EasyManua.ls Logo

KTM 2003 950 Adventure User Manual

KTM 2003 950 Adventure
394 pages
To Next Page IconTo Next Page
To Next Page IconTo Next Page
Page #1 background imageLoading...
Page #1 background image
950/990 ADVENTURE
990 SUPER DUKE
950 SUPERMOTO
950 SUPER ENDURO
REPARATURANLEITUNG
MANUALE DI RIPARAZIONE
MANUEL DE RÉPARATION
MANUAL DE REPARACIÓN
ART.NR.: 3.206.035-E
REPAIRMANUAL2003-2006

Table of Contents

Question and Answer IconNeed help?

Do you have a question about the KTM 2003 950 Adventure and is the answer not in the manual?

KTM 2003 950 Adventure Specifications

General IconGeneral
BrandKTM
Model2003 950 Adventure
CategoryMotorcycle
LanguageEnglish

Summary

Introduction

General Information

Oil System

Explains the engine oil circulation path and components.

Cooling System

Details the closed and open thermostat states of the cooling system.

ABS System

Describes the antilock brake system operation, features, and cautions.

Special Tools – Engine

Lists specific tools required for engine servicing and their part numbers.

Bleeding the Clutch

Provides instructions for bleeding the hydraulic clutch system.

ECU Software Update/Mapping

Guides on downloading and updating the ECU software and mapping.

Checking the Oil Pressure

Outlines the procedure for checking engine oil pressure.

Removing and Refitting Engine

Removing the Engine

Step-by-step guide for dismounting the engine from the motorcycle frame.

Refitting the Engine

Step-by-step guide for mounting the engine back into the motorcycle frame.

Disassembling the Engine

Valve Covers

Instructions for removing the valve covers and associated components.

Camshafts Cylinder Rear

Details on removing the camshafts from the rear cylinder.

Cylinder Head Rear with Cylinder

Procedure for disassembling the rear cylinder head assembly.

Clutch Cover

Steps for removing the clutch cover assembly.

Clutch

Instructions for disassembling the clutch assembly.

Oil Pumps

Steps for removing the engine oil pumps.

Servicing Individual Components

Main Bearings - General Information

Provides general information on main bearings and their replacement.

Replacing the Conrod Bearings

Detailed instructions for replacing the conrod bearings.

Overhauling the Water Pump

Steps for servicing and overhauling the motorcycle's water pump.

Measuring Pistons + Cylinders, Establishing the Piston Mounting Clearance

Guide to measuring critical engine dimensions for piston fitment.

Clutch – Checking Parts for Wear

Procedures for inspecting clutch components for wear.

Assembling the Countershaft

Step-by-step guide for assembling the transmission countershaft.

Assembling the Engine

Axial Clearance of the Main Shaft

Instructions for measuring and adjusting the main shaft axial clearance.

Transmission

Details on assembling the motorcycle's transmission system.

Case Half

Steps for joining the engine case halves during assembly.

Primary Pinion

Instructions for mounting the primary pinion.

Clutch Disks

Guide for installing the clutch disks.

Cylinder Head Rear with Timing Chain

Steps for assembling the rear cylinder head and timing chain.

Camshafts Cylinder Front

Instructions for installing the front cylinder camshafts.

Starter Motor

Procedure for installing the electric starter motor.

Electrical

Electric Starter System 950 Adventure

Details the operation and safety features of the 950 Adventure electric starter.

Ignition System, ECU 950 Adventure

Explains the ignition system and ECU for the 950 Adventure model.

System Diagram

Provides a schematic overview of the motorcycle's electrical system.

Basic Description of the System

Explains the function of fuel, injection, ignition, and control systems.

Wiring Diagram 990 Super Duke

Detailed wiring diagram for the 990 Super Duke model.

Safety Against Failure/Emergency Operation

Lists defective components and their effects on vehicle operation and safety.

Component Tests

Procedures for testing various electrical system components.

Error Codes

Lists diagnostic trouble codes (DTC) with descriptions and engine effects.

ABS System 990 Adventure

Details the operation, features, and cautions of the ABS system.

Fuel System

KEIHIN CARBURETOR CVRD 43

Overview of the Keihin CV RD 43 carburetor system.

Disassembling the Carburetor

Step-by-step guide for taking apart the carburetor.

Assembling the Carburetor

Step-by-step guide for reassembling the carburetor.

Adjusting the Float Level

Instructions for setting the carburetor float level.

KEIHIN ELECTRONIC FUEL INJECTION

Information on the electronic fuel injection system.

Dismounting/mounting the Throttle Body

Procedure for removing and installing the throttle body.

Dismounting/mounting the Fuel Pump

Steps for removing and installing the fuel pump assembly.

Checking the Fuel Pressure

Procedure for measuring fuel system pressure.

Trouble Shooting

Troubleshooting Common Issues

Table listing common engine errors, their causes, and remedies.

Chassis

Dismounting/Mounting the Front Wheel

Procedure for removing and installing the front wheel.

Dismounting/Mounting the Rear Wheel

Procedure for removing and installing the rear wheel.

Replacing the Front Brake Pads

Instructions for replacing the front brake pads.

Replacing the Rear Brake Pads

Instructions for replacing the rear brake pads.

Replacing the Fork Legs

Steps for replacing the motorcycle's front fork legs.

Replacing the Shock Absorber

Procedure for replacing the rear shock absorber.

Replacing the Steering Head Bearing

Steps for replacing the steering head bearings.

Replacing the Chain, Pinion and Rear Sprocket

Instructions for replacing the drive chain and sprockets.

Replacing the ABS Unit

Procedure for replacing the Anti-lock Braking System unit.

Technical Specifications

950 ADVENTURE ENGINE

Engine specifications for the 950 Adventure model.

950 ADVENTURE CHASSIS

Chassis specifications for the 950 Adventure model.

990 SUPER DUKE ENGINE

Engine specifications for the 990 Super Duke model.

990 SUPER DUKE CHASSIS

Chassis specifications for the 990 Super Duke model.

TOLERANCES, MOUNTING CLEARANCES

Lists critical component tolerances and fitting clearances for engine parts.

TIGHTENING TORQUES – ENGINE

Specifies torque values for various engine assembly bolts and nuts.

TIGHTENING TORQUES – CHASSIS

Specifies torque values for various chassis assembly bolts and nuts.

Periodic Maintenance Schedule

950 ADVENTURE

Periodic maintenance schedule tailored for the 950 Adventure model.

990 DUKE

Periodic maintenance schedule tailored for the 990 Duke model.

950 SUPERMOTO

Periodic maintenance schedule tailored for the 950 Supermoto model.

990 ADVENTURE

Periodic maintenance schedule tailored for the 990 Adventure model.

950 SUPER ENDURO

Periodic maintenance schedule tailored for the 950 Super Enduro model.

LUBRICATION AND MAINTENANCE WORK - ENGINE

Procedures for engine oil changes and cleaning oil screens.

LUBRICATION AND MAINTENANCE WORK – CARBURETOR

Maintenance tasks related to carburetor synchronization and idle adjustment.

Changing the cooling liquid

Instructions for draining, refilling, and bleeding the cooling system.

Wiring Diagrams

950 ADVENTURE

Wiring diagrams and connector lists for the 950 Adventure model.

Start System

Wiring diagram for the motorcycle's starting system.

ECU

Wiring diagram for the Engine Control Unit (ECU).

ABS

Wiring diagram for the Anti-lock Braking System.

990 SUPER DUKE

Wiring diagrams and connector lists for the 990 Super Duke model.

ECU

Wiring diagram for the Engine Control Unit (ECU).

950 SUPERMOTO

Wiring diagrams and connector lists for the 950 Supermoto model.

ECU

Wiring diagram for the Engine Control Unit (ECU).

950 SUPER ENDURO

Wiring diagrams and connector lists for the 950 Super Enduro model.

ECU

Wiring diagram for the Engine Control Unit (ECU).

Connector List 950 ADVENTURE

Reference list of connectors and their locations for the 950 Adventure.

Connector List 990 SUPER DUKE

Reference list of connectors and their locations for the 990 Super Duke.

Connector List 950 SUPER ENDURO

Reference list of connectors and their locations for the 950 Super Enduro.

Related product manuals