MotoService Log
KTM 990 Super Duke / R
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KTM · Shim-adjusted overhead-cam four-stroke twin, dry sump, gearbox shares engine oil, chain drive

990 Super Duke / R

Library entry covers 2005-2013

70 factory 37 guideline

Published source

KTM 990 Super Duke / R 2007 Owner's Manual, Periodic Maintenance Schedule pp.32-35

Factory owner's handbook. Covers 2007 owner's manual.

107 items for a 2011 model, grouped by interval the way a factory chart is laid out.

How this bike is built (what the schedule is based on)
Engine cycle
Four-stroke
Engine lubrication
Dry sump (separate oil tank)
Oil filtration
Replaceable cartridge or spin-on filter
Valve gear
Overhead cam, shim adjusted (incl. desmo)
Ignition
Electronic (CDI / transistor / ECU)
Charging
Alternator / stator with rectifier
Battery
Wet cell (flooded lead-acid, needs topping up)
Fuel system
Fuel injection
Cooling
Liquid cooled
Primary drive
Gear or chain inside engine, shares engine oil
Gearbox oil
Shares engine oil
Clutch control
Hand lever, hydraulic
Final drive
Chain
Front suspension
Telescopic fork
Rear suspension
Swingarm, single shock / cantilever
Front brake
Disc, hydraulic
Rear brake
Disc, hydraulic
Wheels
Cast / alloy, tubeless
Sidecar
No sidecar
Maintenance schedule

2011 KTM 990 Super Duke / R

On the road: every 300 km

1 item
  • Check engine oil level
    Pre-ride / on the road
    Guideline

    Each fuel stop on old machines. Dry sump: check the tank hot, engine idling or just stopped, per your manual.

On the road: every 500 km

3 items
  • Check lights, horn, brake light switches
    Pre-ride / on the road
    Guideline
  • Check tire pressures
    Pre-ride / on the road
    Guideline
  • Lubricate drive chain
    Pre-ride / on the road
    Guideline

    Lube warm, ideally at the end of the riding day so it soaks in overnight. Sooner after rain.

On the road: every 800 km

1 item
  • Check coolant level
    Pre-ride / on the road
    Guideline

On the road: every 1,000 km

1 item
  • Check chain slack and rear wheel alignment
    Pre-ride / on the road
    Guideline

Every 1,000 km

3 items
  • Clean drive chain thoroughly (remove and soak, re-lube)
    Final drive
    Factory

    Manual: Clean chain. Factory: Owner checks: every 1000 km

  • Lubricate chain (Vital checks and care procedures to conducted by the owner or the mechanic, p.35)
    Final drive
    Factory

    Factory: As printed: ● after every cleaning; ● every 1000 km

  • Bleed fork legs (Vital checks and care procedures to conducted by the owner or the mechanic, p.35)
    Front end
    Factory

    Factory: As printed: ● every 1000 km

Every 1,600 km or 6 months

1 item
  • Inspect tire tread, sidewalls and date codes
    Wheels and tires
    Guideline

Every 5,000 km or 12 months

6 items
  • Check throttle cable(s) free play and return
    Fuel and air
    Guideline
  • Check steering head bearing adjustment
    Front end
    Guideline
  • Inspect fork seals, stanchions and fork boots
    Front end
    Guideline
  • Check footrests, pegs, rear brake and gear lever pivots
    Rear suspension and frame
    Guideline
  • Grease and check center / side stand and springs
    Rear suspension and frame
    Guideline
  • Check brake pads and discs
    Brakes
    Guideline

Every 6,500 km or 12 months

1 item
  • Inspect, clean and gap spark plugs
    Engine
    Guideline

Every 7,500 km or 12 months

36 items
  • Change engine oil
    Engine
    Factory

    Manual: Change engine oil and oil filter. Factory: 1st service after 1000 km; then every 7500 km or once a year

  • Check all engine bolts accessible from the outside for tight fit
    Engine
    Factory

    Factory: As printed: ● 1st Service after 1000 km; ● every 7500 km or once a year; ● every 15000 km or every 2 years

  • Check cooling system for leaks and antifreeze protection
    Engine
    Factory

    Factory: As printed: ● 1st Service after 1000 km; ● every 7500 km or once a year; ● every 15000 km or every 2 years

  • Check engine fastening bolts for tight fit
    Engine
    Factory

    Factory: As printed: ● 1st Service after 1000 km; ● every 7500 km or once a year; ● every 15000 km or every 2 years

  • Check fault memory with the KTM diagnosis tool
    Engine
    Factory

    Factory: As printed: ● 1st Service after 1000 km; ● every 7500 km or once a year; ● every 15000 km or every 2 years

  • Check headlamp adjustment
    Engine
    Factory

    Factory: As printed: ● 1st Service after 1000 km; ● every 7500 km or once a year; ● every 15000 km or every 2 years

  • Check oil lines for damage and kink-less arrangement
    Engine
    Factory

    Factory: As printed: ● 1st Service after 1000 km; ● every 7500 km or once a year; ● every 15000 km or every 2 years

  • Check radiator fan for proper operation
    Engine
    Factory

    Factory: As printed: ● 1st Service after 1000 km; ● every 7500 km or once a year; ● every 15000 km or every 2 years

  • Check rim joint
    Engine
    Factory

    Factory: As printed: ● 1st Service after 1000 km; ● every 7500 km or once a year; ● every 15000 km or every 2 years

  • Check the exhaust system for leaks and correct suspension and the clamps for a tight fit
    Engine
    Factory

    Factory: As printed: ● 1st Service after 1000 km; ● every 7500 km or once a year; ● every 15000 km or every 2 years

  • Clean magnetic drain plugs of engine and oil tank
    Engine
    Factory

    Factory: As printed: ● 1st Service after 1000 km; ● every 7500 km or once a year; ● every 15000 km or every 2 years

  • Clean oil strainers / mesh screens
    Engine
    Factory

    Manual: Clean oil screens of engine and oil tank. Factory: Dry sump; also clean magnetic drain plugs

  • Make sure all bolts and nuts are tight
    Engine
    Factory

    Factory: As printed: ● 1st Service after 1000 km; ● every 7500 km or once a year; ● every 15000 km or every 2 years

  • Replace oil filter
    Engine
    Factory

    Manual: Change engine oil and oil filter. Factory: With oil change

  • Make sure the fuel hose, hoses on the vacuum sensors, SAS hoses and vent hoses are run correctly and check for damage
    Fuel and air
    Factory

    Factory: As printed: ● 1st Service after 1000 km; ● every 7500 km or once a year; ● every 15000 km or every 2 years

  • Replace the O-ring on the fuel hose connection and check for leaks
    Fuel and air
    Factory

    Factory: As printed: ● 1st Service after 1000 km; ● every 7500 km or once a year; ● every 15000 km or every 2 years

  • Check electrical system for function (low/high beams, stop light, turn indicators,headlamp, flasher, tell-tale lamps, speedometer illumination, horn, side-stand switch, clutch switch, emergency-off switch)
    Primary and gearbox
    Factory

    Factory: As printed: ● 1st Service after 1000 km; ● every 7500 km or once a year; ● every 15000 km or every 2 years

  • Check the oil level in the hydraulic clutch reservoir
    Primary and gearbox
    Factory

    Factory: As printed: ● every 7500 km or once a year; ● every 15000 km or every 2 years

  • Perform a status check of neutral, clutch, 2nd/3rd gear and side stand switch using the KTM diagnosis tool
    Primary and gearbox
    Factory

    Factory: As printed: ● 1st Service after 1000 km; ● every 7500 km or once a year; ● every 15000 km or every 2 years

  • Check bolts on pinion and chain sprocket for locking devices and a tight fit
    Final drive
    Factory

    Factory: As printed: ● 1st Service after 1000 km; ● every 7500 km or once a year; ● every 15000 km or every 2 years

  • Inspect chain and sprockets for wear (measure stretch)
    Final drive
    Factory

    Manual: Check chain, sprockets and chain guides for wear, force fit and tension. Factory: Every 7500 km or once a year

  • Lubricate chain
    Final drive
    Factory

    Factory: As printed: ● 1st Service after 1000 km; ● every 7500 km or once a year; ● every 15000 km or every 2 years

  • Bleed fork legs
    Front end
    Factory

    Factory: As printed: ● 1st Service after 1000 km; ● every 7500 km or once a year; ● every 15000 km or every 2 years

  • Check all chassis bolts for tight fit (fork plates, fork leg, axle nuts/bolts, swinging-fork pivot, reversing lever, shock absorber)
    Front end
    Factory

    Factory: As printed: ● 1st Service after 1000 km; ● every 7500 km or once a year; ● every 15000 km or every 2 years

  • Check shock absorber and fork for leaks and proper operation
    Front end
    Factory

    Factory: As printed: ● 1st Service after 1000 km; ● every 7500 km or once a year; ● every 15000 km or every 2 years

  • Check swinging-fork pivot
    Front end
    Factory

    Factory: As printed: ● 1st Service after 1000 km; ● every 7500 km or once a year; ● every 15000 km or every 2 years

  • Check/adjust steering-head bearing
    Front end
    Factory

    Factory: As printed: ● 1st Service after 1000 km; ● every 7500 km or once a year; ● every 15000 km or every 2 years

  • Clean fork dust sleeves
    Front end
    Factory

    Factory: As printed: ● every 7500 km or once a year; ● every 15000 km or every 2 years

  • Check bolts of brake system for tight fit
    Brakes
    Factory

    Factory: As printed: ● 1st Service after 1000 km; ● every 7500 km or once a year; ● every 15000 km or every 2 years

  • Check brake fluid level, lining thickness, and brake discs
    Brakes
    Factory

    Factory: As printed: ● 1st Service after 1000 km; ● every 7500 km or once a year; ● every 15000 km or every 2 years

  • Check brake lines for damage and leaks
    Brakes
    Factory

    Factory: As printed: ● 1st Service after 1000 km; ● every 7500 km or once a year; ● every 15000 km or every 2 years

  • Check/adjust smooth operation, free travel of handbrake/footbrake levers
    Brakes
    Factory

    Factory: As printed: ● 1st Service after 1000 km; ● every 7500 km or once a year; ● every 15000 km or every 2 years

  • Check tire condition and inflation pressure
    Wheels and tires
    Factory

    Factory: As printed: ● 1st Service after 1000 km; ● every 7500 km or once a year; ● every 15000 km or every 2 years

  • Check wheel bearings for play
    Wheels and tires
    Factory

    Manual: Check wheel bearings and jerk damper for play. Factory: Every 7500 km or once a year

  • Check actuating cables for damage, smooth operation, and kink-less arrangement,adjust and lubricate
    Controls and cables
    Factory

    Factory: As printed: ● 1st Service after 1000 km; ● every 7500 km or once a year; ● every 15000 km or every 2 years

  • Check cables for damage and kink-less arrangement
    Controls and cables
    Factory

    Factory: As printed: ● 1st Service after 1000 km; ● every 7500 km or once a year; ● every 15000 km or every 2 years

Every 9,500 km or 12 months

5 items
  • Inspect coolant hoses and clamps
    Engine
    Guideline
  • Check charging voltage and regulator / cut-out
    Ignition and electrics
    Guideline
  • Check swingarm bushes for play
    Rear suspension and frame
    Guideline
  • Lubricate control cables and lever pivots
    Controls and cables
    Guideline
  • Lubricate speedometer / tachometer cables, check drive
    Controls and cables
    Guideline

    A dry speedo cable whips the needle and eventually kills the instrument.

Every 15,000 km or 2 years

13 items
  • Check rubber boots for cracks or leaks
    Engine
    Factory

    Factory: As printed: ● 1st Service after 1000 km; ● every 15000 km or every 2 years

  • Check the wiring harness on the throttle body for proper installation and damage
    Engine
    Factory

    Factory: As printed: ● 1st Service after 1000 km; ● every 15000 km or every 2 years

  • Check valve clearances (shim adjusted)
    Engine
    Factory

    Manual: Check and adjust valve clearance. Factory: 1st service at 1000 km; then every 15000 km or 2 years

  • Replace coolant
    Engine
    Factory

    Manual: Change coolant fluid. Factory: Additional service work: every 15000 km or every 2 years

  • Replace spark plugs
    Engine
    Factory

    Manual: Renew spark plugs. Factory: Every 15000 km or every 2 years

  • Replace the graphite gasket in the rear exhaust manifold slide
    Engine
    Factory

    Factory: As printed: ● every 15000 km or every 2 years

  • Clean / inspect air filter
    Fuel and air
    Factory

    Manual: Check air filter, renew if necessary, clean air filter box. Factory: Every 15000 km or every 2 years

  • Check clutch pressure booster system
    Primary and gearbox
    Factory

    Factory: As printed: ● every 15000 km or every 2 years

  • Clean the oil jet for the clutch lubrication
    Primary and gearbox
    Factory

    Factory: As printed: ● 1st Service after 1000 km; ● every 15000 km or every 2 years

  • Inspect clutch plates and springs
    Primary and gearbox
    Factory

    Manual: Check clutch linings. Factory: Every 15000 km or every 2 years

  • Rebuild forks: seals, bushes, springs
    Front end
    Factory

    Manual: Perform complete fork maintenance. Factory: Additional service work

  • Inspect rear shocks for leaks and damping
    Rear suspension and frame
    Factory

    Manual: Perform complete shock absorber maintenance. Factory: Additional service work

  • Replace brake fluid
    Brakes
    Factory

    Manual: Change brake fluid. Factory: Every 15000 km or every 2 years

Every 16,000 km or 2 years

1 item
  • Compression test (or leak-down)
    Engine
    Guideline

Every 19,500 km or 2 years

4 items
  • Replace air filter element
    Fuel and air
    Guideline
  • Synchronize throttle bodies
    Fuel and air
    Guideline
  • Clean and grease rear suspension linkage
    Rear suspension and frame
    Guideline
  • Grease swingarm pivot
    Rear suspension and frame
    Guideline

Every 24,000 km or 3 years

1 item
  • Change fork oil
    Front end
    Guideline

    Some early telescopic forks are grease filled or use very small oil quantities. Check your manual.

Every 29,000 km

1 item
  • Replace chain and sprockets (wear based)
    Final drive
    Guideline

Every 32,000 km or 4 years

1 item
  • Repack / replace wheel bearings
    Wheels and tires
    Guideline

    Cup-and-cone and taper roller hubs need periodic repacking and adjustment.

Every 38,500 km or 4 years

1 item
  • Replace fuel filter
    Fuel and air
    Guideline

Every 40,000 km or 6 years

1 item
  • Replace swingarm bushes / bearings
    Rear suspension and frame
    Guideline

Every 6 months

1 item
  • Clean battery terminals, check charge and strap
    Ignition and electrics
    Guideline

Every 12 months

3 items
  • Treat battery connections with contact grease (Additional service work to be performed under a separate order)
    Ignition and electrics
    Factory

    Factory: As printed: ● at least once a year

  • Treat the electrical contacts and switches with contact spray (Additional service work to be performed under a separate order)
    Ignition and electrics
    Factory

    Factory: As printed: ● at least once a year

  • Repack / replace steering head bearings
    Front end
    Factory

    Manual: Clean and lubricate steering-head bearing and sealing elements. Factory: At least once a year

Every 2 years

3 items
  • Inspect wiring, bullet connectors and ground points
    Ignition and electrics
    Guideline
  • Replace hydraulic clutch fluid
    Primary and gearbox
    Guideline
  • Inspect frame, welds and lugs for cracks
    Rear suspension and frame
    Guideline

Every 4 years

3 items
  • Replace fuel lines
    Fuel and air
    Guideline

    Old rubber and modern ethanol fuel do not mix well.

  • Inspect brake hoses; replace old rubber
    Brakes
    Guideline
  • Rebuild calipers and master cylinders (seals)
    Brakes
    Guideline

Every 6 years

1 item
  • Replace tires on age (regardless of tread)
    Wheels and tires
    Guideline

No interval set

15 items
  • Check coolant level (Vital checks and care procedures to conducted by the owner or the mechanic, p.35)
    Engine
    Factory

    Factory: As printed: ● before each start

  • Check horn for proper operation (Vital checks and care procedures to conducted by the owner or the mechanic, p.35)
    Engine
    Factory

    Factory: As printed: ● before each start

  • Check lighting system for proper operation (Vital checks and care procedures to conducted by the owner or the mechanic, p.35)
    Engine
    Factory

    Factory: As printed: ● before each start

  • Check oil level (Vital checks and care procedures to conducted by the owner or the mechanic, p.35)
    Engine
    Factory

    Factory: As printed: ● before each start

  • Treat exposed metal components (except for the braking and exhaust system) with wax-based anti-corrosion agents (Vital checks and care procedures to conducted by the owner or the mechanic, p.35)
    Engine
    Factory

    Factory: As printed: ● after every cleaning

  • Check fuel lines for leaks (Vital checks and care procedures to conducted by the owner or the mechanic, p.35)
    Fuel and air
    Factory

    Factory: As printed: ● before each start

  • Check chain tension (Vital checks and care procedures to conducted by the owner or the mechanic, p.35)
    Final drive
    Factory

    Factory: As printed: ● before each start

  • Treat ignition/steering lock and light switch with contact spray (Vital checks and care procedures to conducted by the owner or the mechanic, p.35)
    Front end
    Factory

    Factory: As printed: ● after every cleaning

  • Check brake fluid level (Vital checks and care procedures to conducted by the owner or the mechanic, p.35)
    Brakes
    Factory

    Factory: As printed: ● before each start

  • Check brake pads for wear (Vital checks and care procedures to conducted by the owner or the mechanic, p.35)
    Brakes
    Factory

    Factory: As printed: ● before each start

  • Check brake performance (Vital checks and care procedures to conducted by the owner or the mechanic, p.35)
    Brakes
    Factory

    Factory: As printed: ● before each start; ● after every cleaning

  • Grease the hand brake lever and clutch lever (Vital checks and care procedures to conducted by the owner or the mechanic, p.35)
    Brakes
    Factory

    Factory: As printed: ● after every cleaning

  • Check tire pressure and wear (Vital checks and care procedures to conducted by the owner or the mechanic, p.35)
    Wheels and tires
    Factory

    Factory: As printed: ● before each start

  • Check all control elements for smooth running (Vital checks and care procedures to conducted by the owner or the mechanic, p.35)
    Controls and cables
    Factory

    Factory: As printed: ● before each start

  • Lubricate actuating cables and nipples (Vital checks and care procedures to conducted by the owner or the mechanic, p.35)
    Controls and cables
    Factory

    Factory: As printed: ● after every cleaning

Guideline lines: Intervals here are general guidelines for the machine's era and layout, compiled for this app. They are not factory manual figures. Check your workshop manual, and edit any interval in the bike's Schedule tab.

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