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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...
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2003-2006 KTM 950 ADVENTURE 990 ADVENTURE 990 Super DUKE 950 SuperMOTO 950 Super ENDURO Workshop Service Repair Manual Best
🏷️ 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
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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