This List is now pretty stable, and covers performance modifications.
Accessories, heandy to have items and looks are not covered here.
Please let me know if you have any suggestions recommendations comments or updates.


Here is a list of modifications that have been done and recommended for the 2005 - 2006 KTM Superduke from this news group. This list is in priority order:

1) 16T front Sprocket
Approx Cost: US$50.00
Rankng: Must do
Notes: This usually needs main shaft seal change
Advantages: Improves accelleration, decreases throttle twitchiness. This should be the factory standard!
Disadvantages: (if you see this as a disadvantage) Reduces your top speed slightly (approx 5%) from 253km/h to approx 240km/h in theory.
Gregz's dyno run shows a maximum of 220km/h that my bike can actully reach.
Part#: 60033029016
URL:

2) Mufflers / ECU Remap
Approx Cost:
Ranking: Highly Recommended
Notes: The remap is done as part of the Akropovic mufflers installation from KTM Hardparts. The re-map also removes the throttle limiter for 2nd and 3rd gears (ECU configured for noise emissions compliance)
Advantages: The noise! Good performance improvements, Much lighter, considerably cooler mufflers.
Disadvantages: Cost. You loose the Catalitic converter and start killing our atmosphere. No other noted issues
Part#: 61005099000 Slipon Titanium Akrapovic silencer set
URL: ?

3) Modify Akropovic Exhaust Baffles
Approx Cost: $0.00
Ranking: Highly Recommended
Notes: This is an easy modification.. but you need specialised tools like a hammer, chisel and most importantly an angle grinder.
Advantages: The noise! My goodness - it sounds great!
Disadvantages: Takes your time and effort. Not proven to improve performance
Part#: To modify the - 61005099000 Slipon Titanium Akrapovic silencer baffles
URL:

4) Air Filter (eg DNA Filter)
Approx Cost: US$110.00
Ranking: Debatable
Notes: Easy installation and
Advantages: Supposedly increases performance by a few hp, easy to cleanand re-oil which saves your $ in the long run.
Disadvantages: None (although you do need to clean it)
Part#: DNA Filters Model # P-KT9S06-01
URL:

5) Disconnect gear position sensor (ATL) > only with standard exhaust
Approx Cost: $0.00 Modification or EUR 39,90 from Sommer KTM
Ranking: Highly Recommended
Notes: The ECU is configured to limit throttle to approx 80% for noise emissions compliance in 2nd and 3rd gears. Removing the gear position signal you override/fool this ECU setting. (The Akropovic map also removes the throttle limiter) (You can also buy a kit from Sommer)
Advantages: You can use 100% throttle opening in 2nd and 3rd gears
Disadvantages: None identified yet
URL:
URL:

6) Fit Ducati Radial or Aftermarket Brembo Levers (eg, CRG)
Approx Cost: US$120.00 + Modifications
Ranking: Much cheaper than KTM OEM levers (plus asthetics or looks)
Notes: The Brake master cylinder is a standard Brembo Radial unit which fits standard lever for example Ducati 749/999. The Clutch is a Magura 195 Radial clutch which uses Magura (KTM) levers. You can modify the Brembo Radail Clutch lever to fit (eg Ducati or CRG, etc)
Advantages: Fitting multi adjustable / non-breakable units like CRG. Otherwise fitting cheaper aftermarket levers.
Disadvantages: You need to buy and modify the clutch lever. The Brembo/Ducati brake levers fit.
URL:
URL:

7) Heat-Tape wrap or Ceramic Coat exhaust headers
Approx Cost: US$30.00 Tape + $US$10.00 Heat SprayPaint + US$10.00 SS clamps
£90.00 ceramic coat headers (approx AU$150.00)
Ranking: Highly Recommended (ceramic coating is dearer)
Note: You need to remove the exhaust to wrap it. This is a good bang for buck esp if you ride in high temp countries/states. Not sure on performance increase but in theory it should give some increase.
Advantages: Much cooler exhaust headers, quieter engine noise. Looks if you like the race look. Steams when riding in the wet.
Ceramic coat effectiveness and 'bang for buck' is yet to be determined.
Disadvantages: Hotter mufflers
Part#: None
URL:

8 ) KTM Hardparts Gel Seat or Seat Modification
Approx Cost: US$100.00 modification or US$170.00 KTM Gel Seat
Ranking: Recommended for shorter riders
Notes: Good for shorter riders or people who get a sore but on the std seat. If you modify, there is very little foam thickness to cut down.
Gel seat does not have positive feedback from owners - it does not seem to be very effective.
Advantages: Helps to reduce bum soreness
Disadvantages: No real disadvantage appart from the cost.
Part#: 6100704010030 Black or 6100704010004 Orange
URL: Gel Seat
URL: Seat Modification

9) Quick Throttle Modification
Approx Cost: <US$0.05
Ranking: If you have a dirtbike/racing heratige + not for bumpy roads
Notes: Glue/screw/solder (with soldering iron) an appropriate width plastic cable-tie around the throttle tube - cable runner.
This requires opening the airbox to adjust the throttle cable tension.
...modify the profile with a slight cam to improve touchyness - see the G2 link below.
Advantages: Quick throttle opening and easier to apply full throttle
Disadvantages: Throttle becomes more sensative and small movements can bump your hand - ie bumps/holes in the road. Fine for A and B roads.
Part#: None
URL:
URL:
URL:
URL:

10) Rapid Bike Module or Power Commander (Newly released) or Tuneboy (coming soon)
Approx Cost: >US$400.00 fitted
Ranking:
Advantages: A few more horsepower, but reported as much smoother throttle and cleaner power application.
Disadvantages: Cost. Not a dramatical increase in performance. You loose more underseat storage space.
Part#: Power Commander 925-411
Part#: Rapid Bike KRB3023
URL: PC
URL: RB
URL: Tuneboy not released yet Feb 2007

11) Dual Intake Velocity Stacks
Approx Cost: US$10.00
Ranking: Low
Note: Benefits are not proven directly, but no disadvantage on dyno.
Advantages: Claimed improved lower rpm response
Disadvantages: Undetermined power improvement so far as it is not dyno tested. You need to custom fit the intakes yourself to fit the standard velocity stacks - these are not bolt on items.
Part#: Jaycar Aust Part# CX2688 (58mm x 120mm)
URL:
URL:
URL:

12) Stack Knobs / Frame Sliders / Crash Bungs (whatever u call them)
Approx Cost: >AU$300.00
Ranking: Highly recommended for protection
Note: Benefits will be evident only after a crash
Advantages: Lower repair costs because u won't break as much. Has been 'tested' and does minimise damage.
Disadvantages: Upfront costs are high for the SD
Part#:
Oggy Knobbs OK350 (AU$300.00)
R&G Top CP0153BL and Bottom CP0154BL (UK£124.00 top & bottom)

13) Steering Damper
Approx Cost: >EUR 349,00
Ranking: Unknown
Note: To install the KTM Damper you need to purchase the Damper, Mounting kit as well as the KTM top triple-clamps
Advantages: It has been confirmed - it does remove those occasional wiggles and provides a more confidence inspiring ride.
Disadvantages: Most importantly the cost is very high from KTM. To fit the new triple clamp you need to swap the ignition barel to fit + replace the anti-tamper bolts. You also need to shim the clamp to align the security bolt. An aftermarket fitting unit will be cheaper & easier to fit. It removes that bar wiggles?
If you don't want to spend the $ then push your forks down the tripleclamps to be flat with them - no wiggles, no cost.
Part#:
KTM Damper 61012005000
KTM Mounting Kit 61012005144
KTM Top Triple-clamp 61001034126
Ohlins from Tecbike 002520
URL:
URL:

14) Carbon Wheels
Approx Cost: >US$4000.00
Ranking: Definately if you can afford it
Advantages: Much lighter giving: better acceleration, better braking, easier wheelies. Confirmed by our wealthy SD owners.
Disadvantages: Cost. Carbon does crack and break in certain circumstance, but there is no evidence of breakage at the time.
KTM Front 6100900100049
KTM Rear 6101000100049
URL:

15) Rear Sprocket Change
Approx Cost: US$80.00
Ranking: Not really needed if you fit a 16T front
Notes: You can fit 16/40T on the standard chain, but you will need to turn the blocks the other way and will be running a very short wheelbase. A new chain is recommended.
Advantages: Further improvement to acceleration. Weight if Alloy
Disadvantages: Reduces your top speed further, approx 16/41T will give a top speed of 190km/h.
Only compatible with the KTM Supermoto 950 and SD 990
(Not compatible with any other KTM model or other manufacturers)
Part#:
JT Rear model # is JTR 898.41 (sizes are 38 and 41 only)
Renthal Rear model # is 443U (sizes are 35 to 56)
KTM Rear model # is 610100511## (sizes are 39, 40 and 45 only)
Rental:
JT:
KTM:
Sub-note: JT (Link Australia) are not importing the SD sprockets

So are we saying that the gel seat is actually lower than the standard?

P.s great list of mods by the way, I really must put the 16 tooth sprocket on asap!

Really useful list. I am in the process of compiling one and it looks similar.

Good to have it all in one place