling.
Manual Value Proposition
Target Audience:
Professional technicians and experienced DIY mechanics with a basic understanding of mechanical and electrical concepts.
Benefit:
Empowers owners to perform maintenance and repairs confidently, saving time and money while ensuring proper vehicle upkeep and safety.
📋 Manual Details
Coverage Areas
Engine:
Complete Overhaul, Tuning, Maintenance
Transmission:
Clutch, Gearbox, Final Drive
Chassis:
Frame, Suspension, Steering
Electrical:
Wiring Diagrams, Ignition, Lighting, ECU
Braking System:
Hydraulic Systems, Calipers, Rotors, ABS (if applicable)
Fuel System:
Fuel Injection, Pumps, Injectors
Cooling System:
Radiator, Coolant Flow, Water Pump
Exhaust System:
Catalytic Converter, Mufflers
Bodywork:
Fairings, Seat, Tank, Plastics
Page Count
Estimated Pages:
Information not explicitly provided, but typical for comprehensive service manuals.
Manual Type
Type:
Service Repair Manual / Workshop Manual
Language
Language:
English
Format
File Format:
PDF
Delivery:
Instant Download
Requirements
Software Requirements:
Adobe PDF Reader, WinZip
Compatibility
Operating Systems:
All Versions of Windows & Mac
📖 Manual Coverage
Systems Covered
Powertrain:
Engine, Transmission, Clutch, Final Drive
Chassis And Suspension:
Front Forks, Rear Shock Absorber, Swingarm, Frame
Brakes:
Front and Rear Brakes, Hydraulic System, ABS Components (if applicable)
Electrical System:
Ignition System, Lighting, Starter Motor, Battery, ECU, Sensors, Wiring Harnesses
Fuel And Emission Control:
Fuel Tank, Fuel Pump, Fuel Injectors, Throttle Body, Emission Control Systems
Cooling System:
Radiator, Cooling Fan, Thermostat, Coolant Hoses
Exhaust System:
Exhaust Headers, Catalytic Converter, Mufflers
Body And Trim:
Body Panels, Seat, Handlebars, Footpegs
Procedures Included
Maintenance:
Regular Service, Oil Changes, Filter Replacements, Chain Adjustment
Troubleshooting:
Diagnostic Procedures for Common Issues, Symptom-Based Troubleshooting
Repair:
Detailed Step-by-Step Repair Instructions for All Major Components
Disassembly And Assembly:
Complete Procedures for Taking Apart and Reassembling Components
Cleaning And Inspection:
Proper Methods for Cleaning and Inspecting Parts During Maintenance and Repair
Technical Depth
Depth:
Comprehensive, covering everything from basic maintenance to in-depth engine and electrical diagnostics and repair. Designed for professional technicians but accessible to skilled DIY mechanics.
📊 Manual Specifications
File Format
Digital Format:
PDF
Print Quality
Printability:
Full Printable
Zoom Functionality:
YES
Binding Type
Binding:
Not Applicable (Digital Download)
Paper Type
Paper Quality:
Not Applicable (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
V-twin, 4-stroke, DOHC, 8 valves
Displacement:
999 cc (61.0 cu in)
Bore X Stroke:
98 x 66 mm (3.86 x 2.60 in)
Performance
Horsepower:
Approx. 118 hp (88 kW) @ 9,000 rpm
Torque:
Approx. 99 Nm (73 lb-ft) @ 7,000 rpm
Fuel System
Fuel Delivery:
Fuel Injection (MPI - Multi Point Injection) with electronic throttle control
Ignition
Ignition System:
Digital CDI with dual ignition
Lubrication
Lubrication System:
Forced lubrication with oil pump, Wet Sump
Cooling
Cooling System:
Liquid-cooled
🔧 Transmission
Standard
Transmission Type:
6-speed, claw-shifted
Clutch:
Wet multi-disc clutch, hydraulically operated
Final Drive:
X-ring chain, 16/42 final drive ratio
📐 Dimensions
Exterior
Length:
2130 mm (83.9 in)
Width:
850 mm (33.5 in) (without mirrors)
Height:
1180 mm (46.5 in) (at handlebars)
Weights
Dry Weight:
Approx. 199 kg (438.7 lbs)
Gross Vehicle Weight Rating:
Not specified for motorcycles
Fuel Tank Capacity:
15 L (3.96 US gal)
Seat Height:
Approx. 850 mm (33.5 in)
🛡️ Safety Features
Ratings
Safety Certifications:
Not applicable in the same way as cars, but compliance with motorcycle safety standards is implied.
Active Features
Braking System:
Dual 320mm front discs with Brembo 4-piston radial calipers, 240mm rear disc with 2-piston caliper. ABS was an optional feature for some markets/versions.
Suspension:
WP Suspension components, adjustable for preload, compression, and rebound damping, contributing to stability and control.
Passive Features
Frame Structure:
Chromoly steel trellis frame for rigidity and impact absorption.
Lighting:
Halogen headlight, LED taillight and turn signals for visibility.
💡 Technology Features
Infotainment
Infotainment System:
Basic digital dashboard displaying speed, RPM, odometer, trip meters, fuel level, and warning lights. No advanced infotainment features.
Driver Assistance
ABS:
Optional Anti-lock Braking System (ABS) available on some 2007 models, enhancing braking safety.
Connectivity
Connectivity Features:
None beyond standard motorcycle electrical systems.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000 - 7,500 km (3,000 - 5,000 miles) or annually, refer to manual for specifics.
Valve Clearance Check:
Typically every 10,000 - 15,000 km (6,000 - 9,000 miles).
Chain Maintenance:
Regular cleaning, lubrication, and tension adjustment every 500-1,000 km.
Fluid Specifications
Engine Oil:
KTM recommends Motorex Power Synt EVO 4T SAE 10W/40 or equivalent fully synthetic ester-based motorcycle oil. Check manual for precise specifications and alternatives.
Coolant:
Ethylene glycol-based coolant with corrosion inhibitors. KTM recommends Motorex Coolant M3.0.
Brake Fluid:
DOT 4 or DOT 5.1 brake fluid.
Clutch Fluid:
Mineral oil (e.g., Brembo brake fluid, as it's often a shared reservoir with brakes on some models, or specific hydraulic fluid if separate).
Known Issues
Common Wear Items:
Clutch plates, fork seals, wheel bearings, fuel pump, and voltage regulator are potential wear items requiring inspection and possible replacement.
Electrical Gremlins:
Early models could sometimes experience minor electrical issues; comprehensive wiring diagrams in the manual are crucial for diagnosis.
Fuel Pump Reliability:
Some owners have reported occasional fuel pump issues, particularly with aftermarket fuel filters or when using certain fuel types.
📚 Vehicle History
Brand Heritage
Heritage:
KTM has a strong heritage in off-road racing, which influences the engineering and performance focus of its street bikes, emphasizing power, durability, and rider engagement.
Model Evolution
Evolution Super Duke:
The 990 Super Duke built upon the legacy of the 950 Super Duke, refining the LC8 engine and chassis for increased performance and street-focused usability, establishing KTM as a serious player in the naked sportbike segment.
Production
Manufacturing Location:
Austria (primarily)
Production Years 990 Super Duke:
2005 - 2013
🏆 Awards & Recognition
Recognitions
Industry Acclaim:
The KTM 990 Super Duke was consistently praised by automotive journalists for its potent engine, sharp handling, and hooligan character, earning it a reputation as one of the most exciting naked bikes of its era.
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