KTM 990 Adventure US blue 2012 Owner's manual

Category
Motorcycles
Type
Owner's manual
OWNER'S MANUAL 2012
990 Adventure USA
990 Adventure R USA
Art. no. 3211793en
DEAR KTM CUSTOMER 1
DEAR KTMCUSTOMER
Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will
give you enormous pleasure if you service and maintain it accordingly.
We wish you a lot of enjoyment in riding this vehicle.
Please enter the serial numbers of your vehicle below.
Chassis number ( p. 26) Dealer's stamp
Engine number ( p. 27)
Key number ( p. 28)
The owner's manual contained the latest information for this model at the time of going to print. Minor differences due to developments in
design cannot be ruled out completely.
All specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifications,
prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt these
to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery options,
deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain special equipment
that does not form part of the regular scope of delivery.
© 2011 KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright owner.
DEAR KTM CUSTOMER 2
ISO 9001(12 100 6061)
According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead to
the maximum possible quality of the products.
Issued by: TÃœV Management Service
KTM-Sportmotorcycle AG
5230 Mattighofen, Austria
TABLE OF CONTENTS 3
TABLE OFCONTENTS
MEANS OF REPRESENTATION ............................................... 7
IMPORTANT INFORMATION ................................................... 8
Overview of labels............................................................. 12
VIEW OF VEHICLE................................................................ 22
View of vehicle, front left side (vehicle differs slightly from
photo) ............................................................................. 22
View of vehicle, rear right side (vehicle differs slightly from
photo) ............................................................................. 24
SERIAL NUMBERS............................................................... 26
Chassis number................................................................ 26
Type label........................................................................ 26
Engine number................................................................. 27
Key number ..................................................................... 28
Fork part number.............................................................. 28
Shock absorber part number.............................................. 29
CONTROLS.......................................................................... 30
Clutch lever ..................................................................... 30
Hand brake lever .............................................................. 30
Light switch ..................................................................... 31
Headlight flasher switch.................................................... 31
Turn signal switch ............................................................ 32
Horn button ..................................................................... 32
Emergency OFF switch...................................................... 33
Electric starter button ....................................................... 33
Ignition/steering lock ........................................................ 34
Immobilizer ..................................................................... 34
Combination instrument.................................................... 35
Combination instrument - function buttons ......................... 35
Combination instrument - tachometer................................. 36
Combination instrument - indicator lamps........................... 36
Combination instrument - display....................................... 37
Combination instrument - speedometer............................... 38
Setting kilometers or miles ................................................ 38
Combination instrument - time .......................................... 39
Setting the clock .............................................................. 40
Combination instrument - ODO display ............................... 40
Combination instrument - setting/resetting TRIP 1............... 41
Combination instrument - setting/resetting TRIP 2............... 41
Combination instrument - TRIP F display............................ 42
Combination instrument - ambient temperature display........ 43
Setting the temperature unit of measure............................. 43
Combination instrument - warning of slippery roads ............. 44
Combination instrument - coolant temperature indicator ...... 44
Hazard warning flasher switch/hazard warning flasher .......... 45
Socket for electrical accessories......................................... 45
Opening the filler caps...................................................... 46
Closing the filler caps ....................................................... 47
Unlocking the storage compartment ................................... 48
Locking the storage compartment....................................... 48
Opening the storage compartment...................................... 49
Closing the storage compartment ....................................... 49
Seat lock ......................................................................... 50
Tool set ........................................................................... 50
Fuel taps ......................................................................... 51
Handrails......................................................................... 51
Luggage rack plate ........................................................... 52
Passenger footrests........................................................... 52
Shift lever........................................................................ 53
TABLE OF CONTENTS 4
Foot brake lever................................................................ 54
Side stand ....................................................................... 54
Center stand .................................................................... 55
PREPARING FOR USE.......................................................... 56
Information on first use..................................................... 56
Running in the engine....................................................... 57
Loading the vehicle .......................................................... 58
RIDING INSTRUCTIONS ....................................................... 60
Checks and maintenance measures when preparing for
use ................................................................................. 60
Starting ........................................................................... 61
Starting off ...................................................................... 63
Shifting, riding................................................................. 63
Braking ........................................................................... 67
Stopping, parking ............................................................. 69
Refueling......................................................................... 71
SERVICE SCHEDULE............................................................ 74
Service schedule .............................................................. 74
TUNING THE CHASSIS......................................................... 77
Fork/shock absorber.......................................................... 77
Adjusting the compression damping of the fork ................... 77
Adjusting the rebound damping of the fork.......................... 78
Adjusting the spring preload of the fork .............................. 80
Compression damping of the shock absorber ....................... 81
Adjusting the low-speed compression damping of the shock
absorber .......................................................................... 81
Adjusting the high-speed compression damping of the
shock absorber ................................................................. 83
Adjusting the rebound damping of the shock absorber.......... 84
Adjusting the spring preload of the shock absorber .............. 85
SERVICE WORK ON THE CHASSIS........................................ 87
Raising the vehicle using the center stand .......................... 87
Raising the vehicle off of the center stand .......................... 88
Bleeding the fork legs ....................................................... 88
Cleaning the dust boots of the fork legs .............................. 89
Checking the steering head bearing play ............................. 90
Removing the front side cover............................................ 91
Installing the front side cover ............................................ 91
Removing the radiator guard.............................................. 92
Installing the radiator guard............................................... 93
Removing the seat ............................................................ 94
Mounting the seat ............................................................ 94
Removing the crash bar x (990 Adventure USA)................ 95
Installing the crash bar x (990 Adventure USA) ................ 96
Removing the storage compartment and hanging it to one
side x............................................................................ 97
Installing the storage compartment x ............................... 97
Removing the left fuel tank x .......................................... 98
Installing the left fuel tank x........................................... 99
Checking for chain dirt.................................................... 101
Cleaning the chain.......................................................... 102
Checking the chain tension ............................................. 103
Adjusting the chain tension ............................................. 104
Checking the chain, rear sprocket and engine sprocket....... 106
Adjusting the basic setting of the clutch lever ................... 109
Checking/rectifying the fluid level of the hydraulic clutch ... 109
Removing the right underride guard.................................. 110
Installing the right underride guard .................................. 110
Removing the underride guard x.................................... 111
TABLE OF CONTENTS 5
Installing the underride guard x..................................... 111
BRAKES............................................................................ 112
ABS/antilock brake system (990 Adventure USA) .............. 112
Checking the free travel of the hand brake lever ................ 113
Adjusting the free travel of the hand brake lever ................ 114
Checking the brake discs................................................. 114
Checking the front brake fluid level .................................. 115
Adding front brake fluid x ............................................. 116
Checking the front brake linings....................................... 118
Checking the free travel of the foot brake lever .................. 118
Checking the rear brake fluid level ................................... 119
Adding rear brake fluid x .............................................. 120
Checking the rear brake linings........................................ 122
WHEELS, TIRES ................................................................ 124
Removing the front wheel x........................................... 124
Installing the front wheel x............................................ 126
Removing the rear wheel x............................................ 127
Installing the rear wheel x............................................. 129
Checking the rear hub rubber dampers x ........................ 131
Checking the tire condition.............................................. 132
Checking the tire air pressure .......................................... 133
Checking spoke tension................................................... 134
ELECTRICAL SYSTEM ........................................................ 136
Removing the battery x................................................. 136
Installing the battery x.................................................. 137
Recharging the battery x............................................... 138
Changing the main fuse .................................................. 140
Changing the ABS fuses (990 Adventure USA).................. 142
Changing the fuses in the fuse box................................... 144
Removing the headlight mask with the headlight ............... 147
Installing the headlight mask with the headlight................ 148
Changing the headlight bulb............................................ 148
Changing the parking light bulb in the headlight................ 150
Changing the turn signal bulb.......................................... 151
Changing the tail light bulb ............................................. 152
Changing the brake light bulb.......................................... 153
Checking the headlight setting......................................... 154
Adjusting the headlight range .......................................... 154
Activating/deactivating the ignition key............................. 155
COOLING SYSTEM ............................................................. 160
Cooling system ............................................................... 160
Checking the antifreeze and coolant level ......................... 161
Checking the coolant level in the compensating tank ......... 164
Draining the coolant x .................................................. 165
Filling/bleeding the cooling system x.............................. 167
TUNING THE ENGINE ........................................................ 170
Checking the play in the throttle cable.............................. 170
Adjusting the play in the throttle cable x ........................ 171
Ignition curve plug-in connector....................................... 171
Adjusting the ignition curve to the fuel quality................... 172
SERVICE WORK ON THE ENGINE ....................................... 173
Checking the engine oil level ........................................... 173
Changing the engine oil and filter, cleaning the oil
screens x..................................................................... 174
Draining engine oil, cleaning oil screens x ...................... 174
Removing the oil filter x................................................ 178
Installing the oil filter x ................................................ 179
TABLE OF CONTENTS 6
Filling up with engine oil x............................................ 179
Adding engine oil ........................................................... 181
CLEANING, CARE .............................................................. 183
Cleaning motorcycle ....................................................... 183
Checks and maintenance steps for winter operation ........... 185
STORAGE .......................................................................... 186
Storage.......................................................................... 186
Preparing for use after storage ......................................... 187
TROUBLESHOOTING.......................................................... 188
IMMOBILIZER BLINK CODE................................................ 191
ENGINE CONTROL BLINK CODE......................................... 193
TECHNICAL DATA - ENGINE............................................... 199
Capacity - engine oil ....................................................... 200
Capacity - coolant........................................................... 200
TECHNICAL DATA - ENGINE TIGHTENING TORQUES........... 201
TECHNICAL DATA - CHASSIS ............................................. 204
Lighting equipment ........................................................ 206
Tires ............................................................................. 206
Capacity - fuel................................................................ 207
TECHNICAL DATA - FORK................................................... 208
990 Adventure USA........................................................ 208
990 Adventure R USA .................................................... 209
TECHNICAL DATA - SHOCK ABSORBER .............................. 211
990 Adventure USA........................................................ 211
990 Adventure R USA .................................................... 212
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ......... 214
SUBSTANCES.................................................................... 217
AUXILIARY SUBSTANCES................................................... 221
STANDARDS...................................................................... 223
INDEX ............................................................................... 224
MEANS OF REPRESENTATION 7
Symbols used
The meaning of specific symbols is described below.
Indicates an expected reaction (e.g. of a work step or a function).
Indicates an unexpected reaction (e.g. of a work step or a function).
All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your
own safety, have these jobs performed by an authorized KTM workshop! There, your motorcycle will be serviced opti-
mally by specially trained experts using the specialist tools required.
Indicates a page reference (more information is provided on the specified page).
Formats used
The typographical formats used in this document are explained below.
Specific name Identifies a proprietary name.
Name
®
Identifies a protected name.
Brandâ„¢ Identifies a brand available on the open market.
IMPORTANT INFORMATION 8
Use definition
KTM sport motorcycles are designed and constructed to meet the normal demands of regular road and light offroad operation (dirt roads),
but not for use on race courses.
Info
The motorcycle is authorized for public road traffic in the homologous version only.
Service
A prerequisite for perfect operation and prevention of premature wear is that the service, care and tuning work on the engine and chassis
are properly carried out as described in the owner's manual. Poor adjustment and tuning of the engine and suspension can lead to damage
and breakage of components.
Using the motorcycle in extreme conditions such as very muddy or wet roads can lead to above-average wear of components such as the
transmission train or the brakes. For this reason, it may be necessary to service or replace worn parts before the limit specified in the
service schedule is reached.
Pay careful attention to the prescribed running-in period and service intervals. Close adherence to these periods will significantly lengthen
the service life of your motorcycle.
Warranty
The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's
service record and in the KTM dealer.net; otherwise, all warranty claims will be void. No warranty claims can be considered for damage
resulting from manipulations and/or alterations to the vehicle.
Materials
The fuels and lubricants named in the owner's manual must be used according to specifications.
IMPORTANT INFORMATION 9
Spare parts, accessories
For your own safety, only use spare parts and accessory products that have been approved and/or recommended by KTM and have them
installed by an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage.
Some of the spare parts and accessory products are specified in parentheses under the respective descriptions. Your KTM dealer will be
glad to advise you.
You will find the current KTM PowerParts for your vehicle on the KTM website.
International KTM Website: http://www.ktm.com
Work rules
Special tools are necessary for some of the work. These are not included with the vehicle and can be ordered under the number in paren-
theses. Ex: valve spring mounter (59029019000)
During assembly, non-reusable parts (e.g. self-locking screws and nuts, seals and seal rings, O-rings, pins, lock washers) must be replaced
by new parts.
Where thread lockers are used on screw connections (e.g., Loctite
®
), follow the instructions for use from the manufacturer.
Parts that you want to reuse following repairs and servicing should be cleaned and checked for damage and wear. Change damaged or
worn parts.
Following repairs or servicing, the vehicle must be checked for roadworthiness.
Transport
Note
Danger of damage The parked vehicle may roll away or fall over.
– Always place the vehicle on a firm and even surface.
Note
Fire hazard Some vehicle components become very hot when the vehicle is operated.
– Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from being
run. Always let the vehicle cool first.
IMPORTANT INFORMATION 10
– Switch off the engine and remove the ignition key.
– Secure the motorcycle against falling over or rolling away using straps or other suitable devices.
Environment
Motorcycling is a wonderful sport and we naturally hope that you can enjoy it to the full. However, it can also lead to problems with the
environment and conflict with other persons. Responsible behavior in handling the motorcycle can help to avoid such problems and con-
flicts. To protect the future of motorcycle sport, make sure that you use your motorcycle legally, display environmental consciousness, and
respect the rights of others.
11
IMPORTANT INFORMATION 12
2.1Overview of labels
101562-10
IMPORTANT INFORMATION 13
1 Information on starting up
2 Information on emission control
3 USA type label
4 Information on the evaporative emission control system
5 Information on suspension tuning
6 Information on refueling
7 Information on chain tension
8 Canada type label
9 Information on noise emission
700210-01
Information on starting up
IMPORTANT INFORMATION 14
101561-01
Information on emission control
101560-01
USA type label
IMPORTANT INFORMATION 15
101557-01
Information on the evaporative emission control system
100644-01
Information on suspension tuning
IMPORTANT INFORMATION 16
400630-01
Information on refueling
400628-01
Information on chain tension
IMPORTANT INFORMATION 17
101559-01
Canada type label
101558-01
Information on noise emission
Notes/warnings
Pay close attention to the notes/warnings.
IMPORTANT INFORMATION 18
Info
Various information and warning labels are affixed to the vehicle. Do not remove information/warning labels. If they are missing,
you or others may not recognize potential hazards and may therefore be injured.
Grades of risks
Danger
Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not
taken.
Warning
Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.
Caution
Identifies a danger that may lead to minor injuries if the appropriate measures are not taken.
Note
Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.
Warning
Identifies a danger that will lead to environmental damage if the appropriate measures are not taken.
Owner's manual
– Be sure to read this owner's manual carefully and completely before taking your first ride. It contains useful information and tips to
help you operate and handle your motorcycle. Only then will you find out how to best customize the motorcycle for your own use and
how you can protect yourself from injury. The owner's manual also contains important information on servicing the motorcycle.
– The owner's manual is an important component of the motorcycle and should be handed over to the new owner if the vehicle is sold.
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KTM 990 Adventure US blue 2012 Owner's manual

Category
Motorcycles
Type
Owner's manual

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