KTM 950 ADVENTURE 2003 User Manual

950 ADVENTURE
2003 to 2006

KTM 950 ADVENTURE 2003 Specifications

General

Displacement	942 cc
Transmission	6-speed
Compression ratio	11.5:1
Final drive	Chain
Front tire	90/90-21
Rear tire	150/70-18
Engine Type	V2, 4-stroke
Power	98 hp (72 kW)
Power RPM	8000 rpm
Torque	95 Nm
Torque RPM	6000 rpm
Bore x stroke	100 x 60 mm
Cooling system	Liquid-cooled
Front suspension	WP USD 48 mm
Front brake	Dual disc
Rear brake	Single disc
Wheelbase	1570 mm

Summary

GENERAL INFORMATION

Oil System

Description of the engine oil circulation system.

Intake System

Explanation of the fresh air intake system for the engine.

Secondary Air System

Function and operation of the secondary air system.

Cooling System

Explanation of the engine cooling system operation.

REMOVING AND REFITTING ENGINE

Removing the Engine

Index for engine removal procedure.

Refitting the Engine

Step-by-step instructions for refitting the engine.

DISASSEMBLING ENGINE

Valve Covers and Spark Plug Inserts

Procedures for removing valve covers and spark plug inserts.

Cylinder Head and Camshafts

Setting rear cylinder to TDC and disassembling camshafts.

Timing Chain and Tensioners

Procedures for rear chain tensioner and timing chain.

Engine Internals

Procedures for water pump, oil screen, and clutch cover.

SERVICING INDIVIDUAL COMPONENTS

Bearing Replacement

Procedure for replacing roller bearings in the engine case.

Pump and Valve Servicing

Step-by-step instructions for overhauling the water pump.

Cylinder Head and Piston Servicing

Disassembly and wear checks for cylinder head components.

Other Component Servicing

Servicing the generator cover and checking valve gear wear.

ASSEMBLING THE ENGINE

Crankshaft and Transmission Assembly

Assembly of the engine oil pump components.

Cylinder Head and Timing Chain Assembly

Assembly of rear cylinder head and timing chain.

ELECTRICAL

System Checks and Troubleshooting

Procedures for checking current loss and generator coils.

Component Checks and Diagrams

Overview of the ignition system and ECU.

FUEL SYSTEM

Carburetor System Overview

Exploded view of the Keihin CVDR 43 carburetor.

Carburetor Disassembly and Assembly

Step-by-step instructions for disassembling the carburetor.

Carburetor Adjustments

Procedures for adjusting float level and idle mixture.

TROUBLE SHOOTING

Engine and System Issues

Troubleshooting for engine not starting when starter button is pressed.

CHASSIS

Wheel Bearing Replacement

Procedure for replacing the front wheel bearings.

Suspension Components

Procedure for replacing the front fork legs.

Drive Train Components

Procedure for replacing chain, pinion, and rear sprocket.

TECHNICAL SPECIFICATIONS

Engine Specifications

Detailed technical specifications for the LC8 engine.

Chassis Specifications

Technical specifications for the 950 Adventure chassis.

Tolerances and Clearances

Table of component tolerances and fitting clearances.

Tightening Torques

List of engine component tightening torques.

PERIODIC MAINTENANCE SCHEDULE

Engine Maintenance

Procedure for changing engine oil and filter.

Chassis and Brake Maintenance

Procedure for changing front brake fluid.

Vital Checks

Procedure for checking engine oil level.

WIRING DIAGRAMS

Main Electrical Schematics

General overview of the motorcycle's electrical system.

Switch and Control Diagrams

Diagrams for the start/stop, clutch, and sidestand switches.

Connector Locations

Lists and locations of electrical connectors AA through AF.