KTM 950 ADVENTURE 2003 User manual

950 ADVENTURE
2003 to 2006

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

2-2
Repair manual KTM LC8 Art.-Nr. 3.206.009-E
Oil system
Pressure pump 1draws engine oil from oil tank
2through oil filter 3and the oil return valve 4
and pumps it past the pressure relief valve 5
through the oil filter 6into the annular groove
7.
The main bearing 8, the conrod bearings 9and
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 line ck that
lubricates the transmission gears. The suction
pump cl draws the oil from the oil sump cn
through the screen cm into the oil tank 2.
1
56
7
8
9
bk
bm
bn
bo
bp
bq
br
bs
bt
ck
cn
cm
cl
bl
8
2
3
4

2-3
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.
1
2
2
3

2-4
Repair manual KTM LC8 Art.-Nr. 3.206.009-E
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).
1
2
3
3
44
4

2-5
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 2.
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
1
1
22
3
4
5
6
7
22
3

2-6
Repair manual KTM LC8 Art.-Nr. 3.206.009-E
SPECIALTOOLS – CHASSIS
FIG PART NO DESCRIPTION
1151.12.017.000 Gear puller
2584.29.086.000 Pressing tool for swing arm bearing
3584.29.089.000 Chassis tool holder
4584.29.091.000 Press-in tool for bearing seat / rear wheel bearing
5584.29.092.000 Knock-out tool for bearing seat
6600.03.022.000 Center stand
7600.10.013.000 Sleeve for pressing tool for swim arm bearing
8600.29.018.000 Internal gear puller 28 mm
9600.29.020.000 Chain rivet tool
10 600.29.055.000 Center stand lock
11 600.29.055.100 Floor jack attachment
12 600.29.056.000 Anvil dolly (for 584.29.086.000)
13 600.29.057.000 Pliers for Öttiker clamps
14 600.29.057.100 Pliers for spring-loaded band-type clamp
12345
7
89
bk
6
bl
bm
bn bo

2-7
648
LOCTITE 243
1
23
4
5
7
8
9bk
6bl
bm
bn bo bp bq
br
bs
bt
cl
cm cn co cp cq cr cs ct dk
dl
dm
dn do
dp dq
dr
ck

2-8
Repair manual KTM LC8 Art.-Nr. 3.206.009-E
SPECIAL TOOLS – ENGINE
FIG PART NO DESCRIPTION
1309098 Seal Three-Bond
20113 080802 Crankshaft locking bolt
3151.12.017.000 Gear puller
4503.29.050.000 Bleeding syringe for hydraulic clutch
5560.12.001.000 Universal-engine work stand
6584.29.059.000 Loctite 648 green 20 ml
7585.29.005.000 Protection sleeve for shaft seal ring of water pump
8590.29.019.000 Valve spring mounter
9590.29.026.006 Limit plug gauge 6,05 mm
10 590.29.041.000 Feeler gauge for valve clearance
11 6 899 785 Loctite 243 blu 6 cm3
12 600.29.002.000 Engine holder for engine work stand
13 600.29.003.000 Clutch holder
14 600.29.005.000 Protection sleeve for shaft seal ring of output shaft
15 600.29.009.000 Magneto extractor
16 600.29.009.010 Protection bolt for magneto extractor
17 600.29.010.000 Degree wheel
18 600.29.011.000 Carburator synchronisation tool
19 600.29.012.000 Plastigauge-measuring strips
20 600.29.015.000 Piston ring mounting tool
21 600.29.016.000 Setting gauge for float level
22 600.29.018.000 Internal gear puller 28 mm
23 600.29.031.000 Protection sleeve for crankshaft (for pulling of the primary gear)
24 600.29.033.000 Puller for primary gear
25 600.29.041.000 Valve spring mounter insert
26 600.29.043.010 Pressing tool for seal of clutch release shaft
27 600.29.043.020 Pressing tool for seal of output shaft
28 600.29.043.030 Pressing tool for seal and bearing of shifting shaft
29 600.29.043.040 Pressing tool for seal of water pump
30 600.29.043.050 Pressing tool for seal of balancer shaft
31 600.29.044.050 Pressing tool for main bearings (In/out)
32 600.29.046.028 Pressing tool for supporting bearing (In)
33 600.29.073.000 Spark plug wrench 16 mm
34 600.29.075.000 Special nut for conrod
35 600.29.081.000 Special tool for cylinder head nuts
36 600.29.082.000 Holder for water pump wheel
37 600.29.083.000 Special nut for cylinder head nuts

2-9
Checking the oil level of the hydraulic clutch
To check the oil level in the master cylinder of the clutch remove the
cover. For this purpose, remove bolts and cover together with the rubber
boot 1. The oil level in the horizontal-standing master cylinder should
be 4 mm below the upper edge. If necessary add SAE 10 biodegradable
hydraulic oil (e.g. Motorex Kupplungs-Fluid 75).
! CAUTION !
ONLY USE SAE 10 BIODEGRADABLE HYDRAULIC OIL TO REFILL THE MASTER
CYLINDER. NEVER USE BRAKE FLUID NOR MIX BIODEGRADABLE HYDRAULIC OILS WITH
MINERAL OILS!
Bleeding of the hydraulic clutch
For bleeding, the cover of the master cylinder of the clutch needs to be
removed. For this purpose, remove bolts and take off cover together
with rubber bellows 1. At the slave cylinder of the clutch, remove the
bleeder nipple. At its place, mount the bleeder syringe 2which is filled
with biodegradable hydraulic oil (e.g. Motorex Kupplungs-Fluid 75).
Refill oil, until oil is discharged from the bore Aof the master cylinder in
a bubble-free state. Make sure that the oil does not overflow.
! CAUTION !
HAVING COMPLETED THE BLEEDING PROCEDURE, YOU HAVE TO VERIFY THAT THE OIL
LEVEL IN THE MASTER CYLINDER IS CORRECT. FOR FILLING OF THE MASTER CYLINDER,
USE SAE 10 BIODEGRADABLE HYDRAULIC OIL ONLY (EX. MOTOREX KUPPLUNGS-
FLUID 75); NEVER USE BRAKE FLUID NOR MIX BIODEGRADABLE HYDRAULIC OILS WITH
MINERAL OILS.
A
1
2