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2003-2007 KTM 950/990 ADVENTURE 990 SUPER DUKE 950 SUPERMOTO 950 SUPER ENDURO Repair Manual - PDF DOWNLOAD
Language :English
Pages :394
Downloadable : Yes
File Type : PDF
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DESCRIPTION:
2003-2007 KTM 950/990 ADVENTURE 990 SUPER DUKE 950 SUPERMOTO 950 SUPER ENDURO Repair Manual - PDF DOWNLOAD
INTRODUCTION
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:
2003-2007 KTM 950/990 ADVENTURE 990 SUPER DUKE 950 SUPERMOTO 950 SUPER ENDURO Repair 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
GENERAL INFORMATION 15
OIL SYSTEM 17
AIR INTAKE SYSTEM 18
SLS-SYSTEM 19
COOLING SYSTEM 20
ABS-SYSTEM 21
SPECIAL TOOLS - ENGINE 22
SPECIAL TOOLS - CHASSIS 24
BLEEDING THE CLUTCH 25
RESETTING THE CONTROL UNIT AFTER REPLACING/REPAIRING THE ENGINE 26
ADJUSTING THE THROTTLE CABLE FOR MODELS WITH FUEL INJECTION 27
ECU-SOFTWARE UPDATE/MAPPING 28
BLEEDING THE COOLING SYSTEM 15
CHECKING THE OIL PRESSURE 30
REMOVING AND REFITTING ENGINE 31
950 ADVENTURE 31
REMOVING THE ENGINE 33
REFITTING THE ENGINE 38
990 SUPER DUKE 31
REMOVING THE ENGINE 43
REFITTING THE ENGINE 44
950 SUPERMOTO 31
REMOVING THE ENGINE 51
REFITTING THE ENGINE 51
DISASSEMBLING THE ENGINE 53
VALVE COVERS 55
SPARK PLUG SHAFT INSERTS 55
STARTER MOTOR 55
SETTING CYLINDER REAR TO TDC 56
CAMSHAFTS CYLINDER REAR 56
CHAIN TENSIONER CYLINDER REAR 57
TIMING CHAIN CYLINDER REAR 57
DOUBLE TIMING GEAR 58
CYLINDER HEAD REAR WITH CYLINDER 58
SETTING CYLINDER FRONT TO TDC 58
CAMSHAFTS CYLINDER FRONT 59
OIL PRESSURE SWITCH 59
CHAIN TENSIONER CYLINDER FRONT 59
TIMING CHAIN CYLINDER FRONT 60
CYLINDER HEAD FRONT WITH CYLINDER 60
WATER PUMP 61
OIL SCREEN 61
CLUTCH COVER 61
CLUTCH 62
PRIMARY PINION AND CLUTCH 63
GENERATOR COVER 64
ROTOR 64
FREEWHEEL 65
BALANCER SHAFT 65
SHIFT MECHANISM 65
ENGINE CASE HALF 66
TRANSMISSION 67
OIL PUMPS 68
SERVICING INDIVIDUAL COMPONENTS 69
ROLLER BEARING 71
MAIN BEARINGS - GENERAL INFORMATION 72
REPLACING BEARING SHELLS, OUTPUT END 73
REPLACING BEARING SHELLS, GENERATOR END 73
REPLACING THE CONROD BEARINGS 74
SELECTING THE BEARING SHELLS 74
REPLACING THE SUPPORTING BEARINGS IN THE CLUTCH COVER 75
OVERHAULING THE WATER PUMP 76
CHECKING THE SUCTION PUMP FOR WEAR 77
CHECKING THE PRESSURE PUMP FOR WEAR 77
BYPASS VALVE 77
DISASSEMBLING THE CYLINDER HEAD AND CHECKING PARTS FOR WEAR 78
CHECKING THE PISTONS 79
ASSEMBLY INSTRUCTIONS FOR PISTON RINGS 79
CHECKING THE PISTON RING END GAP 79
MEASURING PISTONS + CYLINDERS, ESTABLISHING THE PISTON MOUNTING CLEARANCE 79
PISTON AND CYLINDER IDENTIFICATION 80
ASSEMBLING THE CYLINDER HEAD 80
GENERATOR COVER 82
TORQUE LIMITER 82
VALVE GEAR - CHECKING PARTS FOR WEAR 82
PREASSEMBLING THE SPREADER 83
CLUTCH - CHECKING PARTS FOR WEAR 84
SHIFT MECHANISM - CHECKING PARTS FOR WEAR 85
PREASSEMBLING THE SHIFT SHAFT 85
GENERAL INFORMATION ON SERVICING THE TRANSMISSION 86
ASSEMBLING THE MAIN SHAFT 86
ASSEMBLING THE COUNTERSHAFT 87
CHECKING THE FREEWHEEL 88
REPLACING THE FREEWHEEL HUB 88
STARTER 88
ASSEMBLING THE ENGINE 89
OIL PUMPS 91
AXIAL CLEARANCE OF THE MAIN SHAFT 92
TRANSMISSION 93
CASE HALF 94
SHIFT MECHANISM 95
ALIGNING THE RETURN SPRING 95
BALANCER SHAFT 96
FREEWHEEL 96
ROTOR 96
GENERATOR COVER 97
TIMING CHAIN AND BALANCING WEIGHT 97
PRIMARY PINION 98
OUTER CLUTCH HUB 98
CLUTCH DISKS 99
CLUTCH COVER 100
OIL SCREEN 101
WATER PUMP 101
CYLINDER HEAD REAR WITH TIMING CHAIN 102
CHAIN TENSIONER CYLINDER REAR 104
CAMSHAFTS CYLINDER REAR 105
SETTING CYLINDER FRONT TO TDC 106
CYLINDER HEAD FRONT WITH TIMING CHAIN 106
CHAIN TENSIONER CYLINDER FRONT 108
OIL PRESSURE SWITCH 108
CAMSHAFTS CYLINDER FRONT 109
STARTER MOTOR 110
SPARK PLUG SHAFT INSERTS 111
VALVE COVER 111
ELECTRICAL 113
CHECKING FOR LOSS OF CURRENT 115
DISMOUNTING THE BATTERY 115
CHARGING THE BATTERY 115
JUMP START 115
CHECKING THE CHARGING VOLTAGE/ RECTIFIER REGULATOR 115
CHECKING THE GENERATOR COILS 115
ELECTRIC STARTER SYSTEM 950 ADVENTURE 116
ELECTRIC STARTER SYSTEM 990 SUPER DUKE 117
ELECTRIC STARTER SYSTEM 950 SUPERMOTO/950 SUPER ENDURO 118
ELECTRIC STARTER SYSTEM 990 ADVENTURE 119
CHECKING THE AUXILIARY STARTER RELAY 120
FUNCTIONAL CHECK OF THE AUXILIARY STARTER RELAY 121
CHECKING THE DIODES 122
CHECKING THE STARTER RELAY 123
CHECKING THE STARTER MOTOR 123
CHECKING THE CLUTCH SWITCH 124
CHECKING THE TIP SWITCH AND THE EMERGENCY OFF SWITCH 125
TROUBLESHOOTING IN THE STARTER SYSTEM 125
IGNITION SYSTEM, ECU 950 ADVENTURE 126
IGNITION SYSTEM, ECU 950 SUPERMOTO 127
IGNITION SYSTEM, ECU 950 SUPER ENDURO 128
CHECKING THE ECU 950 ADVENTURE/950 SUPERMOTO/SUPER ENDURO 129
CHECKING THE PULSE GENERATOR 950 ADVENTURE/SUPERMOTO/SUPER ENDURO 129
CHECKING THE FUEL PUMP RELAY 950 ADVENTURE/SUPERMOTO/SUPER ENDURO 130
CHECKING THE IGNITION COILS (CARBURETTOR MODELS ONLY) 130
TROUBLESHOOTING IN THE IGNITION SYSTEM 950 ADVENTURE/SUPERMOTO/SUPER ENDURO 131
THE EPC SYSTEM 950 ADVENTURE 132
THE EPC SYSTEM 950 SUPERMOTO 133
THE EPC SYSTEM 950 SUPER ENDURO 134
CHECKING THE SOLENOID VALVE FOR THE EPC 950 ADVENTURE/950 SUPERMOTO 135
CHECKING THE GEAR SENSOR 950 ADVENTURE/950 SUPERMOTO 135
CARBURETOR HEATER 950 ADVENTURE/SUPERMOTO/SUPER ENDURO 136
INJECTION/IGNITION SYSTEM 137
ESTABLISHING THE INJECTION PERIOD 137
CORRECTION SENSORS AND INPUTS 137
SYSTEM DIAGRAM 138
BASIC DESCRIPTION OF THE SYSTEM 139
WIRING DIAGRAM 990 SUPER DUKE 140
WIRING DIAGRAM 990 ADVENTURE 141
BLOCK DIAGRAM 142
DESCRIPTION OF THE ELECTRIC SYSTEM 143
DESCRIPTION OF THE COMPONENTS 144
SAFETY AGAINST FAILURE/EMERGENCY OPERATION 150
COMPONENT TESTS 151
ERROR CODES 162
ABBREVIATIONS, LIMIT VALUES 990 SUPER DUKE 163
ABBREVIATIONS, LIMIT VALUES 990 ADVENTURE 164
ALARM SYSTEM 990 SUPER DUKE 165
ORDER FOR ADDITIONAL HAND-HELD TRANSMITTERS 166
ADAPTING THE HAND-HELD TRANSMITTER 166
STARTING WITH THE EMERGENCY CODE 167
ABS-SYSTEM 990 ADVENTURE 168
CHECKING THE FUSES 168
CHECKING THE ABS FAULT MEMORY USING THE KTM DIAGNOSTICS TOOL 168
CHECKING THE ABS SENSOR WITH THE KTM DIAGNOSTICS TOOL 168
FUEL SYSTEM 169
KEIHIN CARBURETOR CVRD 43 169
DESCRIPTION OF THE ACV (AIR CUT VALVE) SYSTEM 172
DISASSEMBLING THE CARBURETOR 173
ASSEMBLING THE CARBURETOR 176
CHECKING THE FLOAT LEVEL 179
ADJUSTING THE MIXTURE CONTROL SCREW 179
CHECKING THE THROTTLE SENSOR 180
ADJUSTING THE THOTTLE SENSOR 180
ADJUSTING THE CHOKE CABLE 180
ADJUSTING THE THROTTLE CABLES 180
SYNCHRONIZING THE CARBURETOR 169
ADJUSTING THE IDLE SPEED 169
CARBURETOR HEATER 181
KEIHIN ELECTRONIC FUEL INJECTION 169
ADJUSTING THE THROTTLE CABLE 182
DISMOUNTING/MOUNTING THE THROTTLE BODY 182
DISMOUNTING/MOUNTING THE FUEL PUMP 182
REPLACING THE FUEL FILTER 182
CHECKING THE FUEL PRESSURE 183
TROUBLE SHOOTING 185
CHASSIS 189
DISMOUNTING/MOUNTING THE FRONT WHEEL 191
DISMOUNTING/MOUNTING THE REAR WHEEL 192
REPLACING THE FRONT WHEEL BEARING 193
REPLACING THE REAR WHEEL BEARING 194
REPLACING THE FRONT BRAKE PADS 195
REPLACING THE REAR BRAKE PADS 196
REPLACING THE FORK LEGS 197
REPLACING THE SHOCK ABSORBER 198
REPLACING THE STEERING HEAD BEARING 200
REPLACING THE SWING ARM BEARING 201
REPLACING THE CHAIN, PINION AND REAR SPROCKET 202
CUTTING AND RIVETING THE CHAIN 203
REPLACING THE ABS UNIT 204
REPLACING THE FRONT ABS SENSOR 204
REPLACING THE REAR ABS SENSOR 204
TECHNICAL SPECIFICATIONS 205
950 ADVENTURE 205
ENGINE 207
CHASSIS 208
990 SUPER DUKE / SUPER DUKE R 205
ENGINE 210
CHASSIS 211
950 SUPERMOTO / SUPERMOTO R 205
ENGINE 213
CHASSIS 214
990 ADVENTURE 205
ENGINE 216
CHASSIS 217
950 SUPER ENDURO 205
ENGINE 219
CHASSIS 220
TOLERANCES, MOUNTING CLEARANCES 222
TIGHTENING TORQUES 205
ENGINE 224
CHASSIS 225
PERIODIC MAINTENANCE SCHEDULE 227
950 ADVENTURE 228
990 SUPER DUKE 230
950 SUPERMOTO 232
990 ADVENTURE 234
950 SUPER ENDURO 236
MAINTENANCE WORK 227
CHANGING THE ENGINE OIL AND THE OIL FILTER 238
CLEANING THE OIL SCREENS IN THE ENGINE AND OIL TANK 238
CLEANING THE MAGNETS ON THE DRAIN PLUG FOR THE ENGINE AND OIL TANK 238
REPLACING THE SPARK PLUGS 240
CHECKING AND ADJUSTING THE VALVE CLEARANCE 241
CHECKING THE CLUTCH LINING 244
CHECKING THE CLUTCH PRESSURE BOOSTER SYSTEM 244
CLEAN THE OIL JET FOR THE CLUTCH LUBRICATION 244
CARBURETOR SYNCHRONIZATION 245
IDLE ADJUSTMENT 950 ADVENTURE 245
IDLE ADJUSTMENT 950 SUPERMOTO/SUPER ENDURO 246
CHECK FAULT MEMORY WITH THE KTM DIAGNOSIS TOOL 246
PERFORM A STATUS CHECK USING THE KTM DIAGNOSIS TOOL 246
REPLACE THE O-RING OF THE FUEL HOSE CONNECTION 246
CHECKING THE COOLING SYSTEM FOR LEAKAGE AND ANTIFREEZE 246
CHECKING THE RADIATOR FAN FOR PROPER FUNCTIONING 246
LUBRICATING THE CABLES 246
CHECKING THE AIR FILTER, REPLACING IF NECESSARY, CLEANING THE AIR FILTER BOX 246
CHECKING THE BRAKE FLUID LEVEL, LINING THICKNESS, BRAKE DISKS 246
CHANGING THE BRAKE FLUID FRONT 247
CHANGING THE BRAKE FLUID REAR 248
CHECKING THE BOLTS ON THE BRAKE SYSTEM FOR FORCE FIT 248
CHECK ABS FAULT MEMORY WITH THE KTM DIAGNOSIS TOOL 248
CLEANING THE DUST BOOTS 249
BLEEDING THE FORK LEGS 249
CHECKING THE SWING ARM SUPPORT 249
CHECKING/ADJUSTING THE STEERING HEAD BEARING 249
CHECKING ALL CHASSIS BOLTS FOR FORCE FIT 249
CHECKING THE SPOKE TENSION AND RIM RUN-OUT 250
CHECKING THE CHAIN AND CHAIN GUIDES FOR WEAR, FORCE FIT AND TENSION 250
CHECKING THE NUTS/BOLTS ON THE ENGINE SPROCKET AND THE REAR SPROCKET FOR THE SECURING AGENT AND A TIGHT FIT 250
CHECKING THE WHEEL BEARING AND JERK DAMPER FOR CLEARANCE 250
SERVICING THE FORK 251
SERVICING THE SHOCK ABSORBER 251
CLEANING AND GREASING THE STEERING HEAD BEARING AND SEALING ELEMENTS 251
CLEANING AND ADJUSTING THE CARBURETOR 252
CHANGING THE COOLING LIQUID 252
WIRING DIAGRAMS 253
950 ADVENTURE 253
WIRING DIAGRAM 2003-2004 258
EXPLANATION OF CONNECTORS, CABLE COLORS 259
WIRING DIAGRAM 2005 260
EXPLANATION OF CONNECTORS, CABLE COLORS 261
START SYSTEM 262
CHARGING SYSTEM 264
ECU 266
FLASHER, HORN, COOLING FAN 268
LIGHTS 270
LIGHTS USA 272
INSTRUMENTS 274
GROUND CONNECTION 276
POSITIVE CONNECTION 277
CONNECTOR LIST 950 ADVENTURE 253
CONNECTOR AA - AF 278
CONNECTOR AG - AH 279
CONNECTOR AI - AK 280
CONNECTOR AL - AM 281
CONNECTOR AN - AR 282
CONNECTOR AR - AT 283
CONNECTOR AU - AW 284
CONNECTOR AX - AZ, BA 285
CONNECTOR BB - BG 286
CONNECTOR BH - BK 287
990 SUPER DUKE / SUPER DUKE R 254
WIRING DIAGRAM (UP TO THE 2006 MODEL) 288
EXPLANATION OF CONNECTORS, CABLE COLORS 289
START/CHARGING SYSTEM (UP TO THE 2006 MODEL) 290
START/CHARGING SYSTEM (STARTING WITH THE 2007 MODEL) 291
ECU (UP TO THE 2006 MODEL) 292
ECU (STARTING WITH THE 2007 MODEL) 293
FLASHER, HORN, COOLING FAN 294
LIGHTS 296
INSTRUMENTS (UP TO THE 2006 MODEL) 298
INSTRUMENTS (STARTING WITH THE 2007 MODEL) 299
GROUND CONNECTION 300
POSITIVE CONNECTION 301
CONNECTOR LIST 990 SUPER DUKE / SUPER DUKE R 254
CONNECTOR AA - AE 302
CONNECTOR AF - AH 303
CONNECTOR AI - AL 304
CONNECTOR AM 305
CONNECTOR AO - AR1 306
CONNECTOR AR2 - AS 307
CONNECTOR AT - AX 308
CONNECTOR AY - AZ, BB - BD 309
CONNECTOR BE - BI 310
CONNECTOR BJ - BV 311
CONNECTOR BZ, CA 312
CONNECTOR CC - CK 313
CONNECTOR CL - CQ 314
CONNECTOR CR, DJ - DK 315
950 SUPERMOTO / SUPERMOTO R 255
WIRING DIAGRAM (UP TO THE 2007 MODEL) 316
WIRING DIAGRAM (STARTING WITH THE 2007 MODEL) 317
EXPLANATION OF CONNECTORS, CABLE COLORS 318
START/CHARGING SYSTEM (UP TO THE 2007 MODEL) 319
START/CHARGING SYSTEM (STARTING WITH THE 2007 MODEL) 320
ECU 321
FLASHER, HORN, COOLING FAN 322
LIGHTS 324
INSTRUMENTS 326
GROUND CONNECTION 328
POSITIVE CONNECTION 329
CONNECTOR LIST 950 SUPERMOTO / SUPERMOTO R 255
CONNECTOR AA - AF1 330
CONNECTOR AF2 - AH 331
CONNECTOR AI - AJ 332
CONNECTOR AK - AL2 333
CONNECTOR AL3 - AM 334
CONNECTOR AO - AR 335
CONNECTOR AS - AT3 336
CONNECTOR AT4 - AX 337
CONNECTOR AY - AZ, BB - BG 338
CONNECTOR BI - BS 339
CONNECTOR BV - BW, CD, CR 340
CONNECTOR DI - DK 341
990 ADVENTURE 256
WIRING DIAGRAM (UP TO THE 2007 MODEL) 342
WIRING DIAGRAM (STARTING WITH THE 2007 MODEL) 343
EXPLANATION OF CONNECTORS, CABLE COLORS 344
START/CHARGING SYSTEM (UP TO THE 2007 MODEL) 345
START/CHARGING SYSTEM (STARTING WITH THE 2007 MODEL) 346
EFI 347
FLASHER, HORN, COOLING FAN 348
LIGHTS 350
INSTRUMENTS 352
ABS 353
GROUND CONNECTION 354
POSITIVE CONNECTION 355
CONNECTOR LIST 990 ADVENTURE 256
CONNECTOR AA - AE 356
CONNECTOR AF - AI 357
CONNECTOR AJ - AL 358
CONNECTOR AM - AO 359
CONNECTOR AP - AR4 360
CONNECTOR AR5 - AT2 361
CONNECTOR AT3 - AY 362
CONNECTOR AZ, BA - BE 363
CONNECTOR BF - BJ 364
CONNECTOR CA - CK 365
CONNECTOR CL - CQ 366
CONNECTOR CR - CX, DL-DM 367
CONNECTOR DN - DP 368
950 SUPER ENDURO 257
WIRING DIAGRAM (UP TO THE 2006 MODEL) 370
WIRING DIAGRAM (STARTING WITH THE 2007 MODEL) 371
EXPLANATION OF CONNECTORS, CABLE COLORS 372
START/CHARGING SYSTEM (UP TO THE 2006 MODEL) 373
START/CHARGING SYSTEM (STARTING WITH THE 2007 MODEL) 374
ECU 375
FLASHER, HORN, COOLING FAN 376
LIGHTS 378
INSTRUMENTS 380
GROUND CONNECTION 382
POSITIVE CONNECTION 383
CONNECTOR LIST 950 SUPER ENDURO 257
CONNECTOR AA - AF 384
CONNECTOR AH - AI 385
CONNECTOR AJ - AK 386
CONNECTOR AL 387
CONNECTOR AM - AO 388
CONNECTOR AR - AS 389
CONNECTOR AT - AU 390
CONNECTOR AV - AZ 391
CONNECTOR BA - BI 392
CONNECTOR BJ - BT 393
CONNECTOR BW, CD - CR, DI 394
S.M 13/3/2025