KTM 950 ADVENTURE 2004 User Manual

950 ADVENTURE
2003 to 2006

KTM 950 ADVENTURE 2004 Specifications

General

Brand	KTM
Model	950 ADVENTURE 2004
Category	Motorcycle
Language	English

Summary

General Information

Oil System

Explains the engine oil circulation and lubrication paths.

Intake System

Details how fresh air is drawn into the engine for combustion.

Cooling System

Explains the function of the cooling system, including thermostat and fan operation.

Removing and Refitting Engine

Removing the Engine

Step-by-step instructions for engine removal from the motorcycle.

Refitting the Engine

Steps to reinstall the engine into the motorcycle frame and connect components.

Disassembling the Engine

Cylinder Timing and Camshafts (Rear)

Setting rear cylinder TDC, checking valve clearance, removing rear camshafts.

Double Timing Gear and Cylinder Head (Rear)

Cylinder Timing and Camshafts (Front)

Setting front cylinder TDC and removing front camshafts.

Servicing Individual Components

Bearing Replacement Procedures

Conrod and Other Bearing Shells

Procedure for replacing conrod bearings, including measuring and fitting.

Pump Wear Checks and Cylinder Head

Piston, Rings, and Clearances

Cylinder Head Assembly

Clutch and Shift Mechanism Wear

Assembling the Engine

Oil Pumps and Transmission Assembly

Case Half and Shift Mechanism Assembly

Clutch Disks and Cover Assembly

Oil Screen, Water Pump, and Cylinder Heads

Chain Tensioners and Camshafts Assembly

Electrical System Checks and Troubleshooting

Current Loss, Charging System, and Generator Coils

Starter System Operation and Component Checks

Ignition System, ECU, and Sensor Checks

Overview of ignition system, ECU, pulse generator, and fuel pump relay checks.

Ignition Coils and Troubleshooting

Fuel System Maintenance

Carburetor Disassembly and Component Checks

Step-by-step instructions for disassembling the carburetor and checking parts.

Float Level and Mixture Control Screw Adjustment

Procedures for adjusting float level and idle mixture control screw.

Throttle Sensor and Cable Adjustments

Troubleshooting Engine and Electrical Issues

Engine Starting and Power Problems

Troubleshooting steps for engine start failures, lack of power, and stalling.

Overheating and Electrical System Faults

Diagnosing engine overheating and issues with lights, signals, and speedometer.

Battery and Speedometer Display Issues

Technical Specifications

LC8 Engine Specifications

Detailed specifications for the LC8 engine, including dimensions and fluid capacities.

950 Adventure Chassis Specifications

Specifications for the chassis, including frame, suspension, brakes, and tires.

Engine Tolerances and Clearances

Table of component tolerances and fitting clearances for engine parts.

Engine and Chassis Tightening Torques

List of all engine and chassis component tightening torques and required Loctite.

Periodic Maintenance Schedule

950 Adventure Maintenance Schedule

Detailed schedule for routine maintenance tasks based on mileage or time.

Engine Oil and Filter Maintenance

Procedures for changing engine oil, filter, and cleaning oil screens.

Valve Clearance Check and Adjustment

Procedure for checking and adjusting valve clearance on both cylinders.

Carburetor Synchronization and Idle Adjustment

Procedure for synchronizing carburetors and adjusting idle speed.

Wiring Diagrams

Main Wiring Diagram

Complete wiring diagram for the 950 Adventure 03 model.

ECU and Ignition System Wiring

Wiring diagram for the Engine Control Unit (ECU) and ignition system.