KTM 950 ADVENTURE 2003 Operating instructions

950/990 ADVENTURE
990 SUPER DUKE
950 SUPERMOTO
950 SUPER ENDURO
REPARATURANLEITUNG
MANUALE DI RIPARAZIONE
MANUEL DE RÉPARATION
MANUAL DE REPARACIÓN
ART.NR.: 3.206.035-E
REPAIRMANUAL2003-2006

REPAIRMANUAL2003-2006 950/990 ADVENTURE 990 SUPER DUKE 950 SUPERMOTO 950 SUPER ENDURO
KTM Group Partner

1 SERVICE-INFORMATIONS
2 GENERAL INFORMATION
3 REMOVING AND REFITTING ENGINE
4 DISASSEMBLING ENGINE
5 SERVICING INDIVIDUAL COMPONENTS
6 ASSEMBLING ENGINE
7 ELECTRICAL / INJECTION
8 FUEL SYSTEM
9 TROUBLE SHOOTING
10 CHASSIS
11 TECHNICAL SPECIFICATIONS
12 PERIODIC MAINTENANCE SCHEDULE
13 WIRING DIAGRAMS
14
15
16

Remove page (s) Replace by page (s) Insert page (s) after page
2-1 2-1
2-6 to 2-10 2-6 to 2-15
3-1 3-1
3-12 3-12
3-14 3-14
3-17 3-17
3-19 to 3-20 3-19 to 3-20
4-10 to 4-11 4-10 to 4-11
5-3 5-3
5-9 to 5-10 5-9 to 5-10
6-1 to 6-3 6-1 to 6-3
6-9 6-9
6-13 6-13
6-17 6-17
7-1 to 7-42 7-1 to 7-55
8-1 8-1
8-11 8-11
8-13 to 8-14 8-13 to 8-14
9-3 9-3
10-1 to 10-14 10-1 to 10-15
11-1 to 11-11 11-1 to 11-20
12-1 to 12-18 12-1 to 12-26
13-1 to 13-60 13-1 to 13-141
IMPORTANT INFORMATION/UPDATING INSTRUCTIONS
To be able to continue using the existing loose-leaf repair instructions, simply print the
following pages and insert them in the existing repair instructions:
15,21-30,31,43,45,48,50,51,63,64,72,78,79,89,91,92,98,102,106,113-169,180,182,183,
188-394
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.

EXPLANATION - UPDATING
Edition: 01/2006
3.206.009-E Repair Manual LC8
Basicversion Modelyear 2003 4/2003
3.206.016-E Updating of Rep.Manual 3.206.009-E
Modelyear 2004
(Engine number with first digit “4“) 11/2003
3.206.025-E Updating of Rep.Manual 3.206.009-E
Modelyear 2005
(Engine number with first digit “5“) 01/2005
3.206.035-E Updating of Rep.Manual 3.206.009-E
Modelyear 2005/06
(Engine number with first digit “5“ and “6”) 01/2006
950 Supermoto, 990 Adventure, 950 Super Enduro,
ABS, technical details, technical data,
technical specifications, wiring diagrams

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.

WARNING

STRICT COMPLIANCE WITH THESE INSTRUCTIONS IS
ESSENTIAL TO AVOID DANGER TO LIFE AND LIMB.
!
CAUTION
!
NON-COMPLIANCE WITH THESE INSTRUCTIONS CAN LEAD TO
DAMAGE OF MOTORCYCLE COMPONENTS OR RENDER MOTORCYCLES
UNFIT FOR TRAFFIC !
„NOTE” POINTS OUT USEFUL TIPS.
Use only ORIGINAL KTM SPARE PARTS when replacing parts.
The KTM high performance engine is only able to meet user expectations if the maintenance work
is performed regularly and professionally.
In accordance with the international quality management ISO 9001 standard, KTM uses quality
assurance processes that lead to the highest possible product quality.
KTM Sportmotorcycle AG reserves the right to modify any equipment, technical specifications,
colors, materials, services offered and rendered, and the like so as to adapt them to local
conditions without previous announcement and without giving reasons, or to cancel any of the
above items without substituting them with others. It shall be acceptable to stop manufacturing a
certain model without previous announcement. In the event of such modifications, please ask your
local KTM dealer for information.
KTM Sportmotorcycle AG
5230 Mattighofen, Austria
All design and assembly modification rights reserved.
C by KTM SPORTMOTORCYCLE AG, AUSTRIA All rights reserved

REPLY FAX FOR REPAIR MANUALS
Item no. of repair manual Page Current text Correct text
Additional suggestions, requests or comments on our Repair Manuals (in German or English):
Name mechanic/shop foreman Company/work shop
We have made every effort to make our repair manuals as accurate as possible but it is always possible
for a mistake or two to creep in.
To keep improving the quality of our repair manuals, we request mechanics and shop foremen to assist us
as follows:
If you find any errors or inaccuracies in one of our repair manual – whether these are technical errors,
incorrect or unclear repair procedures, tool problems, missing technical data or torques, inaccurate or
incorrect translations or wording, etc. – please enter the error(s) in the table below and fax the completed
form to us at 0043/7742/6000/5349.
NOTE to table:
– Enter the complete item no. for the repair manual in column 1 (e.g.: 3.206.035-E).
You will find the number on the cover page or in the left margin on each right page of the manual.
– Enter the corresponding page number in the repair manual (e.g.: 5-7) in column 2.
– Enter the current text (inaccurate or incomplete) in column 3 by quoting or describing the respective
passage of the text. If your text deviates from the text contained in the repair manual, please write
your text in German or English if possible.
– Enter the correct text in column 4.
Your corrections will be reviewed and incorporated in the next issue of our repair manual.

GENERAL INFORMATION
Repair manual KTM LC8 Art.-No. 3.206.035-E
OIL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
AIR INTAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
SLS-SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
ABS-SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
SPECIAL TOOLS – ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7
SPECIAL TOOLS – CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9
BLEEDING THE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10
RESETTING THE CONTROL UNIT AFTER REPLACING/REPAIRING THE ENGINE . . .2-11
ADJUSTING THE THROTTLE CABLE FOR MODELS WITH FUEL INJECTION . . . . . . .2-12
ECU-SOFTWARE UPDATE/MAPPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13
BLEEDING THE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . .SEE CHAPTER 12
CHECKING THE OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15
INDEX
2-1
2

2-2
Repair manual KTM LC8 Art.-No. 3.206.035-E
1
56
7
8
9
bk
bm
bn
bo
bp
bq
br
bs
bt
ck
cn
cm
cl
bl
8
2
3
4
Oil system
Pressure pump 1draws engine oil from oil tank
2through oil filter 3and the oil return valve
4and pumps it past the pressure relief valve 5
through the oil filter 6into the annular groove
7.
The main bearing 8, the conrod bearings 9
and the spraying nozzle bk (front timing chain)
are supplied with oil through holes in the
crankshaft. An oil duct leads to spraying nozzle
bl (piston cooling), the timing chain tensioner
bm, the camshaft bn and the oil pressure switch
bo in the front cylinder.
Another oil duct leads from the annular groove
to a distributor groove bp in the clutch cover.
From there an oil duct leads to the spraying
nozzle bq (piston cooling). Another oil duct
supplies the timing chain tensioner br, the
spraying nozzle bs (timing chain) and the
camshaft bt on the rear cylinder with oil.
Another oil duct leads to the oil injection tube
ck which lubricates the transmission gears. Oil
is conducted to the pushrod and to the clutch
through the injection tube, another oil duct and
the reducing jet.
The suction pump cl draws the oil from the oil
sump cn through the screen cm into the oil tank
2.
NOTE: each piston is lubricated and cooled by 2
jets starting with the 2005 model.

2-3
1
3
3
2
Intake system
Fresh air is drawn into the filter box through the intake snorkel 1, past the carburetors 2and through the air filter 3.
The cleaned air is conducted to the combustion chamber through the carburetors and intake ports.
The diagram for the injection engine is similar; the air flows to the intake ports through the throttle body instead of through the
carburetor.

2-4
Repair manual KTM LC8 Art.-No. 3.206.035-E
1
2
3
3
44
4
Secondary air system
The secondary air system supplies fresh air to the emissions in the exhaust port, resulting in the afterburning (oxidation) of the
emissions. A line leads from the filter box 1to the control valve 2which opens as soon as the throttle valves 3are opened.
The line continues to the reed valves 4in the cylinder heads which are actuated by the pressure pulsation in the exhaust
system. As a result, cleansed fresh air arrives in the exhaust port. The oxygen content in the air and the high exhaust gas
temperature cause the emissions to oxidize.
If the throttle valves are closed and the engine goes into an overrun condition, the underpressure in the intake port will rise and
the control valve will close. This prevents exhaust backfire (combustion of the unburned fuel/air mixture).
The secondary air system operates in a similar manner in models equipped with an injection engine; a solenoid valve controlled
by the control unit is used instead of the control valve.

2-5
1
1
22
3
4
5
6
7
22
3
Closed thermostat
The thermostat is closed if the temperature of the cooling liquid drops below 75° C. The water pump 1pumps the cooling liquid
through the cylinder and cylinder heads 2and the thermostat 3.
Open thermostat
The thermostat 3opens at 75° C. The water pump 1pumps the cooling liquid through the cylinder and cylinder heads 2, the
aluminum cooler 4and the thermostat. The pressure in the cooling system (max. 1.4 bar) is regulated by a valve in the radiator
cap 5. The cooling liquid level in the compensating tank 6must be between the MIN and MAX marks when the engine is cold.
The fan 7switches on at 102° C.
Cooling system