Positioning:
The KTM 990 Super Duke is a high-performance naked sportbike known for its aggressive styling, potent V-twin engine, and exceptional handling. It targeted riders seeking a thrilling street-focused machine with track-day capabilities.
Competitors:
Competed against other large-displacement naked bikes and sportbikes from manufacturers like Ducati (Monster series), Triumph (Speed Triple), Aprilia (Tuono V4), and various Japanese litre-class bikes.
Engine:
Powerful 999cc LC8 V-twin engine, known for its torque and aggressive power delivery.
Chassis:
Lightweight steel trellis frame, WP suspension components, and strong Brembo braking system.
Design:
Stripped-down, muscular aesthetic with minimalist bodywork, highlighting the mechanical components.
Handling:
Renowned for sharp, agile handling and rider feedback, making it a favorite for spirited riding.
Engine:
Complete engine overhaul, including disassembly, assembly, component inspection, and torque specifications for LC8 V-twin engine.
Fuel System:
Fuel injection system, fuel pump, injectors, throttle body, fuel tank, and fuel lines.
Ignition System:
Ignition coils, spark plugs, ECU control, and troubleshooting ignition faults.
Cooling System:
Radiator, cooling fan, coolant hoses, water pump, thermostat, and bleeding procedures.
Transmission:
Gearbox, clutch operation, lubrication, maintenance, and troubleshooting common transmission issues.
Drivetrain:
Chain and sprockets maintenance, adjustment, and replacement. Rear swingarm and bearings.
Brakes:
Brake fluid replacement, caliper maintenance, master cylinder service, bleeding procedures, and disc/pad inspection.
Suspension:
Front fork (WP) disassembly, service, oil change, seal replacement. Rear shock absorber service and adjustment.
Electrical System:
Wiring diagrams, battery maintenance, starter motor, alternator, lighting system, fuses, relays, and ECU diagnostics.
Frame And Bodywork:
Frame inspection, fairing removal and installation, seat, fuel tank mounting, and handlebars.
Wheels And Tires:
Wheel bearing inspection and replacement, tire pressure, and mounting/dismounting procedures.
Instruments And Controls:
Dashboard, switches, throttle, clutch, and brake lever adjustments.
Routine Maintenance:
Oil and filter changes, chain lubrication, brake checks, tire pressure checks, coolant level checks.
Scheduled Maintenance:
Detailed service intervals for all major components and systems.
Troubleshooting:
Systematic diagnostic procedures for common problems, including no-start conditions, running issues, and electrical faults.
Repair Procedures:
Step-by-step instructions for component removal, repair, and reinstallation across all vehicle systems.
Overhaul Instructions:
Comprehensive guides for engine and transmission overhauls.
Torque Specifications:
Exact torque values for critical fasteners and bolts in all major assemblies.
Wiring Diagrams:
Detailed electrical schematics for easy fault diagnosis and repair.
Depth:
Comprehensive (covers basic maintenance to full engine/transmission rebuilds and advanced electrical diagnostics).
Type:
Four-stroke, V-twin, liquid-cooled, DOHC, 8 valves
Displacement:
999 cc (61.0 cu in)
Bore X Stroke:
98 x 66 mm
Compression Ratio:
11.5:1
Horsepower Claimed:
Approx. 115-125 hp (85-93 kW) @ 9000 rpm (depending on specific year/tuning)
Torque Claimed:
Approx. 95-100 Nm (70-74 lb-ft) @ 7000 rpm (depending on specific year/tuning)
Fuel Delivery:
Electronic Fuel Injection (EFI) with dual throttle bodies
Fuel Type:
Unleaded gasoline, minimum 95 RON (Octane rating)
Oil Type:
Fully synthetic motorcycle oil meeting API SG/SH/SJ or higher, JASO MA/MA2 specifications.
Oil Capacity With Filter:
Approximately 3.5 liters (3.7 US qt)
Oil And Filter Change:
Recommended every 5,000-7,500 km (3,000-4,500 miles) or annually, whichever comes first. Consult manual for exact intervals.
Valve Clearance Check:
Typically around 10,000-15,000 km (6,000-9,000 miles). Crucial for engine performance.
Chain And Sprocket Inspection:
Regularly inspect and lubricate chain (every 500-1000 km) and check for wear/tension. Replacement interval varies with use.
Brake Fluid Change:
Recommended every 2 years to maintain optimal braking performance and prevent moisture absorption.
Coolant Change:
Recommended every 2-3 years or per manual's specified mileage.
Engine Oil:
Fully synthetic SAE 10W-50 or 15W-50 motorcycle oil, API SG/SH/SJ or higher, JASO MA/MA2.
Coolant:
Mixture of distilled water and antifreeze (ethylene glycol based) with corrosion inhibitors, typically a 50/50 mix for optimal temperature and freeze protection.
Brake Fluid:
DOT 4 high-temperature brake fluid.
Clutch Fluid:
DOT 4 or DOT 5.1 brake fluid (check manual for exact specification as it shares system with brakes).
Fork Oil:
Specific viscosity grade as per WP specification (e.g., SAE 5W or 10W). Consult manual for precise type and quantity.
Fuel Pump Reliability:
Some early models reported occasional issues with fuel pump longevity or performance. The manual will cover diagnosis and replacement.
Wiring Harness Concerns:
Like many high-performance bikes of this era, ensuring all electrical connections are clean and secure is important. The manual's wiring diagrams are invaluable here.
Throttle Response:
Proper maintenance of the EFI system, throttle bodies, and air filter is critical for optimal throttle response.
Suspension Seals:
WP suspension components are high-quality but require regular seal maintenance to prevent leaks.
Heritage:
KTM, an Austrian manufacturer, has a strong heritage in off-road racing, particularly motocross and rally raids. This racing DNA translates into their performance-oriented street motorcycles.
Evolution:
The 990 Super Duke built upon the success and reputation of its predecessor, the 950 Super Duke. It represented KTM's move into larger displacement, more powerful street motorcycles, retaining the raw, performance-focused character.
Production Period:
2003-2007 (for this specific manual coverage)
Manufacturing Location:
Austria
