2003-2006 KTM 950 ADVENTURE 990 ADVENTURE 990 Super DUKE 950 SuperMOTO 950 Super ENDURO Workshop Service Repair Manual Best
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🏷️ Basic Information Identification Make: KTM Covered Models: 950 ADVENTURE, 990 ADVENTURE, 990 SUPER DUKE, 950 SUPERMOTO, 950 SUPER ENDURO Applicable Model Years: 2003, 2004, 2005, 2006 Codes Manual Identifier: 3.206.009-E (Base), 3.206.016-E (2004 Update), 3.206.025-E (2005 Update), 3.206.035-E (2005/06 Update) Engine Code Designation: LC8 (indicating the V-Twin engine family) 👋 Introduction Market Position Segment: High-performance adventure touring and sport motorcycles. Target Audience: Owners and independent repair shops seeking comprehensive repair and maintenance information. Competitive Analysis Comparable Models: BMW R1200GS series, Triumph Tiger series, Ducati Multistrada series (of the same era). Key Features Of Vehicles Powertrain: Powerful LC8 V-twin engine, known for its torque and performance. Adventure Capability: Designed for long-distance touring and off-road capability, with robust suspension and chassis. Sport Performance: The Super Duke and Supermoto models leverage the LC8 platform for exhilarating road performance. Manual Benefit Owner Empowerment: Enables owners to perform maintenance and repairs themselves, saving costs and increasing understanding of their machine. Professional Resource: Provides the same level of detail and accuracy used by professional technicians. 📋 Manual Details Coverage Areas Engine Mechanical: Yes Engine Electrical Injection: Yes Fuel System: Yes Transmission: Yes Chassis Suspension: Yes Brakes: Yes Electrical Systems: Yes Wiring Diagrams: Yes Troubleshooting: Yes Periodic Maintenance: Yes Technical Specifications: Yes Bodywork: Implied within general repair procedures Page Count Estimated Page Count: High (typical workshop manuals for this era are several hundred pages) Manual Type Type: Workshop Service Repair Manual Language Languages Covered: English (primary), German (REPARATURANLEITUNG), Italian (MANUALE DI RIPARAZIONE), French (MANUEL DE RÉPARATION), Spanish (MANUAL DE REPARACIÓN) Format Digital Format: PDF 📖 Manual Coverage Systems Covered Engine Disassembly Assembly: Comprehensive, from basic removal and refitting to detailed component servicing and reassembly. Fuel Delivery Management: Includes carburetors (for 950 models) or fuel injection systems (for 990 models), fuel pump, lines, and filters. Ignition And Charging: Covers stator, ignition coil, spark plugs, battery, and charging system components. Cooling System: Radiator, cooling fan, coolant flow, and related components. Lubrication System: Oil pump, oil filter, oil passages, and oil change procedures. Clutch System: Clutch operation, hydraulic system, and clutch plate servicing. Transmission Gearbox: Gear selection, internal components, and lubrication. Suspension Front Rear: Fork servicing, rear shock absorber adjustment and maintenance. Braking System Front Rear: Brake caliper, master cylinder, brake lines, pads, and rotor servicing. Wheel And Tire Assembly: Wheel bearing replacement, tire fitting and balancing. Exhaust System: Exhaust pipe and muffler inspection and replacement. Control Systems: Throttle control, clutch lever, brake lever, and cable routing. Electrical Components: Lights, horn, starter motor, instruments, and switches. Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustment, lubrication points, spark plug replacement. Diagnostic Troubleshooting: Step-by-step guides for identifying and resolving common mechanical and electrical issues. Engine Rebuilding: Detailed instructions for engine disassembly, cleaning, inspection of components (pistons, rings, valves, crankshaft), and reassembly with torque specifications. Suspension Overhaul: Front fork seal replacement, oil level checks, rear shock absorber servicing. Brake System Service: Brake fluid bleeding, pad and rotor replacement, caliper and master cylinder rebuild. Electrical Troubleshooting: Use of wiring diagrams to diagnose faults in lighting, starting, ignition, and accessory circuits. Fuel System Adjustment: Carburetor synchronization and jetting (950 models), fuel injector diagnostics (990 models). Valve Adjustment: Procedure for checking and adjusting valve clearance (shims or screw adjusters depending on specific engine variant). Technical Depth Depth: Comprehensive: Covers everything from basic maintenance checks and adjustments to complete engine and chassis rebuilds, including electrical system diagnostics. Diagnostic Capability: Advanced: Utilizes troubleshooting flowcharts and detailed explanations of system functions. Rebuild Detail: Detailed step-by-step instructions with required torque specifications and critical measurements for engine and component rebuilds. 📊 Manual Specifications File Format Format: PDF Readability: High quality, designed for viewing and printing. Searchability: Likely text-searchable PDF for efficient information retrieval. Print Quality Illustrations: High quality photos, illustrations, and diagrams included. Binding Type Physical Format Analogy: Digital equivalent of a professionally bound workshop manual with clear sections and indexes. Paper Type Digital Paper Analogy: Digital format allows for printing on demand, avoiding wear and tear of physical copies. ⚙️ Engine Specifications Primary Engine Engine Family: LC8 V-Twin 950 Adventure/Supermoto/Super Enduro Engine: 72° V-twin, liquid-cooled, DOHC, 4 valves per cylinder 950 Engine Displacement: 942 cc (57.5 cu in) 950 Engine Power Output: Approx. 98-105 hp (72-77 kW) at 8000 rpm (varies slightly by model and year) 950 Engine Torque: Approx. 95-100 Nm (70-74 lb-ft) at 6000 rpm 990 Adventure/Super Duke Engine: 75° V-twin, liquid-cooled, DOHC, 4 valves per cylinder 990 Engine Displacement: 999 cc (61.0 cu in) 990 Engine Power Output: Approx. 105-115 hp (77-85 kW) at 8000 rpm (varies slightly by model and year) 990 Engine Torque: Approx. 98-105 Nm (72-77 lb-ft) at 6500 rpm Fuel System 950 Models Fueling: Dual Keihin CV carburetors (e.g., 38mm) 990 Models Fueling: Electronic Fuel Injection (EFI) Performance Compression Ratio 950: 10.4:1 Compression Ratio 990: 11.5:1 (approx.) 🔧 Transmission Standard...
Step-by-step guides for identifying and resolving common mechanical and electrical issues.
Engine Rebuilding:
Detailed instructions for engine disassembly, cleaning, inspection of components (pistons, rings, valves, crankshaft), and reassembly with torque specifications.
Suspension Overhaul:
Front fork seal replacement, oil level checks, rear shock absorber servicing.
Brake System Service:
Brake fluid bleeding, pad and rotor replacement, caliper and master cylinder rebuild.
Electrical Troubleshooting:
Use of wiring diagrams to diagnose faults in lighting, starting, ignition, and accessory circuits.
Procedure for checking and adjusting valve clearance (shims or screw adjusters depending on specific engine variant).
Technical Depth
Depth:
Comprehensive: Covers everything from basic maintenance checks and adjustments to complete engine and chassis rebuilds, including electrical system diagnostics.
Diagnostic Capability:
Advanced: Utilizes troubleshooting flowcharts and detailed explanations of system functions.
Rebuild Detail:
Detailed step-by-step instructions with required torque specifications and critical measurements for engine and component rebuilds.
📊 Manual Specifications
File Format
Format:
PDF
Readability:
High quality, designed for viewing and printing.
Searchability:
Likely text-searchable PDF for efficient information retrieval.
Print Quality
Illustrations:
High quality photos, illustrations, and diagrams included.
Binding Type
Physical Format Analogy:
Digital equivalent of a professionally bound workshop manual with clear sections and indexes.
Paper Type
Digital Paper Analogy:
Digital format allows for printing on demand, avoiding wear and tear of physical copies.
⚙️ Engine Specifications
Primary Engine
Engine Family:
LC8 V-Twin
950 Adventure/Supermoto/Super Enduro Engine:
72° V-twin, liquid-cooled, DOHC, 4 valves per cylinder
950 Engine Displacement:
942 cc (57.5 cu in)
950 Engine Power Output:
Approx. 98-105 hp (72-77 kW) at 8000 rpm (varies slightly by model and year)
950 Engine Torque:
Approx. 95-100 Nm (70-74 lb-ft) at 6000 rpm
990 Adventure/Super Duke Engine:
75° V-twin, liquid-cooled, DOHC, 4 valves per cylinder
990 Engine Displacement:
999 cc (61.0 cu in)
990 Engine Power Output:
Approx. 105-115 hp (77-85 kW) at 8000 rpm (varies slightly by model and year)
990 Engine Torque:
Approx. 98-105 Nm (72-77 lb-ft) at 6500 rpm
Fuel System
950 Models Fueling:
Dual Keihin CV carburetors (e.g., 38mm)
990 Models Fueling:
Electronic Fuel Injection (EFI)
Performance
Compression Ratio 950:
10.4:1
Compression Ratio 990:
11.5:1 (approx.)
🔧 Transmission
Standard
Transmission Type:
6-speed constant mesh
Features
Clutch Type:
Hydraulic actuated wet multi-plate clutch
Final Drive:
O-ring sealed chain
📐 Dimensions
Exterior
Seat Height 950 Adventure:
Approx. 880-900 mm (34.6-35.4 in) adjustable
Ground Clearance 950 Adventure:
Approx. 265 mm (10.4 in)
Weights
Dry Weight 950 Adventure:
Approx. 198 kg (436.5 lbs)
Dry Weight 990 Adventure:
Approx. 203 kg (447.5 lbs)
Dry Weight 990 Super Duke:
Approx. 183 kg (403.4 lbs)
🛡️ Safety Features
Ratings
ABS Availability:
Optional on some models/years (e.g., 990 Adventure with ABS)
Active Features
Braking System Type:
Dual front disc brakes, single rear disc brake with dual or triple piston calipers (depending on model).
Suspension Design:
USD (Upside-Down) front forks and Monoshock rear suspension, designed for long travel and adjustability.
💡 Technology Features
Infotainment
Instrument Cluster:
Analog tachometer, digital speedometer, odometer, trip meters, fuel gauge, warning lights.
Driver Assistance
ABS System:
Optional Anti-lock Braking System, offering enhanced safety in braking situations.
Connectivity
Diagnostic Port:
Likely includes a diagnostic port for connection to KTM diagnostic tools for more advanced troubleshooting.
🔧 Maintenance
Service Intervals
Oil And Filter Change:
Typically every 7,500 km (4,660 miles) or annually.
Valve Clearance Check:
Typically every 15,000 km (9,320 miles).
Spark Plug Replacement:
Refer to manual, often around 15,000-20,000 km (9,320-12,430 miles).
Air Filter Service:
Recommended at regular intervals, more frequently in dusty conditions.
Fluid Specifications
Engine Oil Type 950:
SAE 10W-40, API SJ or higher, JASO MA compatible (e.g., Motorex Power Synt 4T 10W-40)
Engine Oil Type 990:
SAE 10W-50, API SJ or higher, JASO MA compatible (e.g., Motorex Power Synt 4T 10W-50)
Coolant Type:
Ethylene glycol-based coolant with corrosion inhibitors (e.g., Motorex Coolant M5.0)
Brake Fluid Type:
DOT 4 hydraulic fluid
Clutch Fluid Type:
DOT 4 hydraulic fluid
Known Issues
Carburetor Sync 950:
Carburetors may require periodic synchronization for optimal performance.
Starter Clutch Wear:
Some early models reported potential wear on the starter clutch mechanism.
Water Pump Seals:
Potential for water pump seal leaks, especially with age.
Fuel Pump Reliability 990:
Early EFI models sometimes experienced fuel pump issues, though often addressed by KTM service bulletins.
📚 Vehicle History
Brand Heritage
Brand Focus:
KTM is renowned for its off-road prowess and performance-oriented motorcycles, often referred to as 'Ready to Race'.
Model Evolution
Lc8 Platform Introduction:
The LC8 engine platform was a significant development for KTM, moving into larger displacement street-legal and adventure bikes.
950 Adventure Debut:
Introduced in 2003, it established KTM as a major player in the adventure touring segment.
990 Series Introduction:
The 990 models, featuring fuel injection and larger displacement, followed, offering further refinement and performance.
Production
Manufacturing Origin:
Austria
🏆 Awards & Recognition
Recognitions
Motorcycle Press Acclaim:
The KTM Adventure and Super Duke models were generally well-received by the motorcycle press for their performance and capabilities.
Segment Dominance:
KTM's adventure bikes, in particular, were noted for their ability to blend serious off-road capability with strong on-road touring performance, setting benchmarks in the segment.
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