User manual KTM 990 ADVENTURE

[. . . ] 3211242en INTRODUCTION » We would like to congratulate you on your purchase of a KTM motorcycle. You are now the owner of a state-of-the-art sport motorcycle that guarantees to bring you lots of fun and enjoyment, provided that you clean and maintain it appropriately. Please insert the serial numbers of your motorcycle in the boxes below: Frame number Stamp of dealer 1 Engine number Key number All information contained is without obligation. KTM-Sportmotorcycle AG particularly reserves the right to modify any equipment, technical specifications, prices, colors, shapes, materials, services, service work, constructions, equipment and the like so as to adapt them to local conditions or to cancel any of the above items, all without previous announcement and without giving reasons. [. . . ] Turn the knob in a clockwise direction to increase damping, turn it in a counterclockwise direction to reduce damping during rebounding. STANDARD ADJUSTMENT: ­ turn the adjusting screw clockwise to the stop. ­ then turn the adjusting screw counterclockwise, counting the number of clicks that corresponds to the respective type of shock absorber. . 15 clicks The damping unit of the shock absorber is filled with high-compression nitrogen. Never try to take the shock absorber apart or to do any maintenance work yourself. Never unscrew the black screw connection [5] (15mm). 5 4 MAINTENANCE WORK ON CHASSIS AND ENGINE » Adjusting the preload of the shock absorber 46 1 The baggage and passenger put the main load on the shock absorber. To guarantee maximum handling performance, the preload of the shock absorber must be adapted to the load. Turning in a clockwise direction will increase the preload, turning in a counterclockwise direction will reduce the preload. Our pragmatical values are provided in the table "Basic settings for the shock absorber" to help you to make the necessary adjustments. STANDARD ADJUSTMENT: ­ Turn the hand wheel in a counterclockwise direction up to the stop ­ Turn the hand wheel 6 turns in a clockwise direction Breathing the fork legs 2 Breath the fork legs regularly (see Maintenance Schedule). To breath, place the motorcycle on the side stand and briefly remove the bleeder screws [2] to allow any overpressure to escape from the fork. Excessive pressure in the interior of the fork can cause leaks in the fork. If your fork is leaking, it is recommended to open the breather plugs before having the seals replaced. MAINTENANCE WORK ON CHASSIS AND ENGINE » Cleaning the dust sleeves of the telescopic fork 47 The dust-protection bellows [3] are to remove dust and coarse dirt particles from the fork tube. However, after some time, dirt may also get in behind the dust-protection bellows. If this dirt is not removed, the oil sealing rings located behind it may start to leak. Use a screwdriver to lever the dust-protection bellows out of the outer tubes and slide them downward. 3 Clean dust-protection bellows, outer tubes, and fork tubes thoroughly, and oil them thoroughly with Universal oil spray (Motorex Joker 440) or engine oil. No oil may reach the front tire or the brake disks since this would considerably reduce the tire's road grip and the braking effect of the front brake. Checking the chain tension 4 Place the motorcycle on the side stand and switch the transmission to idle. ­ If chain tension is too great, parts within the secondary power transmission (chain, chain sprockets, transmission and rear wheel bearings) will be subjected to unnecessary stress, resulting in premature wear and even chain breakage. ­ Too much slack in the chain, on the other hand, can result in the chain jumping off the chain wheels. If this happens, the chain could also block the rear wheel or damage the engine. ­ In either case the operator is likely to lose control of the motorcycle. 35 . . . 40 mm MAINTENANCE WORK ON CHASSIS AND ENGINE » Correct chain tension 1 3 2 48 Loosen collar nut [1], loosen counter nuts [2], and turn right and left adjusting screws [3] equally far. [. . . ] of 160 kph/100 mph: Continental TKC80 90/90-21 M/C 54S TT M+S road/driver only 2, 4 bar (34 psi) road/with passenger 2, 4 bar (34 psi) Pirelli MT90 150/70 18 M/C 70V Up to a max. of 160 kph/100 mph: Continental TKC80 150/70B18 M/C 70Q TT M+S road/driver only 2. 6 bar (37 psi) road/with passenger 2. 8 bar (40 psi) 19. 5 liters (5. 1 USgal), 17:42 525 HV (5/8 x 5/16") X-ring, 118 rolls high beam H3 12V 55W (socket PK22s) low beam H7 12V 55W (socket PX26d) USA: high beam + low beam H4 12V 60/55 W (socket P43t) position light front + rear 12V 5W (socket W2. 1x9. 5d) indicator lamps LED stoplight 12V 21W (socket BA15s) 4 liters (1 USgal) reserve 90 * further tire releases are available on the Internet at www. ktm. com TECHNICAL SPECIFICATIONS ­ CHASSIS » CHASSIS Lighting Battery Steering head angle Wheel base Seat height, unloaded Ground clearance, unloaded Dry weight Max. total weight 990 ADVENTURE / 990 ADVENTURE S flasher 12V RY10W (socket BAU15s) licens plate illumination 12V 5W (socket W2. 1x9, 5d) maintenance-free battery 12V 11. 2 Ah 63. 4° 1570 mm (61. 8 in) ADVENTURE: 860 mm (33. 8 in), ADVENTURE S: 915 mm (36 in) ADVENTURE: 261 mm (10. 3 in), ADVENTURE S: 316 mm (12. 4 in) ADVENTURE: 209 kg (461 lbs) / ADVENTURE S: 207 kg (457 lbs) 200 kg (441. 5 lbs) 250 kg (552 lbs) 430 kg (949 lbs) 91 Maximum Payload Volle Nutzlast Basic Setting Basic Setting Driving Sport Driving Comfort Basic Setting Driving Sport Compression adjuster Low Speed (clicks) 25 20 15 15 Compression adjuster High Speed (turns) 2 1, 5 1 1 Rebound adjuster (clicks) Spring preload (turns) 20 15 10 10 4 4 8 16 Compression adjuster Low Speed (clicks) 25 20 15 15 Compression adjuster High Speed (turns) 2 1, 5 1 1 Rebound adjuster (clicks) Spring preload (turns) 20 15 10 10 4 4 8 10 Compression adjuster (clicks) 20 15 10 10 Rebound adjuster (clicks) Spring preload (turns) 23 18 13 13 5587 Driving Sport BASIC SETTING FORK 990 ADVENTURE 990 ADVENTURE S BASIC SETTING SHOCK ABSORBER 990 ADVENTURE BASIC SETTING SHOCK ABSORBER 990 ADVENTURE S Maximum Payload Driving Comfort Driving Comfort TECHNICAL SPECIFICATIONS ­ CHASSIS » TIGHTENING TORQUES ­ CHASSIS HH clamp bolts on top triple clamp HH clamp bolts for steering stem HH clamp bolts on bottom triple clamp AH bolt for handlebar mount Collar bolts for handlebar clamps HH clamp bolts on fork leg axle passages Collar screw on front wheel spindle Collar nut wheel spindle rear Collar nut for swing arm bolt AH screw shock absorber top AH bolt shock absorber bottom AH bolt for top of brake-hose guide HH bolts on front brake caliper HH bolts on footbrake cylinder Collar bolt front brake disks Collar bolt rear brake disk AH bearing bolt for foot brake pedal HH bolts on foot brake pedal surface AH bolts on subframe AH bolts on back of footrest support AH bolts on tank cover HH bolt on fuel level indicator HH bolts fuel taps AH bolts on tank mounting M8 M8 M8 M10 M8 M8 M24x1, 5 M25x1, 5 M19x1, 5 M14x1, 5 M14x1, 5 M6 M8 M6 M6 M6 M8 M5 M10x1, 25 M8 M5 M5 M6 M8 20 Nm 20 Nm 15 Nm 20 Nm 20 Nm 15 Nm 60 Nm 90 Nm 130 Nm 80 Nm 80 Nm Loctite 243 + 8 Nm Loctite 243 + 25 Nm Loctite 243 + 10 Nm Loctite 243 + 14 Nm Loctite 243 + 14 Nm Loctite 243 + 25 Nm Loctite 243 + 6 Nm Loctite 243 + 45 Nm Loctite 243 + 25 Nm 5 Nm 3 Nm 6 Nm 25 Nm 92 TECHNICAL SPECIFICATIONS ­ CHASSIS » TIGHTENING TORQUES ­ CHASSIS Exhaust nuts on manifold HH bolts on exhaust suspension Spoke nipple HH nuts on rear sprocket bolts Hexagon nut on engine sprocket Engine carrier bolts HH bolts for side stand bracket - engine HH bolts side stand bracket - side stand console HH bolts side stand mounting HH bolt spring retainer side stand HH bolt side stand switch HH bolts for underride protection Drain plug on oil tank Chain sliding guard HH collar screw for front ABS sensor Special screw for rear ABS sensor Nut for plug socket Other bolts on chassis M8 M6 M5 M10x1, 25 M20x1, 5 M10 M10 M10 M10 M8 M6 M8 M12x1, 5 M6 M6 M6 M18x1 M6 M8 M10 Other collar nuts on chassis M6 M8 M10 evenly, do not bend sheet metal Loctite 243 + 12 Nm 5 Nm ± 1 Nm Loctite 243 + 50 Nm Loctite 243 + sheet retainer + 100 Nm 45 Nm Loctite 243 + 40 Nm Loctite 243 + 25 Nm Loctite 243 + 35 Nm Loctite 243 + 25 Nm Loctite 243 + 10 Nm Loctite 243 + 25 Nm 25 Nm Loctite 243 + 6 Nm 6 Nm Loctite 243 + 8 Nm 4 Nm 10 Nm 25 Nm 45 Nm 15 Nm 30 Nm 50 Nm 93 TECHNICAL SPECIFICATIONS ­ ENGINE » ENGINE Design Displacement Bore / Stroke Compression ratio Fuel Valve timing Valve diameter Valve clearance, cold Crankcase bearing Conrod bearing Piston pin bearing Piston Piston rings Engine lubrication Engine oil Quantity of engine oil Primary drive Clutch Transmission Gear ratio 990 LC8 999 cc 101/62. 4 mm 11. 5:1 unleaded fuel with at least RON 95 (USA: Premium PON 91*) / RON 80 - 94 for other ignition curve) 4 valves controlled over bucket tappet and 2 camshafts, camshaft drive with gears/chain Intake: 38 mm Exhaust: 33 mm Intake: 0. 10 - 0. 15 mm Exhaust: 0. 25 - 0. 30 mm Friction bearings (2 main bearings / 1 supporting bearing) Friction bearing Dual-fuel bearing Light alloy ­ forged 1 compression ring, 1 taper face ring, 1 single-piece oil scraper ring with spiral-type expander Dry sump with 2 trochoidal pumps (pressure pump and suction pump) SAE 10W-50 ( Motorex Power Synt 4T) # approx. 3. 0 liters during oil/filter change Straight-toothed spur wheels 35 : 67 Multi-disc clutch in oil bath 6-speed claw shifted 1st gear 12:35 2nd gear 15:32 3rd gear 18:30 4th gear 20:27 5th gear 24:27 6th gear 27:26 94 Liquid-cooled, 2-cylinder 4-stroke engine with 75° V arrangement with balancer shaft and electric starter TECHNICAL SPECIFICATIONS ­ ENGINE » ENGINE Mixture preparation Ignition system Ignition timing Generator Spark plug Electrode distance Cooling system Cooling liquid Starting aid 990 LC8 EFI (electronic fuel injection) breakerless transistorized electronic ignition system with digital ignition advance Map-controlled via TPS 12V 450W at 6000 rpm NGK DCPR 8 E 0. 8 mm liquid cooled, permanent circulation of cooling liquid through water pump 2. 1 liters, 50% antifreeze, 50% distilled water, at least ­25° C 0. 9 kW electric starter 95 # JASO T903 MA TEMPERATURE 0°C 32°F * PON / CLC 87 RON / ROZ 91 MON 83 87 91 Premium 95 PON = CLC = RON = ROZ = MON = Pump Octane Number Cost of Living Council Research Octane Number Research Oktan Zahl Motor Octane Number 5W/40 10W/50 Engine oil Only use fully synthetic engine oils that meet the JASO MA quality requirements (see information on the can). 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