KTM 950-990 ADVENTURE Super DUKE 2003-2005 ONWERS REPIR CHOCK Fork Manual D-I-E-GB
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Basic Information Identification Make: KTM Model: 950 Adventure / 990 Adventure / Super Duke Years Covered: 2003, 2004, 2005 Region Code: D-I-E-GB (Likely Germany, Italy, England - suggesting a European market focus) Introduction Market Position Positioning: Targets owners and independent workshops seeking to perform comprehensive maintenance and repairs on KTM's popular Adventure and Super Duke models, offering significant cost savings over dealership servicing. Competitive Analysis Advantage: Provides factory-level technical information, enabling DIY repairs and maintenance that rivals dealership capabilities. Empowers owners with knowledge previously exclusive to professional mechanics. Key Features Content Highlights: Step-by-step procedures, detailed illustrations, exploded diagrams, torque specifications, troubleshooting charts, wiring diagrams, and essential maintenance data. Manual Details Coverage Areas General Coverage: Comprehensive front-to-back repair and servicing for the specified KTM models. Specific Systems Covered: Frame, body panels, exhaust, cooling system, fuel system, engine (removal/installation, head, cylinder, piston), clutch, gearshift linkage, crankshaft, transmission, front wheel/suspension/steering, rear wheel/suspension, brakes, charging system, alternator, ignition system, electric starter, starter clutch, lights, meters, switches, wiring diagram. Page Count Estimated Page Count: Estimated 300-500 pages (typical for comprehensive workshop manuals of this era). Manual Type Type: Owner's Repair Manual / Workshop Manual Language Primary Language: English (implied by 'GB' and general manual description) Format Format: Print (implied by 'send to you', 'garage or workshop use'). Digital PDF format might be an alternative for online sales. Manual Coverage Systems Covered Powertrain: Engine (V-twin LC8), transmission, clutch, fuel system, exhaust system. Chassis: Frame, suspension (front forks, rear shock/swingarm), steering, wheels, brakes (front and rear). Electrical: Ignition system, charging system (alternator), starting system (electric starter), lighting, instrumentation, switches, wiring diagrams. Bodywork And Accessories: Body panels, fairings, seat, fuel tank, exhaust system. Procedures Included Maintenance: Routine maintenance, lubrication, fluid changes, filter replacements, adjustments. Diagnostics And Troubleshooting: Step-by-step troubleshooting guides for common issues. Repair And Overhaul: Detailed instructions for component removal, disassembly, inspection, repair, and reassembly of major systems. Technical Adjustments: Carburetor/throttle body synchronization, chain adjustment, valve clearance checks, suspension sag settings. Technical Depth Depth: Comprehensive: Covers everything from basic service to in-depth engine and transmission rebuilds, including detailed diagrams and specifications. Manual Specifications File Format Format Detail: Likely a high-quality reproduction of an original factory service manual. If digital, expected to be searchable PDF. Print Quality Quality: High-quality reproductions with clear illustrations and diagrams, designed for workshop use. Binding Type Binding: Likely a durable comb binding or stapled booklet for workshop durability, or a perfect bound book if it's a higher-end reproduction. Paper Type Paper: Durable paper stock, often on gloss or semi-gloss paper to protect against grease and grime in a workshop environment. Engine Specifications Primary Engine Engine Type: V-twin, 4-stroke, Liquid-cooled (LC8 engine) Displacement 950: 942 cc Displacement 990: 999 cc Performance Power Output 950 Adventure: Approx. 98 hp (72 kW) @ 8000 rpm Torque 950 Adventure: Approx. 95 Nm (70 lb-ft) @ 6500 rpm Power Output 990 Adventure: Approx. 105-115 hp (77-85 kW) @ 7500-8000 rpm Torque 990 Adventure: Approx. 98-102 Nm (72-75 lb-ft) @ 6000-6500 rpm Fuel System Fuel Delivery: Carbureted (Keihin CVK 41) for early 950 models, Fuel Injection (EFI) for later 950 models and all 990 models. Fuel Type: Unleaded gasoline, minimum 95 RON. Transmission Standard Transmission Type: 6-speed constant mesh Features Clutch Type: Wet multi-disc clutch, hydraulically operated. Final Drive: O-ring sealed chain Dimensions Exterior Wheelbase 950 Adventure: Approximately 1500-1510 mm (59.1-59.4 in) Wheelbase 990 Adventure: Approximately 1570-1575 mm (61.8-62.0 in) Weights Dry Weight 950 Adventure: Approximately 198 kg (436.5 lbs) Dry Weight 990 Adventure: Approximately 199 kg (438.7 lbs) Fuel Tank Capacity: 22 Liters (5.8 US gal) Safety Features Active Features Braking System: Dual front disc brakes with multi-piston calipers, single rear disc brake. Suspension Technology: Long-travel, adjustable upside-down front forks (WP Suspension), adjustable rear monoshock (WP Suspension). Passive Features Frame Construction: Chromium-molybdenum steel trellis frame, known for rigidity and strength. Technology Features Infotainment Instrumentation: Digital/analog combination instrument cluster displaying speed, RPM, fuel level, engine temperature, odometer, trip meters, and warning lights. Driver Assistance Traction Control ABS: Early models generally lacked advanced electronic aids like traction control or ABS. Later 990 models introduced optional ABS. This manual would cover standard systems. Connectivity Charging Port: Many models feature a 12V power socket for accessory charging. Maintenance Service Intervals Oil Change Interval: Typically every 5,000 - 7,500 km (3,000 - 5,000 miles), or annually. Air Filter Check: Check every 5,000 km (3,000 miles), clean/replace as needed. Valve Clearance Check: Initial check around 10,000 km (6,000 miles), then every 10,000 - 20,000 km (6,000 - 12,000 miles) depending on use. Fluid Specifications Engine Oil Type: SAE 10W-50 or 15W-50, API SG/SH/SJ or higher, JASO MA approved motorcycle oil. Engine Oil Capacity: Approx. 2.7 - 3.0 Liters (with filter change). Coolant Type: Ethylene glycol-based coolant with corrosion inhibitors (e.g., Motorex Coolant M3.0). Brake Fluid Type: DOT 4. Clutch Fluid Type: DOT 4 (same...
D-I-E-GB (Likely Germany, Italy, England - suggesting a European market focus)
Introduction
Market Position
Positioning:
Targets owners and independent workshops seeking to perform comprehensive maintenance and repairs on KTM's popular Adventure and Super Duke models, offering significant cost savings over dealership servicing.
Competitive Analysis
Advantage:
Provides factory-level technical information, enabling DIY repairs and maintenance that rivals dealership capabilities. Empowers owners with knowledge previously exclusive to professional mechanics.
Early models generally lacked advanced electronic aids like traction control or ABS. Later 990 models introduced optional ABS. This manual would cover standard systems.
Connectivity
Charging Port:
Many models feature a 12V power socket for accessory charging.
Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000 - 7,500 km (3,000 - 5,000 miles), or annually.
Air Filter Check:
Check every 5,000 km (3,000 miles), clean/replace as needed.
Valve Clearance Check:
Initial check around 10,000 km (6,000 miles), then every 10,000 - 20,000 km (6,000 - 12,000 miles) depending on use.
Fluid Specifications
Engine Oil Type:
SAE 10W-50 or 15W-50, API SG/SH/SJ or higher, JASO MA approved motorcycle oil.
Engine Oil Capacity:
Approx. 2.7 - 3.0 Liters (with filter change).
Coolant Type:
Ethylene glycol-based coolant with corrosion inhibitors (e.g., Motorex Coolant M3.0).
While generally robust, some owners report minor electrical connector issues or stator/regulator concerns over time, which this manual would help diagnose.
Suspension Tuning:
Proper setup and occasional servicing of WP suspension components are crucial for optimal performance and longevity.
Vehicle History
Brand Heritage
Heritage:
KTM, founded in 1934, has a strong legacy in off-road and motorsport, translating to robust and performance-oriented motorcycles.
Model Evolution
Introduction Of Lc8:
The LC8 V-twin engine platform was a significant step for KTM into larger displacement motorcycles, initially powering the 950 Adventure in 2003, followed by the 990 series.
Adventure Platform:
The Adventure series quickly became a benchmark for dual-sport motorcycles, offering class-leading suspension, powerful engines, and a distinctive Austrian design.
Production
Manufacturing:
Primarily manufactured in Austria.
Awards & Recognition
Recognitions
Model Acclaim:
The KTM Adventure series, particularly the 950 and 990, are widely praised in motorcycle media for their off-road capability, comfort for long-distance touring, and potent V-twin performance, often winning 'adventure bike of the year' accolades in their respective eras.
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