2003-2005 KTM 950 ADVENTURE 990 SUPER DUKE Part Manual - PDF DOWNLOAD

2003-2005 KTM 950 ADVENTURE 990 SUPER DUKE Part Manual - PDF DOWNLOAD

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2003-2005 KTM 950 ADVENTURE 990 SUPER DUKE Part Manual - PDF DOWNLOAD

Language :English_German_Italian_French_Spanish
Pages :273
Downloadable : Yes
File Type : PDF

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2003-2005 KTM 950 ADVENTURE 990 SUPER DUKE Part Manual - PDF DOWNLOAD

INTRODUCTION

• This repair manual offers extensiv repair-instructions and is an up-to-date version that describes the latest models of the series. However, the right to modifications in the interest of technical improvement is reserved without updating the current issue of this manual.
• A description of general working modes common in work shops has not been included. Safety rules common in the work shop have also not been listed. We take it for granted that the repairs are made by qualified profesionally trained mechanics. Read through the repair manual before beginning with the repair work.

KTM REPAIR MANUAL IN LOOSE-LEAF FORM
STORING THE REPAIR MANUAL IN THE BINDER
– Put the index into the binder.
– Put the front page of the repair manual (210x297 mm) into the transparent pocket provided for this purpose on the outside of
the binder.
– Put the spine label (170x45 mm) into the transparent pocket provided for this purpose on the spine of the binder.
– Put the summary list of contents (150x297 mm) into the transparent pocket provided for this purpose on the inside of the
binder or insert this page on the beginning of the manual.
– Then insert the individual chapters of the manual between the sheets of the index according to the page number printed in
the right bottom corner of each page.
Example: page no. 3-5; 3 = chapter 3; 5 = page 5
All pages with a page number that begins with the digit 3, for example, must be put under the index heading „Chapter 3“.
– Index sheets that have not been marked with a certain chapter are for your personal convenience. The respective headings can
be entered in the list of contents.

TABLE OF CONTENTS:

2003-2005 KTM 950 ADVENTURE 990 SUPER DUKE Part Manual - PDF DOWNLOAD

HOME 0
NOTES AND PREFACE 1
Title page and file spine 1
Important information 7
Updating instruction 7
Explanation update 9
Introduction 11
Reply fax for repair manuals 13
TABLE OF CONTENTS 5
SERVICE-INFORMATIONS 1
Oil consumption/low oil pressure 0
Bleeding of cooling circuit 0
Ignition rotor 0
Corrosion in fuel pump 0
Cylinder head collar nuts 0
17" wheels 0
Oil return valve and further recommendations 0
Swingarm bolt 0
Oil circulation and further recommendations 0
Outer Clutch Hub Replacement at the Second Service / 7500km 0
Disc Brake Mounting 0
Clutch LC8 Motor / Technical Information Bulletin 0304/32/02-E 0
Outer clutch hub 0
GENERAL INFORMATION 15
OIL SYSTEM 17
AIR INTAKE SYSTEM 18
SLS-SYSTEM 19
COOLING SYSTEM 20
SPECIALTOOLS - CHASSIS 21
SPECIALTOOLS - ENGINE 22
BLEEDING THE CLUTCH 24
BLEEDING THE COOLING SYSTEM 212
REMOVING AND REFITTING ENGINE 25
950 ADVENTURE 25
REMOVING THE ENGINE 27
REFITTING THE ENGINE 32
990 SUPER DUKE 25
REMOVING THE ENGINE 37
REFITTING THE ENGINE 38
DISASSEMBLING THE ENGINE 45
VALVE COVERS 47
SPARK PLUG SHAFT INSERTS 47
STARTER MOTOR 47
SETTING CYLINDER REAR TO TDC 48
CAMSHAFTS CYLINDER REAR 48
CHAIN TENSIONER CYLINDER REAR 49
TIMING CHAIN CYLINDER REAR 49
DOUBLE TIMING GEAR 50
CYLINDER HEAD REAR WITH CYLINDER 50
SETTING CYLINDER FRONT TO TDC 50
CAMSHAFTS CYLINDER FRONT 51
OIL PRESSURE SWITCH 51
CHAIN TENSIONER CYLINDER FRONT 51
TIMING CHAIN CYLINDER FRONT 52
CYLINDER HEAD FRONT WITH CYLINDER 52
WATER PUMP 53
OIL SCREEN 53
CLUTCH COVER 53
CLUTCH 54
PRIMARY PINION AND CLUTCH 55
GENERATOR COVER 56
ROTOR 56
FREEWHEEL 57
BALANCER SHAFT 57
SHIFT MECHANISM 57
ENGINE CASE HALF 58
TRANSMISSION 59
OIL PUMPS 60
SERVICING INDIVIDUAL COMPONENTS 61
ROLLER BEARING 63
MAIN BEARINGS - GENERAL INFORMATION 64
REPLACING BEARING SHELLS, OUTPUT END 65
REPLACING BEARING SHELLS, GENERATOR END 65
REPLACING THE CONROD BEARINGS 66
SELECTING THE BEARING SHELLS 66
REPLACING THE SUPPORTING BEARINGS IN THE CLUTCH COVER 67
OVERHAULING THE WATER PUMP 68
CHECKING THE SUCTION PUMP FOR WEAR 69
CHECKING THE PRESSURE PUMP FOR WEAR 69
BYPASS VALVE 69
DISASSEMBLING THE CYLINDER HEAD AND CHECKING PARTS FOR WEAR 70
CHECKING THE PISTONS 71
ASSEMBLY INSTRUCTIONS FOR PISTON RINGS 71
CHECKING THE PISTON RING END GAP 71
MEASURING PISTONS + CYLINDERS, ESTABLISHING THE PISTON MOUNTING CLEARANCE 71
PISTON AND CYLINDER IDENTIFICATION 72
ASSEMBLING THE CYLINDER HEAD 72
GENERATOR COVER 74
TORQUE LIMITER 74
VALVE GEAR - CHECKING PARTS FOR WEAR 74
PREASSEMBLING THE SPREADER DRIVE 75
CLUTCH - CHECKING PARTS FOR WEAR 76
SHIFT MECHANISM - CHECKING PARTS FOR WEAR 77
PREASSEMBLING THE SHIFT SHAFT 77
GENERAL INFORMATION ON SERVICING THE TRANSMISSION 78
ASSEMBLING THE MAIN SHAFT 78
ASSEMBLING THE COUNTERSHAFT 79
CHECKING THE FREEWHEEL 80
REPLACING THE FREEWHEEL HUB 80
STARTER 80
ASSEMBLING ENGINE 81
OIL PUMPS 83
TRANSMISSION 85
CASE HALF 86
SHIFT MECHANISM 87
ALIGNING THE RETURN SPRING 87
BALANCER SHAFT 88
FREEWHEEL 88
ROTOR 88
GENERATOR COVER 89
TIMING CHAIN AND BALANCING WEIGHT 89
PRIMARY PINION 90
OUTER CLUTCH HUB 90
CLUTCH DISKS 91
CLUTCH COVER 92
OIL SCREEN 93
WATER PUMP 93
CYLINDER HEAD REAR WITH TIMING CHAIN 94
CHAIN TENSIONER CYLINDER REAR 96
CAMSHAFTS CYLINDER REAR 97
SETTING CYLINDER FRONT TO TDC 98
CYLINDER HEAD FRONT WITH TIMING CHAIN 98
CHAIN TENSIONER CYLINDER FRONT 100
OIL PRESSURE SWITCH 100
CAMSHAFTS CYLINDER FRONT 101
STARTER MOTOR 102
SPARK PLUG SHAFT INSERTS 103
VALVE COVER 103
ELECTRICAL 105
CHECKING FOR LOSS OF CURRENT 107
DISMOUNTING THE BATTERY 107
CHARGING THE BATTERY 107
JUMP START 107
CHECKING THE CHARGING VOLTAGE/ RECTIFIER REGULATOR 107
CHECKING THE GENERATOR COILS 107
ELECTRIC STARTER SYSTEM 950 ADVENTURE 108
ELECTRIC STARTER SYSTEM 990 SUPER DUKE 109
CHECKING THE AUXILIARY STARTER RELAY 110
FUNCTIONAL CHECK OF THE AUXILIARY STARTER RELAY 110
CHECKING THE DIODES 111
CHECKING THE STARTER RELAY 111
CHECKING THE STARTER MOTOR 112
CHECKING THE CLUTCH SWITCH 112
CHECKING THE TIP SWITCH AND THE EMERGENCY OFF SWITCH 112
TROUBLESHOOTING IN THE STARTER SYSTEM 112
IGNITION SYSTEM, ECU 950 ADVENTURE 113
CHECKING THE ECU 950 ADVENTURE 114
CHECKING THE PULSE GENERATOR 950 ADVENTURE 114
CHECKING THE FUEL PUMP RELAY 950 ADVENTURE 114
CHECKING THE IGNITION COILS 950 ADVENTURE 114
TROUBLESHOOTING IN THE IGNITION SYSTEM 950 ADVENTURE 115
THE EPC SYSTEM 950 ADVENTURE 116
CHECKING THE SOLENOID VALVE FOR THE EPC PRÜFEN 950 ADVENTURE 117
CHECKING THE GEAR SENSOR 950 ADVENTURE 117
CARBURETOR HEATER 950 ADVENTURE 118
INJECTION/IGNITION SYSTEM 990 SUPER DUKE 119
ESTABLISHING THE INJECTION PERIOD 119
CORRECTION SENSORS AND INPUTS 119
SYSTEM DIAGRAM 120
BASIC DESCRIPTION OF THE SYSTEM 121
WIRING DIAGRAM 122
BLOCK DIAGRAM 123
DESCRIPTION OF THE ELECTRIC SYSTEM 124
DESCRIPTION OF THE COMPONENTS 125
SAFETY AGAINST FAILURE/EMERGENCY OPERATION 131
COMPONENT TESTS 132
ERROR CODES 143
ABBREVIATIONS, LIMIT VALUES 144
ALARM SYSTEM 990 SUPER DUKE 145
ORDER FOR ADDITIONAL HAND-HELD TRANSMITTERS 146
ADAPTING THE HAND-HELD TRANSMITTER 146
STARTING WITH THE EMERGENCY CODE 147
FUEL SYSTEM 149
950 ADVENTURE: KEIHIN CVRD 43 149
DESCRIPTION OF THE ACV (AIR CUT VALVE) SYSTEM 152
DISASSEMBLING THE CARBURETOR 153
ASSEMBLING THE CARBURETOR 156
CHECKING THE FLOAT LEVEL 159
ADJUSTING THE MIXTURE CONTROL SCREW 159
CHECKING THE THROTTLE SENSOR 160
ADJUSTING THE THOTTLE SENSOR 160
ADJUSTING THE CHOKE CABLE 160
ADJUSTING THE THROTTLE CABLES 160
SYNCHRONIZING THE CARBURETOR 205
ADJUSTING THE IDLE SPEED 205
CARBURETOR HEATER 161
990 SUPER DUKE: KEIHIN ELECTRONIC FUEL INJECTION 149
ADJUSTING THE THROTTLE CABLE 162
DISMOUNTING/MOUNTING THE THROTTLE BODY 162
DISMOUNTING/MOUNTING THE FUEL PUMP 162
REPLACING THE FUEL FILTER 162
TROUBLE SHOOTING 163
CHASSIS 167
DISMOUNTING/MOUNTING THE FRONT WHEEL 169
DISMOUNTING/MOUNTING THE REAR WHEEL 170
REPLACING THE FRONT WHEEL BEARING 171
REPLACING THE REAR WHEEL BEARING 172
REPLACING THE FRONT BRAKE PADS 173
REPLACING THE REAR BRAKE PADS 174
REPLACING THE FORK LEGS 175
REPLACING THE SHOCK ABSORBER 950 ADVENTURE 176
REPLACING THE SHOCK ABSORBER 990 SUPER DUKE 177
REPLACING THE STEERING HEAD BEARING 178
REPLACING THE SWING ARM BEARING 179
REPLACING THE CHAIN, PINION AND REAR SPROCKET 180
CUTTING AND RIVETING THE CHAIN 181
TECHNICAL SPECIFICATIONS 183
950 ADVENTURE 183
ENGINE 185
CHASSIS 186
990 SUPER DUKE 183
ENGINE 188
CHASSIS 189
TOLERANCES, MOUNTING CLEARANCES 191
TIGHTENING TORQUES 183
ENGINE 193
CHASSIS 194
PERIODIC MAINTENANCE SCHEDULE 195
950 ADVENTURE 196
990 SUPER DUKE 198
MAINTENANCE WORK 195
CHANGING THE ENGINE OIL AND THE OIL FILTER 200
CLEANING THE OIL SCREENS IN THE ENGINE AND OIL TANK 200
CLEANING THE MAGNETS ON THE DRAIN PLUG FOR THE ENGINE AND OIL TANK 200
REPLACING THE SPARK PLUGS 202
CHECKING AND ADJUSTING THE VALVE CLEARANCE 203
CHECKING THE CLUTCH LINING 204
CHECKING THE CLUTCH PRESSURE BOOSTER SYSTEM 204
CARBURETOR SYNCHRONIZATION 205
IDLE ADJUSTMENT 205
CHECK FAULT MEMORY WITH THE KTM DIAGNOSIS TOOL 206
PERFORM A STATUS CHECK USING THE KTM DIAGNOSIS TOOL 206
REPLACE THE O-RING OF THE FUEL HOSE CONNECTION 206
CHECKING THE COOLING SYSTEM FOR LEAKAGE AND ANTIFREEZE 206
CHECKING THE RADIATOR FAN FOR PROPER FUNCTIONING 206
LUBRICATING THE CABLES 206
CHECKING THE AIR FILTER, REPLACING IF NECESSARY, CLEANING THE AIR FILTER BOX 206
CHECKING THE BRAKE FLUID LEVEL, LINING THICKNESS, BRAKE DISKS 206
CHANGING THE BRAKE FLUID FRONT 207
CHANGING THE BRAKE FLUID REAR 208
CHECKING THE BOLTS ON THE BRAKE SYSTEM FOR FORCE FIT 208
CLEANING THE DUST BOOTS 209
BLEEDING THE FORK LEGS 209
CHECKING THE SWING ARM SUPPORT 209
CHECKING/ADJUSTING THE STEERING HEAD BEARING 209
CHECKING ALL CHASSIS BOLTS FOR FORCE FIT 209
CHECKING THE SPOKE TENSION AND RIM RUN-OUT 210
CHECKING THE CHAIN AND CHAIN GUIDES FOR WEAR, FORCE FIT AND TENSION 210
CHECKING THE NUTS/BOLTS ON THE ENGINE SPROCKET AND 210
CHECKING THE WHEEL BEARING AND JERK DAMPER FOR CLEARANCE 210
SERVICING THE FORK 211
SERVICING THE SHOCK ABSORBER 211
CLEANING AND GREASING THE STEERING HEAD BEARING AND SEALING ELEMENTS 211
CLEANING AND ADJUSTING THE CARBURETOR 212
CHANGING THE COOLING LIQUID 212
WIRING DIAGRAMS 213
950 ADVENTURE 213
WIRING DIAGRAM 2003-2004 216
EXPLANATION OF CONNECTORS, CABLE COLORS 217
WIRING DIAGRAM 2005 218
EXPLANATION OF CONNECTORS, CABLE COLORS 219
START SYSTEM 220
CHARGING SYSTEM 222
ECU 224
FLASHER, HORN, COOLING FAN 226
LIGHTS 228
LIGHTS USA 230
INSTRUMENTS 232
GROUND CONNECTION 234
POSITIVE CONNECTION 235
CONNECTOR LIST 213
CONNECTOR AA - AF 236
CONNECTOR AG - AH 237
CONNECTOR AI - AK 238
CONNECTOR AL - AM 239
CONNECTOR AN - AR 240
CONNECTOR AR - AT 241
CONNECTOR AU - AW 242
CONNECTOR AX - AZ, BA 243
CONNECTOR BB - BG 244
CONNECTOR BH - BK 245
990 SUPER DUKE 215
WIRING DIAGRAM 246
EXPLANATION OF CONNECTORS, CABLE COLORS 247
START/CHARGING SYSTEM 248
ECU 250
FLASHER, HORN, COOLING FAN 252
LIGHTS 254
INSTRUMENTS 256
GROUND CONNECTION 258
POSITIVE CONNECTION 259
CONNECTOR LIST 215
CONNECTOR AA - AE 260
CONNECTOR AF - AH 261
CONNECTOR AI - AL 262
CONNECTOR AM 263
CONNECTOR AO - AR1 264
CONNECTOR AR2 - AS 265
CONNECTOR AT - AX 266
CONNECTOR AY - AZ, BB - BD 267
CONNECTOR BE - BI 268
CONNECTOR BJ - BV 269
CONNECTOR BZ, CA 270
CONNECTOR CC - CK 271
CONNECTOR CL - CQ 272
CONNECTOR CR, DJ - DK 273

S.M 13/3/2025