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KTM 950 Super Moto 2003-2006 Service Repair Manual

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🏷️ Basic Information Identification Make: KTM Model: 950 Super Moto Model Variant: Supermoto Model Designation: 950 SM Codes Chassis Code: LC8 👋 Introduction Market Position Segment: High-performance naked sportbike/supermoto Target Audience: Enthusiast riders seeking off-road inspired agility with street performance Competitive Analysis Key Competitors: Ducati Hypermotard, Aprilia Dorsoduro, Yamaha TDM series (early iterations) Key Features Unique Selling Points: V-twin LC8 engine, long-travel suspension, aggressive styling, lightweight chassis Manual Value Proposition Dealer Level Access: Provides the same technical data used by authorized KTM technicians Diy Enablement: Empowers owners with the knowledge for self-maintenance and repairs 📋 Manual Details Coverage Areas Covered Years: 2003, 2004, 2005, 2006 Page Count Estimated Page Count: Estimated 500+ pages (typical for comprehensive service manuals) Manual Type Type: Service Repair Manual Language Language: English (Presumed, standard for manufacturer documentation) Format Format: PDF (Digital Download) Compatibility Operating Systems: Windows, macOS, Linux 📖 Manual Coverage Systems Covered Engine: Full engine disassembly, assembly, tuning, and diagnostics Transmission: Clutch operation, gear selection, internal transmission components Fuel System: Carburetor/throttle body service, fuel pump, fuel lines, fuel filters Ignition System: Ignition coils, spark plugs, ignition control module Electrical System: Wiring diagrams, charging system, starting system, lighting, instrumentation Cooling System: Radiator, coolant hoses, thermostat, fan operation Braking System: Brake fluid replacement, caliper service, pad replacement, master cylinder Suspension: Front fork service (seals, oil, springs), rear shock absorber service Steering: Steering head bearing maintenance and adjustment Chassis: Frame inspection, subframe, wheels, tires Bodywork: Fairings, seat, tank removal and installation Procedures Included Maintenance: Routine maintenance, oil changes, filter replacement, chain adjustment, valve clearance checks Troubleshooting: Diagnostic procedures for common and uncommon faults Repair: Component-level repair, replacement of worn or damaged parts Rebuilds: Engine, transmission, and suspension component rebuilds Technical Service Bulletins: Inclusion of manufacturer-issued TSBs Recall Information: Inclusion of manufacturer-issued recall notices Technical Depth Depth: Comprehensive: From basic fluid changes to full engine and transmission overhauls 📊 Manual Specifications File Format File Type: PDF Print Quality Quality: High-resolution, suitable for printing Binding Type Binding: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) Searchability Text Search: Searchable text content (typical for well-produced PDFs) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 75-degree V-twin, four-stroke Displacement: 942 cc (57.5 cu. in.) Bore X Stroke: 97.0 mm x 65.0 mm (approximate) Valve Train: DOHC, 4 valves per cylinder Performance Horsepower: Approx. 98 hp @ 8,000 rpm (manufacturer claim) Torque: Approx. 94 Nm (69 lb-ft) @ 6,000 rpm (manufacturer claim) Fuel System Carburetors: Initially Mikuni BSR-42 CV carburetors (later models and variants may differ) Fuel Type: Unleaded gasoline, minimum 95 RON Lubrication System Oil Capacity: Approx. 3.2 liters (108.2 fl. oz.) with filter change Engine Internals Compression Ratio: 11.1:1 (approximate) 🔧 Transmission Standard Type: 6-speed, constant mesh Clutch: Wet multi-disc clutch, hydraulically operated Features Final Drive: O-ring sealed chain Fluid Specifications Transmission Oil Type: API SG or higher, SAE 10W/40 or 15W/50 motorcycle specific lubricant 📐 Dimensions Exterior Length: Approx. 2,200 mm (86.6 in.) Width: Approx. 880 mm (34.6 in.) Height: Approx. 1,200 mm (47.2 in.) Weights Dry Weight: Approx. 197 kg (434.3 lbs) Wet Weight: Approx. 218 kg (480.6 lbs) (with all fluids) Payload Capacity: Not specified, typically rider and minimal luggage Wheels Tires Front Wheel Size: 17 x 3.50 inch Rear Wheel Size: 17 x 5.00 inch Front Tire Size: 120/70ZR-17 Rear Tire Size: 180/55ZR-17 Wheel Bolt Pattern: N/A (cast wheels, not bolt-on pattern in the car sense) 🛡️ Safety Features Ratings Crash Test Ratings: N/A (Motorcycle, not subject to automotive NHTSA/Euro NCAP) Active Features Braking System Type: Dual disc front, single disc rear Front Brakes: Dual 320mm discs with 4-piston calipers (e.g., Brembo) Rear Brakes: Single 240mm disc with 2-piston caliper ABS: Optional or not available on early models (check specific VIN) Passive Features Lighting: Halogen headlight, LED taillight, standard turn signals 💡 Technology Features Infotainment Display: Analog tachometer, digital speedometer, multi-function LCD display Driver Assistance ABS: Availability varies by model year and region Connectivity Usb Charging: Not standard, may be an aftermarket addition 🔧 Maintenance Service Intervals Oil Change Interval: Every 5,000 km (3,000 miles) or annually Oil Filter Replacement Interval: Every 5,000 km (3,000 miles) or annually Valve Clearance Check Interval: Every 10,000 km (6,000 miles) Chain Maintenance Interval: Lubricate and adjust every 1,000 km (600 miles) and after washing or rain Fluid Specifications Engine Oil Type: JASO MA certified motorcycle oil, SAE 10W/40 or 15W/50 Coolant Type: Ethylene glycol based antifreeze with corrosion inhibitors (KTM recommends specific pre-mix) Brake Fluid Type: DOT 4 Fork Oil Type: SAE 5W or 10W (specific viscosity detailed in manual) Known Issues Common Wear Items: Clutch plates, swingarm bearings, steering head bearings, fork seals Potential Electrical Gremlins: Wiring harness integrity, starter solenoid issues (less common but documented) Engine Vibrations: Characteristic of the V-twin, but can be exacerbated by poor balance shaft alignment or worn mounts Recommended Filters...
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KTM 950 Super Moto 2003-2006 Service Repair Manual
🏷️ Basic Information
Identification
Make:
KTM
Model:
950 Super Moto
Model Variant:
Supermoto
Model Designation:
950 SM
Codes
Chassis Code:
LC8
👋 Introduction
Market Position
Segment:
High-performance naked sportbike/supermoto
Target Audience:
Enthusiast riders seeking off-road inspired agility with street performance
Competitive Analysis
Key Competitors:
Ducati Hypermotard, Aprilia Dorsoduro, Yamaha TDM series (early iterations)
Key Features
Unique Selling Points:
V-twin LC8 engine, long-travel suspension, aggressive styling, lightweight chassis
Manual Value Proposition
Dealer Level Access:
Provides the same technical data used by authorized KTM technicians
Diy Enablement:
Empowers owners with the knowledge for self-maintenance and repairs
📋 Manual Details
Coverage Areas
Covered Years:
2003, 2004, 2005, 2006
Page Count
Estimated Page Count:
Estimated 500+ pages (typical for comprehensive service manuals)
Manual Type
Type:
Service Repair Manual
Language
Language:
English (Presumed, standard for manufacturer documentation)
Format
Format:
PDF (Digital Download)
Compatibility
Operating Systems:
Windows, macOS, Linux
📖 Manual Coverage
Systems Covered
Engine:
Full engine disassembly, assembly, tuning, and diagnostics
Transmission:
Clutch operation, gear selection, internal transmission components
Fuel System:
Carburetor/throttle body service, fuel pump, fuel lines, fuel filters
Ignition System:
Ignition coils, spark plugs, ignition control module
Electrical System:
Wiring diagrams, charging system, starting system, lighting, instrumentation
Cooling System:
Radiator, coolant hoses, thermostat, fan operation
Braking System:
Brake fluid replacement, caliper service, pad replacement, master cylinder
Suspension:
Front fork service (seals, oil, springs), rear shock absorber service
Steering:
Steering head bearing maintenance and adjustment
Chassis:
Frame inspection, subframe, wheels, tires
Bodywork:
Fairings, seat, tank removal and installation
Procedures Included
Maintenance:
Routine maintenance, oil changes, filter replacement, chain adjustment, valve clearance checks
Troubleshooting:
Diagnostic procedures for common and uncommon faults
Repair:
Component-level repair, replacement of worn or damaged parts
Rebuilds:
Engine, transmission, and suspension component rebuilds
Technical Service Bulletins:
Inclusion of manufacturer-issued TSBs
Recall Information:
Inclusion of manufacturer-issued recall notices
Technical Depth
Depth:
Comprehensive: From basic fluid changes to full engine and transmission overhauls
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Quality:
High-resolution, suitable for printing
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
Searchability
Text Search:
Searchable text content (typical for well-produced PDFs)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, 75-degree V-twin, four-stroke
Displacement:
942 cc (57.5 cu. in.)
Bore X Stroke:
97.0 mm x 65.0 mm (approximate)
Valve Train:
DOHC, 4 valves per cylinder
Performance
Horsepower:
Approx. 98 hp @ 8,000 rpm (manufacturer claim)
Torque:
Approx. 94 Nm (69 lb-ft) @ 6,000 rpm (manufacturer claim)
Fuel System
Carburetors:
Initially Mikuni BSR-42 CV carburetors (later models and variants may differ)
Fuel Type:
Unleaded gasoline, minimum 95 RON
Lubrication System
Oil Capacity:
Approx. 3.2 liters (108.2 fl. oz.) with filter change
Engine Internals
Compression Ratio:
11.1:1 (approximate)
🔧 Transmission
Standard
Type:
6-speed, constant mesh
Clutch:
Wet multi-disc clutch, hydraulically operated
Features
Final Drive:
O-ring sealed chain
Fluid Specifications
Transmission Oil Type:
API SG or higher, SAE 10W/40 or 15W/50 motorcycle specific lubricant
📐 Dimensions
Exterior
Length:
Approx. 2,200 mm (86.6 in.)
Width:
Approx. 880 mm (34.6 in.)
Height:
Approx. 1,200 mm (47.2 in.)
Weights
Dry Weight:
Approx. 197 kg (434.3 lbs)
Wet Weight:
Approx. 218 kg (480.6 lbs) (with all fluids)
Payload Capacity:
Not specified, typically rider and minimal luggage
Wheels Tires
Front Wheel Size:
17 x 3.50 inch
Rear Wheel Size:
17 x 5.00 inch
Front Tire Size:
120/70ZR-17
Rear Tire Size:
180/55ZR-17
Wheel Bolt Pattern:
N/A (cast wheels, not bolt-on pattern in the car sense)
🛡️ Safety Features
Ratings
Crash Test Ratings:
N/A (Motorcycle, not subject to automotive NHTSA/Euro NCAP)
Active Features
Braking System Type:
Dual disc front, single disc rear
Front Brakes:
Dual 320mm discs with 4-piston calipers (e.g., Brembo)
Rear Brakes:
Single 240mm disc with 2-piston caliper
ABS:
Optional or not available on early models (check specific VIN)
Passive Features
Lighting:
Halogen headlight, LED taillight, standard turn signals
💡 Technology Features
Infotainment
Display:
Analog tachometer, digital speedometer, multi-function LCD display
Driver Assistance
ABS:
Availability varies by model year and region
Connectivity
Usb Charging:
Not standard, may be an aftermarket addition
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 km (3,000 miles) or annually
Oil Filter Replacement Interval:
Every 5,000 km (3,000 miles) or annually
Valve Clearance Check Interval:
Every 10,000 km (6,000 miles)
Chain Maintenance Interval:
Lubricate and adjust every 1,000 km (600 miles) and after washing or rain
Fluid Specifications
Engine Oil Type:
JASO MA certified motorcycle oil, SAE 10W/40 or 15W/50
Coolant Type:
Ethylene glycol based antifreeze with corrosion inhibitors (KTM recommends specific pre-mix)
Brake Fluid Type:
DOT 4
Fork Oil Type:
SAE 5W or 10W (specific viscosity detailed in manual)
Known Issues
Common Wear Items:
Clutch plates, swingarm bearings, steering head bearings, fork seals
Potential Electrical Gremlins:
Wiring harness integrity, starter solenoid issues (less common but documented)
Engine Vibrations:
Characteristic of the V-twin, but can be exacerbated by poor balance shaft alignment or worn mounts
Recommended Filters
Oil Filter Part Number:
Refer to manual for OEM or compatible aftermarket part numbers (e.g., HF152 or equivalent)
📚 Vehicle History
Brand Heritage
Manufacturer Origin:
Austria
Brand Focus:
Performance off-road and street motorcycles
Model Evolution
Introduction Year:
2003
Lc8 Platform:
Based on the successful LC8 V-twin engine platform initially developed for adventure bikes
Production
Production Years Covered:
2003-2006 (as per manual)
Manufacturing Location:
Austria (primarily)
🏆 Awards & Recognition
Recognitions
Sportbike Of The Year:
Received accolades in various motorcycle publications for its performance and handling upon release
Ratings
Handling Reviews:
Consistently praised for sharp, agile handling and off-road inspired chassis dynamics
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