Page 1 REPAIRMANUAL2003-2006 950/990 ADVENTURE 990 SUPER DUKE 950 SUPERMOTO 950 SUPER ENDURO REPARATURANLEITUNG MANUALE DI RIPARAZIONE MANUEL DE RÉPARATION MANUAL DE REPARACIÓN...
Page 3 KTM Group Partner...
Page 5 1 SERVICE-INFORMATIONS 2 GENERAL INFORMATION 3 REMOVING AND REFITTING ENGINE 4 DISASSEMBLING ENGINE 5 SERVICING INDIVIDUAL COMPONENTS 6 ASSEMBLING ENGINE 7 ELECTRICAL / INJECTION 8 FUEL SYSTEM 9 TROUBLE SHOOTING 10 CHASSIS 11 TECHNICAL SPECIFICATIONS 12 PERIODIC MAINTENANCE SCHEDULE 13 WIRING DIAGRAMS...
Page 7 12-1 to 12-26 13-1 to 13-60 13-1 to 13-141 KTM REPAIR MANUAL IN LOOSE-LEAF FORM STORING THE REPAIR MANUAL IN THE BINDER – Put the index into the binder. – Put the front page of the repair manual (210x297 mm) into the transparent pocket provided for this purpose on the outside of the binder.
Page 9 X P L A N A T I O N P D A T I N G 3.206.009-E Repair Manual Basicversion Modelyear 2003 4/2003 3.206.016-E Updating of Rep.Manual 3.206.009-E Modelyear 2004 (Engine number with first digit “4“) 11/2003 3.206.025-E Updating of Rep.Manual 3.206.009-E Modelyear 2005 (Engine number with first digit “5“) 01/2005...
Page 11 „NOTE” POINTS OUT USEFUL TIPS. Use only ORIGINAL KTM SPARE PARTS when replacing parts. The KTM high performance engine is only able to meet user expectations if the maintenance work is performed regularly and professionally. In accordance with the international quality management ISO 9001 standard, KTM uses quality assurance processes that lead to the highest possible product quality.
Page 13 REPLY FAX FOR REPAIR MANUALS We have made every effort to make our repair manuals as accurate as possible but it is always possible for a mistake or two to creep in. To keep improving the quality of our repair manuals, we request mechanics and shop foremen to assist us as follows: If you find any errors or inaccuracies in one of our repair manual –...
Page 15 GENERAL INFORMATION INDEX OIL SYSTEM ..........2-2 AIR INTAKE SYSTEM .
Page 17: Oil System
Oil system Pressure pump draws engine oil from oil tank through oil filter and the oil return valve and pumps it past the pressure relief valve through the oil filter into the annular groove The main bearing , the conrod bearings and the spraying nozzle (front timing chain) are supplied with oil through holes in the...
Page 18 Intake system Fresh air is drawn into the filter box through the intake snorkel , past the carburetors and through the air filter The cleaned air is conducted to the combustion chamber through the carburetors and intake ports. The diagram for the injection engine is similar; the air flows to the intake ports through the throttle body instead of through the carburetor.
Page 19 Secondary air system The secondary air system supplies fresh air to the emissions in the exhaust port, resulting in the afterburning (oxidation) of the emissions. A line leads from the filter box to the control valve which opens as soon as the throttle valves are opened.
Page 20: Cooling System
Cooling system Closed thermostat The thermostat is closed if the temperature of the cooling liquid drops below 75° C. The water pump pumps the cooling liquid through the cylinder and cylinder heads and the thermostat Open thermostat The thermostat opens at 75° C. The water pump pumps the cooling liquid through the cylinder and cylinder heads , the aluminum cooler...
Page 21 ABS is switched off. To switch the ABS on again, stop and switch off the ignition. The ABS will be active again when you switch on the ignition. See the KTM ABS training documents for a detailed description of the ABS system.
Page 22 SPECIAL TOOLS – ENGINE PART NO DESCRIPTION 309098 Seal Three-Bond 0113 080802 Crankshaft locking bolt 151.12.017.000 Gear puller 451.29.075.000 Tachometer 503.29.050.000 Bleeding syringe for hydraulic clutch 560.12.001.000 Universal-engine work stand 584.29.059.000 Loctite 648 green 20 ml 585.29.005.000 Protection sleeve for shaft seal ring of water pump 590.29.019.000 Valve spring mounter 590.29.021.044...
Page 23 br bs bt cs ct dk dl dm dn ds dt ek el...
Page 24 SPECIALTOOLS – CHASSIS PART NO DESCRIPTION 151.12.017.000 Gear puller 584.29.086.000 Pressing tool for swing arm bearing 584.29.089.000 Chassis tool holder 584.29.091.000 Press-in tool for bearing seat / rear wheel bearing 584.29.092.000 Knock-out tool for bearing seat 600.03.022.000 Center stand 600.10.013.000 Sleeve for pressing tool for swim arm bearing 600.29.018.000 Internal gear puller 28 mm...
Page 25 2-10 Checking the oil level of the hydraulic clutch - 950/990 Adventure/950 Supermoto To check the oil level in the master cylinder of the clutch remove the cover. For this purpose, remove bolts and cover together with the rubber boot .
Page 26 The engine may have a poor idle behavior if the control unit is not reset. – Connect the KTM diagnostics tool, turn the ignition switch on and start the program. – Select "Extend"...
Page 27 KTM diagnostics tool. If this step is omitted, the throttle cable clearance cannot be correctly adjusted. – Connect the KTM diagnostics tool, turn the ignition switch on and start the program. – Select "Extend" – Select "Device operation"...
Page 28 The software can be downloaded from KTM's dealer.net site; the software is transferred to the control unit via the KTM diagnostics tool (FAN). – Some exhaust systems require new "mapping". If these exhaust systems are replaced by the production system again, the "mapping"...
Page 29 DMT program. NOTE: – If the DMT is not installed yet, install with the KTM diagnostics tool – If the program is already installed but the DMT icon does not appear on your screen, start the program under "Start" (in the task bar at the bottom of the screen) by clicking "Programs".
Page 30 2-15 – The mapping file will be transferred to the ECU. CAUTION O NOT SWITCH OFF THE IGNITION OR DISCONNECT THE DIAGNOSTICS CABLE WHILE (" "). T ECU. THE FILE IS BEING TRANSFERRED FLASHING HIS CAN DAMAGE THE NOTE: – All of the indicator lamps in the digital speedometer will light up while the file is being transferred.
Page 31 REMOVING AND REFITTING ENGINE INDEX 950 ADVENTURE REMOVING THE ENGINE ......... .3-2 REFITTING THE ENGINE .
Page 33: Removing The Engine
Removing the engine – Screw the center stand 600.03.022.000 onto the frame and jack up the motorcycle on a firm, even surface. – Remove the left bump rubber and lock the center stand with the lock 600.29.055.000 NOTE: if available, use the center stand already on the bike. –...
Page 34 – Unscrew the bolts and remove the intake snorkel together with the frame from the air filter box. – Disconnect the vent hose and the EPC hose and remove the upper half of the air filter box. – Turn the intake trumpet in a clockwise direction and remove.
Page 35 – Disconnect the electric connections from the fan motor and the temperature switch – Drain the cooling liquid from the radiator and engine: see Chapter 12. – Detach the water hoses from the radiator (special pliers 600.29.057.100) and unscrew the radiator NOTE: fan and radiator shield do not need to be dismounted from the radiator.
Page 36 – Unscrew the nut on the wheel spindle, pull out the rear wheel spindle, take the chain off of the rear sprocket and place over the side of the bracket . Remove the chain from the engine sprocket. – Detach the connector –...
Page 37 – Use the trolley jack to position the attachment 600.29.055.100 on the engine, insert the bolt through the front of the engine bracket and fasten with the nut. Screw one of the bolts on the rear of the side stand fixture and slightly lift the engine. –...
Page 38: Refitting The Engine
Refitting the engine - 950 Adventure – Before mounting the engine, attach the water, SLS and vacuum hoses (Öttiger clamps - special pliers 600.29.057.000 or spring- loaded band-type clamps - special pliers 600.29.057.100) – Position the swing arm and fix with the swing arm pivot on the right and a suitable pipe on the left.
Page 39 – Mount the front oil line inserting new O-rings. Tighten the bolts. NOTE: up to engine number 2-600-1186 a washer must be used to preload the O-rings on the oil terminal. – Align the side supports and battery case against the engine, insert the bolt and mount the nut.
Page 40 – Place the chain over the pinion and rear sprocket, lift the rear wheel and slide the wheel spindle through. – Press the rear wheel towards the front to apply the chain tensioner and tighten the nut on the wheel spindle to 90 Nm. –...
Page 41 3-10 – Screw on the radiator together with the fan and the radiator shield , tighten the bolts to 10 Nm. – Connect water hoses radiator (special pliers 600.29.057.100) – Attach the electric connections for the fan motor and the temperature switch –...
Page 42 3-11 – Fit the upper battery cover and place a battery with battery cover into the battery compartment. – Fit the front battery compartment lid and connect both battery cables together to the connections on the front lid (start with the positive cable).
Page 43 3-12 Dismounting the engine - 990 Super Duke NOTE: the procedure for dismounting the engine is the same as the procedure used for the 950 Adventure; the only deviations are in the preparatory work: – Remove the spoiler and tank side covers. –...
Page 44 3-13 Mounting the engine - 990 Super Duke – Connect the water, SLS and vacuum hoses to the engine before mounting (Öttiger clamps - special pliers 600.29.057.000 or spring-loaded band-type clamps - special pliers 600.29.057.100). – Position the exhaust system under the motorcycle according to the installation position.
Page 45 3-14 – Mount the exhaust pipe clamp between the manifold and the main silencer and slightly tighten. – Slightly tighten the exhaust pipe clamp on the rear manifold. NOTE: – Do not tighten the screw connections until the exhaust system is completely installed and mounted stress-free.
Page 46 3-15 – Place the battery in the battery case and attach the battery case cover. – Connect the positive starter relay cable to the positive pole on the battery. – Connect the two ground connections to the negative pole on the battery (2 green cables from the controller and 1 black cable from the starter engine).
Page 47 3-16 – Fasten the wiring harnesses and connector on the pulse generator with cable clips. – Run the chain over the pinion and rear sprocket, raise the rear wheel and push the wheel spindle through. – Push the rear wheel forward until the chain tensioner rests against the stop screw and tighten the wheel spindle nut to 90 Nm.
Page 48 3-17 – Screw on the radiator, the fan and the radiator shield , tighten the screws to 10 Nm. – Mount water hoses radiator (special pliers 600.29.057.100) – Connect the electric connectors for the temperature switch fan motor – Connect the hose on the front vacuum sensor and the connector on the front lambda probe ;...
Page 49 3-18 – Mount the throttle cable duct – Screw on the left side cover of the lower air filter box together with the bracket for the vacuum hose to the rear vacuum sensor. – Connect the hose on the rear vacuum sensor. CAUTION –...
Page 50 3-19 – Run the tank vent hose down parallel to the overflow hose on the compensating tank, tilt the tank forward and screw on. Connect the tank vent hose and fuel connector. – Mount both tank side covers and the spoiler and tighten the screws. –...
Page 51 3-20 Dismounting/mounting the engine - 950 Supermoto NOTE: the procedure for dismounting the engine is the same as the procedure used for the 950 Adventure; the only difference is in the preparatory work: Jack up the motorcycle with the assembly stand 625.29.055.000: –...
Page 53: Table Of Contents
DISASSEMBLING THE ENGINE INDEX VALVE COVERS ..........4-2 SPARK PLUG SHAFT INSERTS .
Page 55: Valve Covers
Clean the engine thoroughly on the outside prior to disassembling. – Clamp the engine in the work stand using the special tool 600.29.002.000. Valve covers – Pull out the spark plug connectors. – Unscrew the spark plugs using the special tool 600.29.073.000. –...
Page 56: Setting Cylinder Rear To Tdc
Setting cylinder rear to TDC – Unscrew the plug from the generator cover to be able to turn the crankshaft. – Turn the crankshaft in a counterclockwise direction until the rear cylinder is in the TDC position. The marks (crosses) must coincide with the flat outer surface of the cylinder head at the camshaft gears.
Page 57: Chain Tensioner Cylinder Rear
Chain tensioner cylinder rear – Remove the bolt from the chain tensioner NOTE: measure the preload on the chain tensioner element before dismounting: – Apply the chain tensioner bolt to the chain tensioner element without compressing the spring. – Measure the distance between the sealing washer and the cylinder head.
Page 58: Double Timing Gear
Double timing gear – Lift the double timing gear out of the cylinder head, letting the chain fall into the slot. Cylinder head rear with cylinder – Remove the outer nut – Loosen cylinder-head nuts crosswise. Special 600.29.083.000 is required for the inside nuts –...
Page 59: Camshafts Cylinder Front
Camshafts cylinder front – Check and note down the valve clearance before you dismount the camshafts. Valve clearance (at 20ºC): intake 0.10 - 0.15 mm exhaust 0.25 - 0.30 mm – Loosen the bolts on the camshaft bearing bridge from the front cylinder and carefully remove the camshaft bearing bridge.
Page 60: Timing Chain Cylinder Front
Timing chain cylinder front – Loosen the bearing bolt on the double timing gear and pull out of the cylinder head together with the needle bearing. The double timing gear will slide down slightly, relieving the timing chain. – Remove the O-ring on the bearing bolt. –...
Page 61: Water Pump
Water pump – Remove the water pump cover , discard the O-ring gasket. NOTE: also remove the 2 dowel pins used to keep the water pump cover in a central position. – Hold the water pump wheel with special tool 600.29.082.000, remove the bolt and pull the water pump wheel off of the...
Page 62: Clutch
Clutch – Remove the bolts on the clutch springs crosswise and lift off the pressure cap. – Pull out the clutch push rod. – Insert a wire hook in the recess in the clutch disks and pull all of the clutch disks out of the clutch hub. NOTE: leave the spring washer and supporting ring in the clutch.
Page 63: Primary Pinion And Clutch
4-10 Primary pinion and clutch If you are completely dismounting the engine, the primary pinion must be detached before you remove the clutch. – Mount the special tool 0113 080802 (engine locking bolt) and hold the crankshaft in the rear or front cylinder's TDC position. –...
Page 64: Generator Cover
4-11 – Insert the pressure tool 600.29.031.000 in the crankshaft bore, turn the balance weight up and pull the primary pinion off the crankshaft with the puller 600.29.033.000. – Remove the balance weight from the balancer shaft; carefully pry the woodruff key out of the shaft groove with a screwdriver. –...
Page 65: Freewheel
4-12 Freewheel – Remove the freewheel lock and lift the freewheel of the crankshaft. – Pull the lower starter idler gear from the balancer shaft. Balancer shaft – Gently tap the balancer shaft off on the clutch side with a rubber hammer.
Page 66: Engine Case Half
4-13 Engine case half – Remove the gear shift sensor with the pin and spring. Unscrew the oil filter cover , discarding the gasket on the oil filter cover and the oil filter. – Unscrew all HH bolts accessible from the generator side. –...
Page 67: Transmission
4-14 Transmission – Remove the oil rail for the transmission lubrication. It is secured at the bottom to keep it from twisting. NOTE: the oil rail is sealed with 2 O-rings from the 2005 model which should be replaced. – Pull out the shift rails together with the upper shift rail springs.
Page 68: Oil Pumps
4-15 Oil pumps – Remove the lock ring from the oil pump shaft; remove the spacing washer and oil pump gear – Pull the needle roller out of the pump gear and remove the washer underneath. – Loosen the bolts on the outer oil pump (pressure pump) and remove the oil pump housing.
Page 69 SERVICING INDIVIDUAL COMPONENTS INDEX ROLLER BEARING ..........5-2 MAIN BEARINGS - GENERAL INFORMATION .
Page 71 – the output-end antifriction bearing on the countershaft mounted by KTM does not have a sealing from the 2005 model. An antifriction bearing with a one-sided sealing is provided for repair; to keep it from blocking the lubrication, the open side must point towards the inside (towards the center of the housing).
Page 72 Replacing the main bearings-general information NOTE: – The bearing shells for the friction bearings are pressed in and out in a cold state. – Mark the position of the bearing end gap on the engine case with a felt-tip pin to facilitate reassembly. NOTE: the main bearing shells have retaining brackets to hold them in position from the 2005 model;...
Page 73 Replacing bearing shells, output end – Center the new bearing shells (both smooth) with the assembling sleeve 600.29.044.050 . The assembling sleeve is beveled on one side so the bearing shells can be pushed in easily. The bearing shells should protrude 1-2 mm on the other side of the assembling sleeve to make it easier to position them in the engine case.
Page 74 Replacing the conrod bearings – Clamp each conrod in a vise using protective jaws. – Loosen the bolts on the conrod bearing covers with the special wrench socket 600.29.075.000 and remove the bearing covers. NOTE: mark the conrod caps to ensure that each cap is mounted to the same conrod when it is measured and assembled.
Page 75 Replacing the supporting bearings in the clutch cover – Pull the bearing shells out of the clutch cover using the puller 151.12.017.000 and the internal extractor 600.29.018.000 – Measure the diameter of the bearing pin at 3 points that are 120° apart using a micrometer gauge.
Page 76 Overhauling the water pump – Remove the washer from the water pump shaft and pry the shaft sealing ring out of the case. NOTE: if the water pump wheel cannot be removed because it is being held by residual thread adhesive, the water pump shaft and the water pump wheel can be pressed out from the inside after the lock ring removed.
Page 77 Checking the suction pump for wear – Insert both suction pump rotors in the housing. – Use a feeler gauge to check the clearance between the inner and outer rotor: Setpoint value: 0.1 mm Wear limit: 0.2 mm – Use a feeler gauge to check the clearance between the outer rotor and the housing: Setpoint value: 0.2 mm...
Page 78 Disassembling the cylinder head and checking parts for wear NOTE: the illustration shows the font cylinder. The procedure for the rear cylinder is identical. – Pull all of the bucket tappets out of the cylinder head. NOTE: – Note down the mounting position to ensure that the same bucket tappet is inserted in the same bore during installation.
Page 79 NOTE: if the Nicasil coating on the cylinder is worn but not damaged, a replacement cylinder can be ordered from our KTM dealer/importer (new Nicasil coating, used cylinder). – Measure the piston at the piston skirt across the piston pin, 9 mm from the lower edge.
Page 80 5-11 Piston and cylinder identification The cylinder size is impressed in the bottom of the cylinder near the chain tunnel; 1 is size I, 2 is size II. The piston size is impressed in the top of the piston; 1 is size I, 2 is size II.
Page 81 5-12 – Place the lubricated piston on the cylinder and clamp the piston rings together with the piston ring clamping band 600.29.015.000 – Use a plastic hammer to tap lightly on the top of the piston ring clamping band until it is flush with the cylinder. –...
Page 82 5-13 Generator cover – Loosen the three bolts on the stator. – Tilt the cable retaining bracket away from the cable with long nose pliers (see small arrow) and pull out of the housing. Take the cable duct out of the generator cover and remove the stator. –...
Page 83 5-14 Preassembling the spreader drive NOTE: – The tension spring bolts must be attached as illustrated. – The other holes are used to block the spreader drive. – Attach the tension spring bolts in the drive wheel and press the tension spring into the recess of the drive wheel. –...
Page 84 5-15 Clutch – checking parts for wear Check the thrust bearing for wear. Check the front end of the pushrod for wear and blow compressed air through the holes. NOTE: the pushrod is made of nitride steel from the 2005 model. If you are repairing an engine older than the 2004 model, replace the old pushrod with the newer version.
Page 85 5-16 Shift mechanism – checking parts for wear Shift forks Check the leaf for wear. Check the driving bolt for the shift drum for wear. Shift rolls Check the shift rolls for hair cracks and pressure marks. It should be easy to turn the shift rolls on the driving bolts of the shift forks.
Page 86 5-17 General information on servicing the transmission – Clamp the main shaft in the vise (use protective jaws) and remove the gears. – Clean and check all parts. Use new lock rings whenever you repair the transmission. Check the tooth profile on the transmission shafts and sliding gears for wear.
Page 87 5-18 General information on servicing the transmission – Clamp the main shaft or countershaft in the vise (use protective jaws) and remove the gears. Pull off the bearing ring. – Clean and check all parts. Use new lock rings whenever you repair the transmission. Check the tooth profile on the transmission shafts and sliding gears for wear.
Page 88 5-19 Checking the freewheel – Insert the freewheel gear in the freewheel. – You should be able to turn the freewheel gear in a counterclockwise direction. – The freewheel gear should block without backlash in a clockwise direction. – Check the reduction gear and the needle bearings for wear, replace if necessary.
Page 89 ASSEMBLING THE ENGINE INDEX OIL PUMPS ...........6-2 AXIAL CLEARANCE OF THE MAIN SHAFT .
Page 91 Clean all parts thoroughly before reassembling. – Clamp the output-end engine case on the engine work stand and move into a vertical position (installation position). Oil pumps NOTE: lubricate the oil pump rotors and the oil pump shaft prior to installation.
Page 92 – Apply Loctite 243 to the three remaining oil pump bolts (M6x40) and screw in. Tighten bolts to 10 Nm. – Slide on the disk, insert the needle roller and mount the oil pump gear with the collar facing the rear. –...
Page 93 Transmission – Simultaneously push both transmission shafts into the bearing seats. NOTE: pay attention to the spacing washer on the countershaft. – Slide the washer on the counter shaft and mount the lock ring – Move the engine into a horizontal position. –...
Page 94 – Insert the crankshaft in the friction bearing. NOTE: – The crankshaft end with the thread for the primary pinion bolt connection must point down. – The conrod for the rear cylinder must face up. Both conrods should be in the position shown in the illustration. –...
Page 95 Shift mechanism – Mount the locking lever with the spring. Apply Loctite 243 to the M5x20 bolt and tighten to 6 Nm. – Press the locking lever down and mount the shift locating drum NOTE: the flat parts of the shift locating drum are off center. –...
Page 96 – Screw on the generator-end timing chain tensioning rail . Apply Loctite 243 to the bolt and tighten to 20 Nm. CAUTION AKE SURE NO LOCTITE THREAD ADHESIVE IS ON THE PIVOT AREA OF THE BOLT THIS COULD CAUSE THE TIMING CHAIN TENSIONING RAIL TO BLOCK AND BREAK Balancer shaft –...
Page 97 Generator cover – Mount dowel pins on the engine case and put a new gasket in place. M6x30 Position the generator cover and tighten the generator cover bolts to M6x30 (A) 10 Nm (see illustration for bolt lengths). NOTE: the bolts marked with an A must be mounted with new copper M6x30 (A) sealing washers (6x10x1);...
Page 98 Primary pinion – Mount the woodruff key for the primary pinion in the shaft groove (if dismounted). – Mount the primary pinion with the longer collar towards the rear. The bore for the pickup ring must face towards the outside. –...
Page 99 6-10 – Slide the 25 x 48 x 6.5 mm disk and inner clutch hub together with the clutch pressure booster onto the main shaft teeth. NOTE: the two clutch pressure booster parts are marked with coinciding circles. – Attach the holder for the inner clutch hub 600.29.003.000.
Page 100: Clutch Cover
6-11 Clutch cover – A vibration damper is mounted in the outer clutch cover from the 2005 model, screw may not be loosened. CAUTION F THE SCREW ON THE VIBRATION DAMPER IS LOOSENED A NEW OUTER CLUTCH OVER WITH A VIBRATION DAMPER OR THE OLD CLUTCH OVER WITHOUT THE VIBRATION DAMPER MUST BE USED SINCE THE SELF CUTTING SCREW CANNOT BE...
Page 101 6-12 Oil screen – Insert the oil screen in the opening in the case. NOTE: the oil screen has a TOP marking which must point up. – Mount the oil screen cover; tighten the two M6x35/M6x40 bolts to 10 Nm. Water pump –...
Page 102 6-13 Cylinder head rear with timing chain – Remove the M10x161 stud bolts, strength class 10.9, and replace with stud bolts in class 12.9. NOTE: you can tell the two strength classes apart by their thread length. Stud bolts in class 12.9 have a thread length of 26 mm; stud bolts in any other length must be replaced.
Page 103 6-14 – Push the double timing gear down into the chain tunnel draw the timing chain along the side on the inside. – Use the wire hook to lift the side of the chain on the inside over the gear teeth onto the chain teeth of the double timing gear.
Page 104 6-15 Chain tensioner cylinder rear – Insert the chain tensioner element in the cylinder head bore. NOTE: the housing and tensioning piston of the chain tensioner are compression molded. If the two parts cannot be separated, the chain tensioner must be replaced. –...
Page 105 6-16 Camshafts cylinder rear – Insert the two camshafts marked "in re" (rear intake camshaft) and "ex re" (rear exhaust camshaft) into the bearings without tilting. The marks on the camshaft gears must coincide with the flat outer surface of the cylinder head (see illustrations). NOTE: –...
Page 106 6-17 Setting cylinder front to TDC – Loosen crankshaft locking bolt turn engine counterclockwise 1 rotation and then 75° towards the front cylinder's TDC position, keeping the timing chain on the cylinder rear slightly tensioned and holding the conrod in the center of the opening in the case.
Page 107 6-18 – Push the cylinder head and cylinder down. Oil the cylinder head nuts and mount with the washer - see Technical Information. The cylinder head nuts are tightened in 2 stages. 1st stage: – Tighten the cylinder head nuts crosswise. Use the special nut 600.29.083.000 for the internal nuts and the special wrench 600.29.081.000 for the outer nut...
Page 108 6-19 Chain tensioner cylinder front – Insert the chain tensioning element in the cylinder head bore. NOTE: the housing and tensioning piston of the chain tensioner are compression molded. If the two parts cannot be separated, the chain tensioner must be replaced. –...
Page 109 6-20 Camshafts cylinder front – Insert the two camshafts marked "in fr" (front intake camshaft) and "ex fr" (front exhaust camshaft) into the bearings without tilting. The marks on the camshaft gears must coincide with the cylinder head surface (see illustrations). NOTE: –...
Page 110 6-21 NOTE: – Check the position of the camshafts on cylinder front in the TDC position of cylinder rear. The cams on the exhaust camshaft point towards the inside and push open the exhaust valves, the cams on the intake camshaft also point towards the inside, the bucket tappets are not actuated.
Page 111 6-22 Spark plug shaft inserts – Mount new O-rings on the spark plug shafts and grease. Push the spark plug shaft inserts all the way in. – Mount the valve cover gaskets and spark plug shaft gaskets Valve cover – Mount the valve cover. Insert bolts with the sealing washers and tighten to 10 Nm.
Page 113: Abs-System
CHECKING THE ABS FAULT MEMORY USING THE KTM DIAGNOSTICS TOOL ..7-55 CHECKING THE ABS SENSOR WITH THE KTM DIAGNOSTICS TOOL ....7-55...
Page 115 Checking for loss of current Check for loss of current before you check the rectifier regulator. – Switch off the ignition and disconnect the ground wire from the battery. – Connect an ammeter between the ground wire and the negative pole on the battery.
Page 116 start/stop switch start-relay orange 1 fuse C_BB/9 10 A C_AB/9 C_AE/4 black-orange 0.5 start auxillary relay yellow 0.5 battery C_AI/2 C_AI1/2 red 4 red 0.5 diode diode C_AL starter motor C_AR/2 C_AT2/2 C_AM3/3 page 7/9 page 4/9 clutch switch sidestand switch Electric starter system 950 Adventure NOTE: the starter system is equipped with a safety feature.
Page 117 s / t a r o r - r i f i t t i n a l l l e r t u l Starting system 990 Super Duke NOTE: The starting system is equipped with security features. The motorcycle can only be started under the following conditions: –...
Page 118 s / t o i t i f i t a l l k n i 5 . 0 a p - 8 / 3 l l e 5 . 0 e r g - n e a l b 5 .
Page 119 s / t o i t i f i t a l l o l l e t i 5 . 0 e r g - n e a l b 5 . 0 g i l a p - 9 / 3 a p - 9 / 7...
Page 120 Checking the auxiliary starter relay – Dismount the auxiliary starter relay (950 Adventure). NOTE: orange, yellow, red and white/red cable colors. – Dismount the auxiliary starter relay (990 Adventure). NOTE: red/black (2x), yellow/white, red/blue cable colors. – Dismount the auxiliary starter relay (990 Super Duke).
Page 121 Functional check of the auxiliary starter relay (950 Adventure) – Pull the auxiliary starter relay out of the bracket. – Connect an ohmmeter or continuity tester to the cable of the auxiliary starter relay (red and red/white cables). – Perform the tests in the specified order. The auxiliary starter relay must switch under the following 2 conditions: –...
Page 122 Checking the diodes NOTE: Diodes only conduct the current in one direction. They block in the other direction. Diodes can have 2 defects: – the diode has no continuity. – the diode has continuity in both directions. Various malfunctions can occur, depending on the type of defect. Each diode (950/990 Adventure), (990 Super Duke) and...
Page 123 7-10 Checking the starter relay – Disconnect the negative pole from the battery and dismount the start relay. – Connect the starter relay to a 12 V battery, making sure you hear the relay switch (nonrecurring "click"). NOTE: the 12 V battery must be connected to the terminals to which the connectors with following cable colors 950 Adventure: white/red and brown...
Page 124 7-11 Checking the clutch switch – Disconnect the clutch switch connector from the cable tree. – Connect an ohmmeter to the bipolar connector AT2 (950 Adventure) or AT1 (990 Adventure) or AT1 (990 Super Duke) or AT3 (950 Supermoto) of the clutch switch and slowly pull the clutch lever.
Page 125 7-12 Checking the tip switch and emergency OFF switch – Disconnect the four-terminal connector BB (950/990 Adventure), (990 Super Duke) or (950 Supermoto) on the tip switch / emergency OFF switch from the cable tree. – Check both switches with an ohmmeter. Tip switch: between pin 1 and pin 8 Ω...
Page 126 7-13 orange 1 start/stop switch pick up throttle position sensor orange 1 fuse fuse 10 A C_BB/9 C_AB/9 C_AR1/2 C_AT/2 C_AL1/2 orange 0.5 C_AM/3 black-orange 0.5 orange 0.5 fuel pump relay yellow-blue 0.5 page 2/9 yellow-white 0.5 blue 0.5 yellow 0.5 black 0.5 blue-grey 0.5 page 7/9...
Page 127 7-14 s / t a p - 8 / 2 c t i a p - 8 / 2 e l t o i t d e r 5 . 0 l l e n a r 5 . 0 l l e e u l 5 .
Page 128 7-15 a p - 8 / 2 a p - 8 / 5 n a r - e g a l b 5 . 0 a p - 8 / 2 t i s c t i d e r 5 .
Page 129 7-16 ECU 950 Adventure/Supermoto/Super Enduro Check the cables and socket connectors on the ECU (950 Adventure) and (950 Supermoto/Super Enduro). A functional check of the ECU can only be performed on an ignition test stand. – Check the ignition coil control: remove the ignition coil connector and apply the measuring tips of the peak voltage adapter to the pins of the connector AS (see checking the ignition coils).
Page 130 7-17 Checking the fuel pump relay 950 Adventure/950 Supermoto – Dismount the fuel pump relay (950 Adventure) and (950 Supermoto). NOTE: black/blue, blue/gray, yellow/black and brown cable colors – Connect the fuel pump relay to a 12 V battery as shown, making sure you hear the relay switch (nonrecurring "click").
Page 131 7-18 Troubleshooting in the ignition system 950 Adventure/950 Supermoto Before checking the ignition, make sure: – the ignition lock is in the ON position – the emergency OFF switch is in the ON position (does not apply to the 950 Super Enduro) –...
Page 132 7-19 orange 1 start/stop switch pick up throttle position sensor orange 1 fuse fuse 10 A C_BB/9 C_AB/9 C_AR1/2 C_AT/2 orange 0.5 C_AL1/2 C_AM/3 black-orange 0.5 orange 0.5 fuel pump relay yellow-blue 0.5 page 2/9 yellow-white 0.5 blue 0.5 yellow 0.5 black 0.5 blue-grey 0.5 page 7/9...
Page 133 7-20 s / t a p - 8 / 2 c t i a p - 8 / 2 e l t o i t d e r 5 . 0 l l e n a r 5 . 0 l l e e u l 5 .
Page 134 7-21 a p - 8 / 2 a p - 8 / 5 n a r - e g a l b 5 . 0 a p - 8 / 2 t i s c t i d e r 5 .
Page 135 7-22 Checking the solenoid valve for the EPC 950 Adventure/ Supermoto/Super Enduro – To check, disconnect connector AW from the solenoid valve. – Connect a 12-V battery with the two terminals on the solenoid valve. – You should hear a click in the solenoid valve (the diaphragm opening) when the circuit is closed.
Page 136 7-23 g i l c t i - e r - e r r g - l b - a l l - e r e r - r o - l e r - u b - c t i - l b l b - l b -...
Page 137 7-24 INJECTION/IGNITION SYSTEM Establishing the injection period (injection volume) Generally, the injection volume, i.e. the quantity of injected fuel, is dependent on the fuel pressure and the time the injection valve is open. Since the fuel pressure regulator keeps the fuel pressure constant, the quantity of fuel injected is controlled by the time the injection valve is open.
Page 138 7-25 SYSTEM DIAGRAM CLUTCH: Clutch switch MR: Main relay CRK: Pulse generator NLSW: Neutral switch ECU: Control unit PA: Ambient air pressure sensor EXAI: Secondary air valve PM: Manifold air pressure sensors FLPR: Fuel pump relay PRESSURE REGULATOR: Pressure FUEL PUMP: Fuel pump regulator GP2: 2nd gear switch PVC: Carbon canister purge valve (USA)
Page 139 The error lamp will stay on during operation if an error is detected; if the vehicle is standing (gear in neutral) the error lamp will start to blink according to the respective error code. The registered error codes can be read out through the diagnostics connector using the KTM diagnostics tool and deleted after the error has been eliminated.
Page 140 7-27 WIRING DIAGRAM 990 SUPER DUKE...
Page 141 7-28 WIRING DIAGRAM 990 ADVENTURE...
Page 142 7-29 BLOCK DIAGRAM Ignition Switch Kill Switch Battery Power Relay Start button Starter Regulator / Relay1 Generator. RECTA Starter Relay2 Sidestand Switch SSTAND(A/D) Fuel Injector INJ#1 #1(REAR) Starter MAP Sensor PM#2 Motor #2(FRONT) Fuel Injector HEGO Sensor #1(REAR) INJ#2 #2(FRONT) HG#1 HGHT#1 HEGO Sensor #2(FRONT)
Page 143 7-30 DESCRIPTION OF THE ELECTRIC SYSTEM Fuel pump relay: A positive charge travels to the start/stop switch via the ignition switch and a fuse (10 amperes), then via the diode to the relay coil (positive side). The ground for the relay coil is switched for several seconds by the control unit with the ignition on during the starting process.
Page 144 7-31 DESCRIPTION OF THE COMPONENTS Fuel pump The vane-type pump mounted in the fuel tank is driven by an electric motor whose rotor is rinsed and simultaneously cooled and lubricated with fuel. A back-pressure valve is installed in the outlet opening which closes when the ignition is switched off, stopping the pump in order to maintain the residual fuel pressure;...
Page 145 Reducing jets with a 1 mm air hole are connected to the intake port. NOTE: If the vacuum hoses are damaged, they must be replaced with new, original KTM hoses. CAUTION – A LWAYS REPLACE THE VACUUM HOSES ON THE INTAKE MANIFOLD IF THEY WERE PULLED OFF –...
Page 146 7-33 Pulse generator (crankshaft) The pulse generator is located under the clutch cover on the right side of the engine. It is an inductive sensor, i.e. the control unit calculates the speed and the crankshaft position based on the output signal.
Page 147 7-34 Catalytic converter The catalytic converter is installed in the main silencer and transforms most of the main toxic constituents into non-toxic compounds. It is designed as a three-way catalytic converter and consists of a coiled metal support whose surface is coated with precious metals such as platinum and rhodium;...
Page 148 7-35 Ignition coils The ignition coils are mounted directly on the spark plugs; the same ignition coils are used for the injection engine as for the carburetor engine. Fuel pump relay The fuel pump relay is installed under the seat. Each relay has a coil and at least one load contact;...
Page 149 Installation: behind the headlight mask. Diagnostics connector The diagnostics connector is located under the seat. The diagnostics connector connects the KTM diagnostics tool and the control unit to read error codes or perform function tests. Side stand switch The side stand switch...
Page 150 7-37 SAFETY AGAINST FAILURE/EMERGENCY OPERATION Defective component Defect/Effect Backup value/ Possible to Possible to Spare sensor start engine? run vehicle? Fuel pump Total failure: will not start Lack of pressure: power loss limited Pressure regulator same as fuel pump see above see above Injection valve Electric error...
Page 151 Checking the fuel presure Switch on the ignition, the pump will run for 2 seconds or switch on the pump with the KTM diagnostics tool. If not, perform the following tests: – Scan the fault memory with the KTM diagnostics tool.
Page 152 The signal from the coolant temperature sensor can be scanned with the KTM diagnostics tool (see table for voltage figures). If the displayed value does not correspond to the actual temperature or if an error code is displayed, perform the following tests: –...
Page 153 If an intake pressure sensor breaks down, exchange the two and scan the values again with the KTM diagnostics tool - if the error is in the other position, replace the affected intake pressure sensor. If the...
Page 154 (input) The signal from the 2nd throttle valve sensor can be scanned with the KTM diagnostics tool. In case of an error, perform the following tests: – Apply the ground (black cable) and the 5-volt supply (blue cable) to the AM connector with the ignition switched on.
Page 155 (control unit disconnected). Lambda probe heater (output) The lambda probe heater can be tested and controlled with the KTM diagnostics tool. In case of an error, perform the following tests: – Check the positive supply (with the ignition on, orange cable) at sensor connector CA or CA1.
Page 156 The effectiveness of the catalytic converter can only be tested with an emissions tester. Before replacing a catalytic converter suspected to be defective, take a test ride and use the KTM diagnostics tool to check the injection system for proper functioning. Idle speed control motor...
Page 157 Both ignition coils must be dismounted but stay connected. If an ignition coil breaks down, exchange the two and control again with the KTM diagnostics tool - if the error is in the other position, replace the affected ignition coil. If not, perform the following tests: –...
Page 158 Secondary air valve (output) The secondary air valve can be tested and controlled with the KTM diagnostics tool. If the secondary air valve fails to switch, perform the following tests: – There should be positive voltage at connector CK Pin 2 (ignition on, orange cable).
Page 159 7-46 Roll angle sensor (input) The signal from the roll angle sensor can be scanned with the KTM diagnostics tool. Output signal "No crash detected": 0.4 - 1.4 volts Output signal "Crash detected": 3.7 - 4.1 volts In case of an error, perform the following tests: –...
Page 160 Error lamp (output) The error lamp (FI) can be tested with the KTM diagnostics tool. NOTE: the error lamp must light up for 2 seconds and then go out after the ignition is switched on if no ignition error is detected by the ECU.
Page 161 NOTE: the coolant temperature display will rise very slowly when controlled and will drop very slowly afterwards. Diagnostics line If there is not connection between the KTM diagnostics tool and the vehicle ECU, perform the following test: – Ground supply (brown cable) at connector AP1 Pin 6.
Page 162 7-49 ERROR CODES DTC (Code) Blink code Signal/Component Description of error Engine P0201 Injection valve, rear cylinder Malfunction Stalls P0202 Injection valve, front cylinder Malfunction Stalls P0351 Ignition coil, rear cylinder Malfunction Stalls P0352 Ignition coil, front cylinder Malfunction Stalls P0335 Pick up Malfunction...
Page 163 7-50 ABBREVIATIONS, LIMIT VALUES 990 SUPER DUKE Abbreviation Description Min. limit value Max. limit value Unit Remarks THAD Throttle valve sensor voltage volts Completely closed 0.56-0.64 V Throttle valve sensor signal 75-85 degrees PM1AD Manifold air pressure, rear voltage volts PM1M Manifold air pressure, rear 13.3...
Page 164 7-51 ABBREVIATIONS, LIMIT VALUES 990 ADVENTURE Abbreviation Description Min. limit value Max. limit value Unit Remarks THAD Throttle valve sensor voltage volts Completely closed 0.56-0.64 V Throttle valve sensor signal 75-85 degrees PM1AD Manifold air pressure, rear voltage volts PM1M Manifold air pressure, rear 13.3 119.99...
Page 165 Alarm system for 990 Super Duke (optional) General information: a Power Parts alarm system is available for the KTM 990 Super Duke which should be retrofitted by your dealer (under the seat). The vehicle wiring harness is already equipped to accommodate the alarm system (see mounting instructions).
Page 166 7-53 Order for additional hand-held transmitters New hand-held transmitters for the alarm system will be delivered by KTM pre-programmed. Indicate the bar code from the code card and the next available programming space when ordering. Adapting the hand-held transmitter NOTE: –...
Page 167 7-54 Starting with the emergency code NOTE: – Use the following procedure if no functioning hand-held transmitter is available to deactivate the alarm system. – This procedure must be repeated each time the engine is started since the engine lock is automatically activated 50 seconds after the ignition is switched off –...
Page 168 – Remove the protection covers and check fuse . Always replace a blown fuse with an equivalent fuse. Checking the ABS fault memory using the KTM diagnostics tool – Connect the diagnostics plug, switch on the ignition and select "ABS-ECU"...
Page 169 FUEL SYSTEM INDEX KEIHIN CARBURETOR CVRD 43 DESCRIPTION OF THE ACV (AIR CUT VALVE) SYSTEM ....8-3 DISASSEMBLING THE CARBURETOR ....... . .8-4 ASSEMBLING THE CARBURETOR .
Page 171 CARBURATOR - KEIHIN CVRD 43...
Page 172 Description of the ACV (air cut valve) system ACV stands for Air Cut Valve. The ACV system enriches the mixture by reducing the idle-air quantity to prevent the exhaust from backfiring in an overrun condition or upon sudden closure of the throttle valve. Normally the required idle-air reaches the mixture through two air jets, the idle air jet (jet diameter 50) and the ACV jet...
Page 173 Disassembling the carburetor – Loosen the throttle linkage arm and remove together with the shims. – Unscrew the throttle sensor and cable for the idle setting. – Loosen the screws and remove both connecting rods NOTE: – The screws on the connecting rods are glued in. Place the carburetor on an aluminum plate and tap the screws carefully with a hammer to loosen.
Page 174 – Remove the float chamber and discard the gasket. – Loosen the fixing screw on the float hinge pin and remove the float together with the hinge pin and the needle valve. – Check the needle valve for wear at the conical seat. –...
Page 175 – Unscrew the main air jet , the ACV jet and the idle-air jet with a suitable screwdriver. – Unscrew the idle-air jet , the main jet with the main jet holder and starter jet – Before removing the idle-air mixture control screw , screw in to the limit.
Page 176 Assembling the carburetor – Push the throttle shaft into the carburetor housing, fit the spring and mount the lock ring – Mount the throttle valve , tighten and caulk the screws. CAUTION OLD A SUITABLE MANDREL AGAINST THE THROTTLE SHAFT TO KEEP IT FROM BENDING –...
Page 177 – Place the O-ring in the recess around the air jet. – Mount the ACV diaphragm so that the pin presses on the ACV valve plate – Place the spring on the diaphragm and mount the ACV cover – Position the float together with the needle valve and float hinge in the carburetor housing.
Page 178 – Mount the lock ring in the respective position on the jet needle (2nd notch from the top – see technical specifications). – Insert the spring in the jet needle holder and position in the throttle slide together with the jet needle. Clip the jet needle holder into place.
Page 179 8-10 – Position both connecting rods , coat the thread of the screws with Loctite 243 and mount. NOTE: bend the fuel connections according to the recesses in the connecting rods before mounting the connecting rods. – Mount the throttle linkage arm with shims as shown in the drawing and secure with the pins.
Page 180 8-11 Checking the throttle sensor NOTE: the adjustment must be made in a mounted condition with the cable connected and the ignition switched on. – Use a digital multimeter to measure the voltage between the black and yellow cables at the connector AM (under the fuse box).
Page 181 8-12 Carburetor heater – Pull the wiring harness connectors from the carburetor heater elements. – Unscrew the carburetor heater elements – Check the carburetor heater elements for damage at the connectors, check the electrical resistance (see Chapter 7). – Tightening torque for the carburetor heater elements: 4 Nm...
Page 182 8-13 INJECTION SYSTEM Dismounting/mounting the throttle body (see Chapter 3) NOTE: never carry out any work on the throttle body; no adjustments are necessary. Dismounting/mounting the fuel pump with pressure regulator and fuel level sensor – Disconnect the fuel line. To disconnect, press down lightly on the metal shim and pull the connector off.
Page 183 8-14 Checking the fuel pressure – Disconnect the fuel connection (see page 8-13). – Connect the EFI pressure gauge 610.29.094.000 and run the hose on the pressure manometer to the handlebar if taking a trial run. Hold in place with cable clips if necessary. CAUTION O NOT BEND THE HOSES –...
Page 185 TROUBLE SHOOTING INDEX TROUBLE SHOOTING ..........9-2...
Page 187 Remove the covering and the fuel tank, clean the plug and socket connector and treat with contact spray wiring harness is oxidizing Error injection system Error diagnosis with the KTM diagnostics tool, eliminate error (Super Duke) Engine does have Fuel supply partly interrupted...
Page 188 600.31.003.044) FI lamp is blinking/lights up Error in the injection system (Super Duke) Error diagnosis with the KTM diagnostics tool, eliminate error Poor idling after replacing Control unit was not adapted to Delete preset values using the KTM diagnostics tool (see...
Page 189 10-1 CHASSIS INDEX DISMOUNTING/MOUNTING THE FRONT WHEEL ......10-2 DISMOUNTING/MOUNTING THE REAR WHEEL ......10-3 REPLACING THE FRONT WHEEL BEARING .
Page 191 10-2 Dismounting/mounting the front wheel 950/990 Adventure: – Jack up the motorcycle with the center stand (use 600.03.022.000 if not available), unscrew the left bump rubber and block the center stand with the lock 600.29.055.000. – Put a weight on the rear end of the vehicle to lift the front wheel off the ground.
Page 192 10-3 Dismounting/mounting the rear wheel 950/990 Adventure: – Place the motorcycle on the center stand to lift the rear wheel off the ground. 950 Supermoto/990 Super Duke: – Jack up the motorcycle with the assembly stand 625.29.055.000, see Chapter 3. –...
Page 193 10-4 Replacing the front wheel bearing – To dismount the front wheel, see page 10-2. – Pull out both distance bushings , pry both shaft seal rings of the hub and take the lock ring out of the hub with suitable pliers.
Page 194 10-5 Replacing the rear wheel bearing – Dismount the rear wheel (see page 10-3). – Remove the rear sprocket carrier from the rear hub and pull out the damper rubber. – Remove the distance bushing and pry the shaft seal ring out of the hub, then take the lock ring out of the hub with suitable...
Page 195 10-6 Replacing the front brake pads (950/990 Adventure) – Press the brake caliper against the brake disk to move the brake pistons into the basic position. Remove the retainers , pull out the bolts and take the brake pads out of the brake caliper. –...
Page 196 10-7 Replacing the rear brake pads (950/990 Adventure/950 Supermoto) – Press the brake caliper towards the rear sprocket to move the brake piston into the basic position. Remove the retainers , pull out the bolt and remove the brake pads. Thoroughly clean the brake caliper with compressed air and check the guide bolt bellows for damage.
Page 197 10-8 Replacing the fork legs – Dismount the front wheel (see page 10-2). – Unscrew the bracket for the brake hose and the speed pickup cable and remove from the fender (950/990 Adventure only). – Remove all fender bolts and then the fender. –...
Page 198 10-9 Replacing the shock absorber (950/990 Adventure) – Jack up the motorcycle on the center stand 600.03.022.000, unscrew the left bump rubber and lock the center stand with the locking device 600.29.055.000. – Unscrew the left side cover and the seat lock. –...
Page 199 10-10 Replacing the fork leg (950 Supermoto/990 Super Duke) – Jack up the motorcycle and dismount the rear wheel (see page 10-3). – Remove the seat and the splash protector , loosen the tank and lift slightly in the rear (950 Supermoto only). –...
Page 200 10-11 Replacing the steering head bearing – Dismount the fork legs (see page 10-8). – Unscrew the brake hose guide from the lower and upper triple clamp (950/990 Adventure) or unscrew the mask support (990 Super Duke). – Remove the handlebar clamps and lay the handlebar back.
Page 201 10-12 Replacing the swing arm bearing – Dismount the rear wheel (see page 10-3). – Dismount the splash protector – Remove the lower shock absorber bolt and press the swing arm down to release the shock absorber from the recess in the swing arm.
Page 202 10-13 Replacing the chain, pinion and rear sprocket – Unscrew the engine sprocket cover , bend up the lock washer and loosen the engine sprocket nut – Open the chain with a cutting/riveting tool (see page 10-14) and remove the chain. –...
Page 203 10-14 Opening the chain with a separating/rivet tool NOTE: an X-ring chain, type 525 HV (5/8 x 5/16“), is used for the models with LC8-engine. will need special tool 600.29.020.000 to separate or rivet the chain according to the manufacturer's specifications. This special tool consists of a bracket with 2 marks (A and B), a pressing tool with spindle and a locking screw, pressing pin...
Page 204 10-15 Replacing the ABS unit – Gently actuate the hand brake lever and foot brake lever until you start to feel resistance; this closes the supply bore to the brake cylinder pistons and prevents the brake fluid from leaking out; fix in this position.
Page 205 11-1 TECHNICAL SPECIFICATIONS INDEX 950 ADVENTURE ENGINE ........... . 11-2 CHASSIS .
Page 207 11-2 TECHNICAL SPECIFICATIONS – ENGINE 950 ADVENTURE Engine Design Liquid-cooled, 2-cylinder 4-stroke engine with 75° V arrangement with balancer shaft and electric starter Displacement 942 cm3 Bore / Stroke 100/60 mm Compression ratio 11.5:1 Fuel unleaded premium fuel with at least RON 95 (ROZ 80 - 94 for other ignition curve) Valve timing 4 valves controlled over bucket tappet and 2 camshafts, camshaft drive with gears/chain Valve diameter...
Page 208 11-3 TECHNICAL SPECIFICATIONS – CHASSIS 950 ADVENTURE/ADVENTURE S 950 ADVENTURE / 950 ADVENTURE S Frame Tubular chrome-molybdenum-steel space frame, powder-coated Fork White Power – Up Side Down 4860 MXMA (Multiadjuster) Spring travel front model year 2003/2004: ADVENTURE = 230 mm, ADVENTURE S = 265 mm model year 2005/2006: ADVENTURE = 210 mm, ADVENTURE S = 245 mm Rear suspension WP Progressive Damping System shock absorber with hydraulic preload adjuster,...
Page 209 11-4 STANDARD ADJUSTMENT – FORK 950 LC8 ADVENTURE WP USD 4860 MXMA Spring 4,8 N/mm Air chamber length 100 mm Fork oil SAE 5 (WP 4860.0211) STANDARD ADJUSTMENT – SHOCK ABSORBER 950 ADVENTURE / ADVENTURE S WP PDS 5018 PA Spring 140/255 140/265...
Page 210 11-5 TECHNICAL SPECIFICATIONS – ENGINE 990 SUPER DUKE Engine Design Liquid-cooled, 2-cylinder 4-stroke engine with 75° V arrangement with balancer shaft and electric starter Displacement 999.9 cm3 Bore / Stroke 101/62.4 mm Compression ratio 11.8:1 Fuel unleaded premium fuel with at least RON 95 Valve timing 4 valves controlled over bucket tappet and 2 camshafts, camshaft drive with gears/chain Valve diameter...
Page 211 11-6 TECHNICAL SPECIFICATIONS – CHASSIS 990 DUKE 990 SUPER DUKE Frame Tubular chrome-molybdenum-steel space frame, powder-coated Fork White Power – Up Side Down 4860 ROMA Spring travel front 135 mm Rear suspension WP 4618 BAVP Spring travel rear 160 mm Front brake Disk brake, 2 perforated brake disks Ø...
Page 212 11-7 STANDARD ADJUSTMENT – FORK 990 SUPER DUKE WP 4860 ROMA Spring 9 N/mm Air chamber length 110 mm Fork oil SAE 5 (WP 4860.0211) STANDARD ADJUSTMENT – SHOCK ABSORBER 990 SUPER DUKE WP 4618 BAVP Spring 160/185 STANDARD ADJUSTMENT – FORK AND SHOCK ABSORBER 990 SUPER DUKE FORK SHOCK ABSORBER...
Page 213 11-8 TECHNICAL SPECIFICATIONS – ENGINE 950 SUPERMOTO Engine Design Liquid-cooled, 2-cylinder 4-stroke engine with 75° V arrangement with balancer shaft and electric starter Displacement 942 cm3 Bore / Stroke 100/60 mm Compression ratio 11.5:1 Fuel unleaded premium fuel with at least RON 95 Valve timing 4 valves controlled over bucket tappet and 2 camshafts, camshaft drive with gears/chain Valve diameter...
Page 214 11-9 TECHNICAL SPECIFICATIONS – CHASSIS 950 SUPERMOTO 950 SUPERMOTO Frame Tubular chrome-molybdenum-steel space frame, powder-coated Fork White Power – Up Side Down 4860 ROMA Spring travel front 200 mm Rear suspension WP 4618 BAVP Spring travel rear 210 mm Front brake Disk brake, 2 perforated brake disks Ø...
Page 215 11-10 STANDARD ADJUSTMENT – FORK 950 SUPERMOTO WP 4860 ROMA Spring 5.6-450 Air chamber length 110 mm Fork oil SAE 5 (WP 4860.0401) STANDARD ADJUSTMENT – SHOCK ABSORBER 950 SUPERMOTO WP 4618 BAVP Spring 130/215 STANDARD ADJUSTMENT – FORK AND SHOCK ABSORBER 950 SUPERMOTO FORK SHOCK ABSORBER...
Page 216 11-11 TECHNICAL SPECIFICATIONS – ENGINE 990 ADVENTURE Engine Design Liquid-cooled, 2-cylinder 4-stroke engine with 75° V arrangement with balancer shaft and electric starter Displacement 999.9 cm3 Bore / Stroke 101/62.4 mm Compression ratio 11.8:1 Fuel unleaded premium fuel with at least RON 95 (ROZ 80 - 94 for other ignition curve) Valve timing 4 valves controlled over bucket tappet and 2 camshafts, camshaft drive with gears/chain Valve diameter...
Page 217 11-12 TECHNICAL SPECIFICATIONS – CHASSIS 990 ADVENTURE/ADVENTURE S 990 ADVENTURE / 990 ADVENTURE S Frame Tubular chrome-molybdenum-steel space frame, powder-coated Fork White Power – Up Side Down 4860 MXMA (Multiadjuster) Spring travel front ADVENTURE = 210 mm, ADVENTURE S = 245 mm Rear suspension WP Progressive Damping System shock absorber with hydraulic preload adjuster, aluminum rear wheel swinging fork supported by needle bearings...
Page 218 11-13 STANDARD ADJUSTMENT – FORK 990 ADVENTURE WP USD 4860 MXMA Spring 4,8 N/mm Air chamber length 100 mm Fork oil SAE 5 (WP 4860.0211) STANDARD ADJUSTMENT – SHOCK ABSORBER 990 ADVENTURE / ADVENTURE S WP PDS 5018 PA Spring 140/255 140/265 STANDARD ADJUSTMENT –...
Page 219 11-14 TECHNICAL SPECIFICATIONS – ENGINE 950 SUPER ENDURO Engine Design Liquid-cooled, 2-cylinder 4-stroke engine with 75° V arrangement with balancer shaft and electric starter Displacement 942 cm3 Bore / Stroke 100/60 mm Compression ratio 11.5:1 Fuel unleaded premium fuel with at least RON 95 Valve timing 4 valves controlled over bucket tappet and 2 camshafts, camshaft drive with gears/chain Valve diameter...
Page 220 11-15 TECHNICAL SPECIFICATIONS – CHASSIS 950 SUPER ENDURO 950 SUPER ENDURO Frame Tubular chrome-molybdenum-steel space frame, powder-coated Fork WP Up Side Down 4860 MXMA PA (Multi/Preloadadjuster) Spring travel front 250 mm Rear suspension WP 4618 BAVP, aluminum rear wheel swinging fork supported by needle bearings Spring travel rear 255 mm Front brake...
Page 221 11-16 STANDARD ADJUSTMENT – FORK 950 SUPER ENDURO WP 4860 MXMA PA Spring 5.9-450 Air chamber length 100 mm Fork oil SAE 5 (WP 4860.0401) STANDARD ADJUSTMENT – SHOCK ABSORBER 950 SUPER ENDURO WP 4618 BAVP Spring (59) 140-215 STANDARD ADJUSTMENT – FORK AND SHOCK ABSORBER 950 SUPER ENDURO FORK SHOCK ABSORBER...
Page 222 11-17 TOLERANCES AND FITTING CLEARANCES COMPONENT MEASUREMENT/TEST ..... . .SETPOINT VALUE .TOLERANCE LIMIT Valves Valve clearance (at 20ºC) intake ....0,10 mm - 0,15 mm Valve clearance (at 20ºC) exhaust .
Page 223 11-18 TOLERANCES AND FITTING CLEARANCE COMPONENT MEASUREMENT/TEST ..... .SETPOINT VALUE . .TOLERANCE LIMIT Crankshaft/conrod Diameter of crankshaft journal ...49.975 mm – 49.985 mm (blue) Diameter of crankshaft journal .
Page 224 11-19 TIGHTENING TORQUES – ENGINE Hexagon nut on primary gear M33x1.5 left Loctite 243 + 130 Nm Multipoint head bolt on conrod caps M10x1 25 Nm/30Nm/60° Hexagon nut on balancer shaft M20x1.5 Loctite 243 + 150 Nm Hexagon nut on balancer shaft preloaded (spreader) M20x1.5 Loctite 243 + 120 Nm Hexagon nut on cylinder head...
Page 225 11-20 TIGHTENING TORQUES – CHASSIS Collar bolt on front wheel spindle (except 950 Super Enduro) M24x1.5 60 Nm Collar bolt on front wheel spindle (950 Super Enduro only) M24x1.5 40 Nm Collar nut wheel spindle rear M25x1.5 90 Nm AH bolt shock absorber top/bottom M14x1.5 80 Nm Collar nut for swing arm bolt...
Page 226 11-21...
Page 227 IDLE ADJUSTMENT 950 SUPERMOTO/SUPER ENDURO ....12-20 CHECK FAULT MEMORY WITH THE KTM DIAGNOSIS TOOL ....12-20 PERFORM A STATUS CHECK USING THE KTM DIAGNOSIS TOOL .
Page 228 12-2 PERIODIC MAINTENANCE SCHEDULE 950 ADVENTURE Change engine oil and oil filter Clean oil screens of engine and oil tank Clean magnetic drain plugs of engine and oil tank Check oil lines for damage and kink-less arrangement Replace the oil line connection from the front valve cover to the oil tank Renew spark plugs Check the spark plug connector for a tight fit to the spark plug Check and adjust valve clearance...
Page 229 12-3 PERIODIC MAINTENANCE SCHEDULE MPORTANT AINTENANCE ROCEDURES ERFORMED ASED EPARATE UPPLEMENT RDER at least every 2 years or every 4 years or once a year 15000 km 30000 km Perform complete fork maintenance Perform complete shock absorber maintenance Clean and lubricate steering-head bearing and sealing elements Clean and adjust the carburetors Treat the electrical contacts and switches with contact spray Treat battery connections with contact grease...
Page 230 Clean the oil jet for the clutch lubrication Check rubber boot for cracks or leaks Check fault memory with the KTM diagnosis tool Perform a status check of neutral, clutch, 2nd/3rd gear and side stand switch using the KTM diagnosis tool...
Page 231 12-5 PERIODIC MAINTENANCE SCHEDULE MPORTANT AINTENANCE ROCEDURES ERFORMED ASED EPARATE UPPLEMENT RDER at least every 2 years or once a year 15000 km Perform complete fork maintenance Perform complete shock absorber maintenance Clean and lubricate steering-head bearing and sealing elements Treat the electrical contacts and switches with contact spray Treat battery connections with contact grease Change coolant fluid...
Page 232 12-6 PERIODIC MAINTENANCE SCHEDULE 1. Service 7500 km or 15000 km or 950 SUPERMOTO after once every 1000 km a year 2 years Change engine oil and oil filter Clean oil screens of engine and oil tank Clean magnetic drain plugs of engine and oil tank Check oil lines for damage and kink-less arrangement Renew spark plugs Check and adjust valve clearance...
Page 233 12-7 PERIODIC MAINTENANCE SCHEDULE MPORTANT AINTENANCE ROCEDURES ERFORMED ASED EPARATE UPPLEMENT RDER at least every 2 years or once a year 15000 km Perform complete fork maintenance Perform complete shock absorber maintenance Clean and lubricate steering-head bearing and sealing elements Clean and adjust the carburetors Treat the electrical contacts and switches with contact spray Treat battery connections with contact grease...
Page 234 Check brake lines for damage and leaks Check/adjust smooth operation, free travel of handbrake/footbrake levers Check bolts of brake system for tight fit Check ABS fault memory with the KTM diagnosis tool Check shock absorber and fork for leaks and proper operation Clean fork dust sleeves...
Page 235 12-9 PERIODIC MAINTENANCE SCHEDULE MPORTANT AINTENANCE ROCEDURES ERFORMED ASED EPARATE UPPLEMENT RDER at least every 2 years or once a year 15000 km Perform complete fork maintenance Perform complete shock absorber maintenance Clean and lubricate steering-head bearing and sealing elements Treat the electrical contacts and switches with contact spray Treat battery connections with contact grease Change coolant fluid...
Page 236 12-10 PERIODIC MAINTENANCE SCHEDULE 1. Service 7500 km or 15000 km or 950 SUPER ENDURO after once every 1000 km a year 2 years Change engine oil and oil filter Clean oil screens of engine and oil tank Clean magnetic drain plugs of engine and oil tank Check oil lines for damage and kink-less arrangement Renew spark plugs Check and adjust valve clearance...
Page 237 12-11 PERIODIC MAINTENANCE SCHEDULE MPORTANT AINTENANCE ROCEDURES ERFORMED ASED EPARATE UPPLEMENT RDER at least every 2 years or once a year 15000 km Perform complete fork maintenance Perform complete shock absorber maintenance Clean and lubricate steering-head bearing and sealing elements Clean and adjust the carburetors Treat the electrical contacts and switches with contact spray Treat battery connections with contact grease...
Page 238 12-12 Lubrication and maintenance work - engine Changing the engine oil and filter, cleaning the oil screens and magnets on the drain plugs NOTE: Change the engine oil when the engine is at operating temperature. WARNING – HE ENGINE AND ENGINE OIL ARE VERY HOT AT OPERATING TEMPERATURE CAREFUL NOT TO BURN YOURSELF NOTE: before you start with the lubricating and maintenance work described below, remove the engine guard, seat and both tanks...
Page 239 Only use fully synthetic engine oils that meet the JASO MA quality requirements (see information on the can). KTM recommends Motorex Power Synt 4T in the 10W/50 viscosity (for JASO T903 MA temperatures over 0°C) or 5W/40 (for temperatures under 0°C).
Page 240 12-14 Checking the engine oil level Check the engine oil level when the engine is warm (at least 4 bars on the temperature indicator will light up). Place the motorcycle on a level surface (not on the side stand). Turn off the engine, unscrew the oil dipstick and wipe off with a cloth.
Page 241 12-15 Checking and adjusting the valve clearance NOTE: to make it easier to work on the front cylinder, remove the 4 radiator retaining bolts and pull the radiator forward. – Pull the EPC valve on the front cylinder from the bracket. –...
Page 242 12-16...
Page 243 12-17...
Page 244 12-18 Checking the clutch lining – Remove the lock clip on the foot brake lever bolt and pull out the bolt. – Loosen the bearing bolt on the foot brake lever and remove the foot brake lever. – Dismount the clutch lining (see Chapter 4). –...
Page 245 12-19 LUBRICATION AND MAINTENANCE WORK – CARBURETOR Check the carburetor synchronization with an vacuum gauge and adjust if necessary – Disconnect the vacuum hoses from the air filter box and from the secondary air system valve and run up on the side between the frame and the air filter box.
Page 246 Check the fault memory with the KTM diagnostics tool See KTM diagnostics tool operating instructions Scan the status of the neutral, clutch, 2nd/3rd gear and side stand switch using the KTM diagnostics tool See KTM diagnostics tool operating instructions Replacing the O-ring on the fuel hose connector...
Page 247 12-21 Changing the front brake fluid – Open the brake fluid reservoir – Use a syringe to extract the used brake fluid and add fresh DOT 5.1 brake fluid (Motorex Brake Fluid DOT 5.1). – Press the front brake caliper pistons all the way back (950/990 Adventure only).
Page 248 (if it can easily be screwed in further), remove the bolt, clean, secure with Loctite 243 and tighten to the correct torque (see technical data). Check ABS fault memory with the KTM diagnosis tool see chapter 7...
Page 249 12-23 LUBRICATION AND MAINTENANCE WORK - CHASSIS Cleaning the dust boots – See Owner's Manual Bleeding the fork legs – See Owner's Manual Checking the swing arm support – Try to move the rear wheel to each side in an unloaded condition. You should not feel any clearance NOTE: –...
Page 250 12-24 LUBRICATION AND MAINTENANCE WORK - WHEELS Checking the spoke tension and rim run-out – Spoke nipple: 5 Nm – maximum radial/lateral run-out of the rim (without tires): 1.2 mm – maximum radial/lateral run-out of the rim (with tires): front 2.3 mm, rear 2.5 mm Checking the chain and chain guides for wear, force fit and tension.
Page 251 12-25 LUBRICATION AND MAINTENANCE WORK – ADDITIONAL WORK Completely servicing the fork – Dismounting the fork legs: see Chapter 10 – Maintenance: see WP-documentation Completely servicing the shock absorber – Dismounting the shock absorber: see Chapter 10 – Maintenance: see WP-documentation Cleaning and greasing the steering head bearing and sealing elements –...
Page 252 12-26 LUBRICATION AND MAINTENANCE WORK – ADDITIONAL WORK Cleaning and adjusting the carburetor – See Chapter 8 Changing the cooling liquid NOTE: change the cooling liquid after you have finished the general lubrication and maintenance work. CAUTION O AVOID BURNING YOURSELF ALWAYS DRAIN THE COOLING LIQUID WHEN THE ENGINE IS COLD –...
Page 253 13-1 WIRING DIAGRAMS INDEX 950 ADVENTURE WIRING DIAGRAM 2003-2004 ........12-6 EXPLANATION OF CONNECTORS, CABLE COLORS .
Page 254 13-2 WIRING DIAGRAMS INDEX 990 SUPER DUKE WIRING DIAGRAM ..........12-36 EXPLANATION OF CONNECTORS, CABLE COLORS .
Page 255 13-3 WIRING DIAGRAMS INDEX 950 SUPERMOTO WIRING DIAGRAM ..........12-64 EXPLANATION OF CONNECTORS, CABLE COLORS .
Page 256 13-4 WIRING DIAGRAMS INDEX 990 ADVENTURE WIRING DIAGRAM ..........12-90 EXPLANATION OF CONNECTORS, CABLE COLORS .
Page 257 13-5 WIRING DIAGRAMS INDEX 950 SUPER ENDURO WIRING DIAGRAM ......... . .12-117 EXPLANATION OF CONNECTORS, CABLE COLORS .
Page 258 13-6...
Page 259 13-7 NOTE to the connector designations: The connector designations are comprised of letters and numbers - e.g.: C_AA1/20 – The 1st position C stands for connector (connector). – The 2nd and 3rd positions AA stand for the connector type. – The 4th position numbers the same type of connector if the connector is used for different applications.
Page 260 13-8...
Page 261 13-9 NOTE to the connector designations: The connector designations are comprised of letters and numbers - e.g.: C_AA1/20 – The 1st position C stands for connector (connector). – The 2nd and 3rd positions AA stand for the connector type. – The 4th position numbers the same type of connector if the connector is used for different applications.
Page 262 13-10...
Page 263 13-11 start switch ignition switch cable harness cable switch START unpushed LOCKED kill switch sidestand switch cable cable harness harness cable cable switch switch folded up STOP folded down clutch switch switch position pulled unpulled...
Page 264 13-12...
Page 265 13-13 ignition switch LOCKED...
Page 266 13-14...
Page 267 13-15 ignition switch LOCKED start switch cable harness cable switch START unpushed kill switch cable harness cable switch STOP...
Page 268 13-16...
Page 269 13-17 ignition switch LOCKED flasher switch cable harness cable bu- bu- switch TURN L TURN R horn switch cable harness cable switch HORN...
Page 270 13-18...
Page 271 13-19 ignition switch LOCKED light switch high/low beam switch cable cable harness harness cable cable wh wh switch switch LIGHT OFF P. LIGHT LIGHT passing light brake switch cable cable harness harness cable cable switch switch pushed P. HORN unpushed...
Page 272 13-20...
Page 273 13-21 ignition switch LOCKED light switch high/low beam switch cable cable harness harness cable cable wh wh switch switch LIGHT OFF P. LIGHT LIGHT passing light brake switch cable cable harness harness cable cable switch switch pushed P. HORN unpushed...
Page 274 13-22...
Page 275 13-23 ignition switch LOCKED...
Page 276 13-24...
Page 277 13-25...
Page 278 13-26 Connector AA 20-pole 11 1 Multifunctional digital speedometer Behind multi- functional digital speedometer 20 10 Connector AB 9-pole Start/stop/light switch connector support under multifunctional digital speedometer Connector AC 6-pole Front light connector support under multifunctional digital speedometer Connector AD 12-pole Light/turn signal/horn switch...
Page 279 13-27 Connector AG 3-pole Tachometer connector support under multifunctional digital speedometer Connector AH 2-pole Turn signal relay connector support under multifunctional digital speedometer Connector AH1 2-pole Rear brake light switch Under the right rear side cover Connector AH2 2-pole Left front turn signal Under the right front side cover Connector AH3...
Page 280 13-28 Connector AI 2-pole Diode neutral switch connector support under multifunctional digital speedometer Connector AI1 2-pole Diode side stand switch connector support under the multi- functional digital speedometer Connector AJ 3-pole Rear lighting Under the right rear side cover Connector AK 2-pole Rear brake light switch Under the right rear side...
Page 281 13-29 Connector AL 2-pole Clutch switch Behind headlight under connector support Connector AL1 2-pole Pick up Between the water pipe and the front cylinder head Connector AL2 2-pole Fuel sender Between the left tank and the frame Connector AM 3-pole Carburetor potentiometer Under the fuse box...
Page 282 13-30 Connector AN 4-pole Tripmaster switch Near connector support under multifunctional digital speedometer Connector AO 26-pole ECU (control unit) Under fuse behind steering head Connector AP 6-pole Ignition lock Under the fuse box Connector AQ 1-pole Connector for auxiliary devices: Kl 15 (ignition) Kl 30 (battery) Kl 31 (ground)
Page 283 13-31 Connector AR 3-pole Speed sensor Behind headlight under connector support Connector AS 2-pole Rear ignition coil Behind the air filter box Connector AS1 2-pole Front ignition coil Behind the radiator Connector AT 2-pole Pick up Between the water pipe and the front cylinder head Connector AT1...
Page 284 13-32 Connector AU 2-pole Radiator fan motor On the right behind the radiator next to the fan Connector AU1 2-pole Regulator On the right side of the battery case under the starter relay Connector AV 2-pole Temperature switch for the radiator fan On the right behind the radiator next...
Page 285 13-33 Connector AX 2-pole Temperature sensor for the multifunctional digital speedometer On the left side of the engine between cylinders Connector AY 1-pole Oil pressure switch On the left side of the frame under filter box Connector AZ 4-pole Rear turn signal Under the right rear side cover Connector BA...
Page 286 13-34 Connector BB 9-pole Start/stop/light switch connector support under multifunctional digital speedometer Connector BC 6-pole Front light connector support under multifunctional digital speedometer Connector BD 12-pole Light/turn signal/horn switch connector support under multifunctional digital speedometer Connector BE 3-pole Tachometer connector support under multifunctional...
Page 287 13-35 Connector BH 6-pole Ignition lock Under the fuse box Connector BI 2-pole Radiator fan motor On the right behind the radiator next to the fan Connector BI1 2-pole Regulator On the right side of the battery case under the starter relay Connector BJ 1-pole...
Page 288 13-36...
Page 289 13-37 NOTE to the connector designations: The connector designations are comprised of letters and numbers - e.g.: C_AA1/20 – The 1st position C stands for connector (connector). – The 2nd and 3rd positions AA stand for the connector type. – The 4th position numbers the same type of connector if the connector is used for different applications.
Page 290 13-38...
Page 291 13-39 start switch ignition switch cable harness cable switch START unpushed LOCKED c t i clutch switch switch position pulled unpulled...
Page 292 13-40...
Page 293 13-41 start switch ignition switch cable harness cable switch START unpushed LOCKED c t i clutch switch switch position pulled unpulled...
Page 294 13-42...
Page 295 13-43 ignition switch flasher switch cable harness cable bu- bu- switch TURN L TURN R LOCKED horn switch cable harness cable switch HORN...
Page 296 13-44...
Page 297 13-45 light switch ignition switch cable harness cable wh wh switch LIGHT OFF P. LIGHT LOCKED LIGHT high/low beam switch brake switch cable cable harness harness cable cable switch switch pushed unpushed passing light cable harness cable switch P. HORN...
Page 298 13-46...
Page 299 13-47 ignition switch LOCKED...
Page 300 13-48...
Page 301 13-49...
Page 302 13-50 Connector AA 20-pole 11 1 Multifunctional digital speedometer Behind multi- functional digital speedometer 20 10 Connector AB 9-pole Start/stop/light switch Behind headlight mask Connector AC 6-pole Front lighting Behind headlight mask Connector AD 12-pole Turn signal, horn, high beam switch Behind headlight mask...
Page 303 13-51 Connector AF 4-pole Main relay Under the seat Connector AF1 4-pole Fuel pump relay Under the seat Connector AF2 4-pole Auxiliary starter relay Under the seat Connector AG 3-pole Speedometer Behind headlight mask Connector AH 2-pole Front brake light switch Behind headlight mask...
Page 304 13-52 Connector AI, AI1, AI2 2-pole Diodes Under the seat Connector AI3 2-pole Diode Behind headlight mask Connector AJ 3-pole Rear lighting Under the seat Connector AK 2-pole Front brake light switch Behind headlight mask Connector AK1 2-pole Rear brake light switch In front of the fuse box Connector AL 2-pole...
Page 305 13-53 Connector AM 3-pole Throttle sensor for the 2nd throttle On the throttle body Connector AM1 3-pole Throttle sensor On the throttle body Connector AM2 3-pole Gear sensor On the left next to the battery case Connector AM3 3-pole Side stand On the left next to the battery case Connector AM4...
Page 306 13-54 Connector AO 26-pole Behind steering head Connector AP 6-pole Ignition switch Behind steering head Connector AP1 6-pole Diagnosis connector Behind the fuse box Connector AP2 6-pole Rollover sensor Behind headlight mask Connector AR 3-pole Throttle sensor for the 2nd throttle On the throttle body Connector AR1 3-pole...
Page 307 13-55 Connector AR2 3-pole Gear sensor On the left next to the battery case Connector AR3 3-pole Side stand On the left next to the battery case Connector AR4 3-pole Fuel pump In front of the fuse box Connector AR5 3-pole Speed sensor Behind...
Page 308 13-56 Connector AT 2-pole Pick up In front of the 2nd cylinder over the battery case Connector AT1 2-pole Clutch switch Behind headlight mask Connector AU 2-pole Regulator output On the left next to the battery case Connector AU1 2-pole Fan motor Behind the radiator Connector AV...
Page 309 13-57 Connector AY 1-pole Oil pressure switch On the outer left side of the frame Connector AZ 4-pole Rear blinker Under the seat Connector BB 9-pole Start/stop/light switch Behind headlight mask Connector BC 6-pole Front lighting Behind headlight mask Connector BD 12-pole Turn signal, horn, high beam switch...
Page 310 13-58 Connector BE 3-pole Speedometer Behind headlight mask Connector BG 3-pole Rear lighting Under the seat Connector BH 6-pole Ignition switch Behind steering head Connector BH1 6-pole Diagnosis connector Behind the fuse box Connector BI 2-pole Regulator output On the left next to the battery case Connector BI1 2-pole...
Page 311 13-59 Connector BJ 1-pole Oil pressure switch On the outer left side of the frame Connector BK 4-pole Rear turn signal Under the seat Connector BS 2-pole Alarm LED Instrument panel (only for alarm systems) Connector BS1 Seat switch Under the seat (only for alarm systems) Connector BV 2-pole...
Page 312 13-60 Connector BZ 3-pole Pressure sensor for rear cylinder On the left side of the frame Connector BZ1 3-pole Manifold air pressure sensor for front cylinder On the right side of the frame Connector BZ2 3-pole Ambiant air pressure sensor Behind headlight mask...
Page 313 13-61 Connector CC 12-pole Front wiring harness Behind headlight mask Connector CE 4-pole Rear lambda probe On the left next to the battery case Connector CE1 4-pole Front lambda probe On the right side of the frame Connector CE2 4-pole Control motor for 2nd throttle On the throttle body...
Page 314 13-62 Connector CL 2-pole Rear injection valve On the throttle body Connector CL1 2-pole Front injection valve On the throttle body Connector CM 2-pole Air temperature sensor On the top of the air filter box Connector CO 34-pole Behind the steering head Connector CP 16-pole Wiring harness EFI...
Page 315 13-63 Connector CR 1-pole Connector for attachments: Kl 15 (ignition) Kl 31 (ground) Under the seat next to the fuse box Connector DJ 20-pole Connector for the alarm system control unit Under the seat Connector DK 20-pole Connector (without alarm system) Under the seat...
Page 316 13-64...
Page 317 13-65 NOTE to the connector designations: The connector designations are comprised of letters and numbers - e.g.: C_AA1/20 – The 1st position C stands for connector (connector). – The 2nd and 3rd positions AA stand for the connector type. – The 4th position numbers the same type of connector if the connector is used for different applications.
Page 318 13-66...
Page 319 13-67 c t i Stop switch c t i c t i c t i c t i c t i o i t e l l e l l...
Page 320 13-68...
Page 321 13-69 c t i Stop switch c t i c t i c t i...
Page 322 13-70...
Page 323 13-71 c t i c t i c t i c t i...
Page 324 13-72...
Page 325 13-73 g i l c t i c t i c t i c t i c t i c t i...
Page 326 13-74...
Page 327 13-75...
Page 328 13-76...
Page 329 13-77...
Page 330 13-78 Connector AA 20-pole 11 1 Multifunctional digital speedometer Behind multi functional digital speedometer 20 10 Connector AB 9-pole Start/stop/light switch Behind multi functional digital speedometer Connector AC 6-pole Ignition switch Behind multi functional digital speedometer Connector AD 12-pole Light/turn signal/horn switch Behind multi...
Page 331 13-79 Connector AF2 4-pole Lighting relay Under the seat Connector AF3 2-pole Start relay Under the seat Connector AH 2-pole Rear brake light switch On the right side of the frame Connector AH1 2-pole Front brake light switch Behind the headlight Connector AH2 2-pole Temperature switch for...
Page 332 13-80 Connector AI 2-pole Neutral switch diode Under the seat, next to the battery Connector AI1 2-pole Diode for side stand switch Under the seat, next to the battery Connector AI2 2-pole Diode for side stand switch Under the seat, next to the battery Connector AI3 2-pole...
Page 333 13-81 Connector AK 2-pole Rear brake light switch On the right side of the frame Connector AK1 2-pole Front brake light switch Behind the headlight Connector AK2 2-pole Temperature switch for carburetor heater Behind the headlight Connector AL 2-pole Pick up On the left between the tank generator cover...
Page 334 13-82 Connector AL3 2-pole Clutch switch Behind the headlight Connector AL4 2-pole Carburetor heater Behind steering head and the ECU Connector AM 3-pole Throttle sensor Behind steering head and the ECU Connector AM1 3-pole Gear sensor On the left between the tank generator cover Connector AM2...
Page 335 13-83 Connector AO 26-pole Behind steering head Connector AR 3-pole Throttle sensor Behind steering head and the ECU Connector AR1 3-pole Gear sensor On the left between the tank generator cover Connector AR2 3-pole Side stand switch On the left between the tank generator cover Connector AR3...
Page 336 13-84 Connector AS 2-pole Rear ignition coil Behind the air filter box Connector AS1 2-pole Front ignition coil Behind the radiator Connector AT 2-pole Pick up On the left between the tank generator cover Connector AT1 2-pole Fuel sender On the front left next to the radiator Connector AT2 2-pole...
Page 337 13-85 Connector AT4 2-pole Carburetor heater Behind steering head and the ECU Connector AU 2-pole Controller outlet Under the seat next to the battery case Connector AV 2-pole Temperature switch On the left side of the radiator Connector AW 2-pole Front EPC On the right side of the frame...
Page 338 13-86 Connector AY 1-pole Oil pressure switch On the left side of the frame under filter box Connector AZ 4-pole Rear turn signal Under the seat in the back storage compartment Connector BB 9-pole Start/stop/light switch connector support under multifunctional digital speedometer Connector BC...
Page 339 13-87 Connector BI 2-pole Controller outlet Under the seat next to the battery case Connector BJ 1-pole Oil pressure switch On the left side of the frame under filter box Connector BK 4-pole Rear turn signal Under the seat in the back storage compartment...
Page 340 13-88 Connector BV 2-pole Alarm LED Instrument panel (for alarm system only) Connector BV1 2-pole Seat switch Under seat (for alarm system only) Connector BW 3-pole Headlight Behind the headlight Connector CD/CD1 2-pole Radiator fan Behind the left radiator Connector CR/CR1/CR2/CR3 1-pole Connector for...
Page 341 13-89 Connector DI 2-pole Parking light On the headlight Connector DJ 18-pole Connector for the alarm Under the seat Connector DK 18-pole Dummy plug (without alarm system) Under the seat...
Page 342 13-90...
Page 343 13-91 NOTE to the connector designations: The connector designations are comprised of letters and numbers - e.g.: C_AA1/20 – The 1st position C stands for connector (connector). – The 2nd and 3rd positions AA stand for the connector type. – The 4th position numbers the same type of connector if the connector is used for different applications.
Page 344 13-92...
Page 345 13-93 c t i c t i c t i o i t e l l e l l l i k c t i c t i c t i c t i...
Page 346 13-94...
Page 347 13-95 c t i c t i o i t e l l e l l...
Page 348 13-96...
Page 349 13-97 c t i c t i c t i c t i...
Page 350 13-98...
Page 351 13-99 g i l c t i c t i c t i c t i c t i c t i...
Page 352 13-100...
Page 353 13-101...
Page 354 13-102...
Page 355 13-103...
Page 356 13-104 Connector AA 20-pole 11 1 Multifunctional digital speedometer Behind multi functional digital speedometer 20 10 Connector AB 9-pole Start/stop/light switch connector support under multifunctional digital speedometer Connector AC 6-pole Front light connector support under multifunctional digital speedometer Connector AD 12-pole Light/turn signal/horn switch...
Page 357 13-105 Connector AF 4-pole Main relay Connector AF1 4-pole Fuel pump relay Connector AF2 4-pole Auxiliary starter relay Connector AF3 4-pole Lighting relay connector support under multifunctional digital speedometer Connector AG 3-pole Tachometer connector support under multifunctional digital speedometer Connector AH 2-pole Rear brake light switch Under the right rear side...
Page 358 13-106 Connector AJ 3-pole Rear lighting system Under the right rear side cover Connector AK 2-pole Rear brake light switch Under the right rear side cover Connector AL 2-pole Pick up Between the water pipe and the front cylinder head Connector AL1 2-pole Clutch switch...
Page 359 13-107 Connector AM 3-pole Throttle sensor for the 2nd throttle Connector AM1 3-pole Throttle sensor On the throttle body Connector AM2 3-pole Gear sensor Connector AM3 3-pole Side stand switch On the left side of the engine in front of the generator cover Connector AM4 3-pole Fuel pump...
Page 360 13-108 Connector AP 6-pole Ignition switch Under the fuse box Connector AP1 6-pole Diagnosis connector Under the seat next to the ABS unit Connector AP2 6-pole Rollover sensor Behind headlight mask Connector AR 3-pole Throttle sensor 2nd throttle Connector AR1 3-pole Throttle sensor On the throttle body...
Page 361 13-109 Connector AR5 3-pole Speed sensor Behind headlight under connector support Connector AS 2-pole Rear ignition coil Behind the air filter box Connector AS1 2-pole Front ignition coil Behind the radiator Connector AT 2-pole Pick up Between the water pipe and the front cylinder head Connector AT1...
Page 362 13-110 Connector AT3 2-pole ABS connection Under the seat next to the ABS unit Connector AU 2-pole Controller On the right side of the battery case under the starter relay Connector AU1 2-pole Fan motor Behind the radiator on the right side of the fan Connector AV 2-pole Temperature switch for...
Page 363 13-111 Connector AZ 4-pole Rear turn signal Under the right rear side cover Connector BA 1-pole Octane selector Behind the air filter box Connector BB 9-pole Start/stop/light switch connector support under multifunctional digital speedometer Connector BC 6-pole Front light connector support under multifunctional...
Page 364 13-112 Connector BF 1-pole Octane selector Behind the air filter box Connector BH 6-pole Ignition switch Under the fuse box Connector BH1 6-pole Diagnosis connector Under the seat next to the ABS unit Connector BI 2-pole Controller On the right side of the battery case under the starter relay Connector BI1...
Page 365 13-113 Connector CA 4-pole Rear lambda probe On the left side of the air filter box Connector CA1 4-pole Front lambda probe On the right side of the frame Connector CA2 4-pole Control motor for the 2nd throttle On the throttle body Connector CE 4-pole Rear lambda probe...
Page 366 13-114 Connector CL 2-pole Rear injection valve On the throttle body Connector CL1 2-pole Front injection valve On the throttle body Connector CM 2-pole Air temperature sensor On the top of the air filter box Connector CO 34-pole ECU (Control unit) Under the headlight Connector CP 16-pole...
Page 367 13-115 Connector CR 1-pole Connector for attachments: Kl 15 (positive ignition) Kl 30 (continuous positive polarity) Kl 31 (ground) Behind the headlight under the connector support Connector CW 2-pole Left front turn signal Connector CX 2-pole Right front turn signal Under the front left side cover Connector CW1...
Page 368 13-116 Connector DN 8-pole ABS control lamp Behind the headlight Connector DO 8-pole ABS control lamp Behind the headlight Connector DP 3-pole Manifold air pressure sensor for the rear cylinder On the left side of the frame Connector DP1 3-pole Manifold air pressure sensor for the front cylinder...
Page 370 13-117...
Page 371 13-118 NOTE to the connector designations: The connector designations are comprised of letters and numbers - e.g.: C_AA1/20 – The 1st position C stands for connector (connector). – The 2nd and 3rd positions AA stand for the connector type. – The 4th position numbers the same type of connector if the connector is used for different applications.
Page 372 13-119...
Page 373 13-120 c t i c t i c t i o i t e l l e l l...
Page 374 13-121...
Page 375 13-122 c t i...
Page 376 13-123...
Page 377 13-124 c t i c t i...
Page 378 13-125...
Page 379 13-126 g i l c t i c t i c t i c t i...
Page 380 13-127...
Page 381 13-128...
Page 382 13-129...
Page 383 13-130...
Page 384 13-131 Connector AA 20-pole 11 1 Multifunctional digital speedometer Behind multi functional digital speedo meter 20 10 Connector AC 6-pole Ignition switch Behind headlight mask Connector AC1 6-pole Light/horn/stop switch Behind headlight mask Connector AF 4-pole Auxiliary starter relay Under the seat Connector AF1 4-pole Fuel pump relay...
Page 385 13-132 Connector AH 2-pole Rear brake light switch On the right side of the frame Connector AH1 2-pole Front brake light switch Behind headlight mask Connector AH2 2-pole Temperature switch for the carburetor heater Behind headlight mask Connector AH3 2-pole Flasher relay Behind headlight...
Page 386 13-133 Connector AJ 3-pole Rear lighting Under the seat in the back storage compartment Connector AJ1 3-pole Flasher switch Behind headlight mask Connector AK 2-pole Rear brake light switch On the right side of the frame Connector AK1 2-pole Front brake light switch Behind headlight mask...
Page 387 13-134 Connector AL 2-pole Pulse generator On the left between the tank generator cover Connector AL1 2-pole Fuel sender On the front left next to the radiator Connector AL2 2-pole Fuel pump On the front left next to the radiator Connector AL3 2-pole Clutch switch...
Page 388 13-135 Connector AM 3-pole Throttle sensor Between steering head and the ECU Connector AM1 3-pole Gear sensor On the left between the tank generator cover Connector AM2 3-pole Side stand switch On the left between the tank generator cover Connector AM3 3-pole Speed sensor Behind the headlight...
Page 389 13-136 Connector AR 3-pole Throttle sensor Between steering head and the ECU Connector AR1 3-pole Gear sensor On the left between the tank generator cover Connector AR2 3-pole Side stand switch On the left between the tank generator cover Connector AR3 3-pole Speed sensor Behind the headlight...
Page 390 13-137 Connector AT 2-pole Pulse generator On the left between the tank generator cover Connector AT1 2-pole Fuel sender On the front left next to the radiator Connector AT2 2-pole Fuel pump On the front left next to the radiator Connector AT3 2-pole Clutch switch...
Page 391 13-138 Connector AV 2-pole Temperature switch On the left side of the radiator Connector AW 2-pole Front EPC cylinder On the right side of the frame Connector AW1 2-pole Rear EPC cylinder Behind the air filter box Connector AX 2-pole Coolant temperature sensor On the left between the...
Page 392 13-139 Connector BA 1-pole Emergency off switch Behind headlight mask Connector BC 6-pole Ignition switch Behind headlight mask Connector BC1 6-pole Light/horn/stop switch Behind headlight mask Connector BF 1-pole Emergency off switch Behind headlight mask Connector BG 3-pole Rear lighting Under the seat in the back storage...
Page 393 13-140 Connector BJ 1-pole Oil pressure switch On the left side of the frame under filter box Connector BK 4-pole Rear flasher Under the seat in the back storage compartment Connector BK1 4-pole Tip switch Behind headlight mask Connector BL/BL1 2-pole Radiator fan On the left under the...
Page 394 13-141 Connector BW 3-pole Headlight Behind headlight mask Connector CD/CD1 2-pole Radiator fan On the left under the radiator hose Connector CR/CR1/CR2/CR3 1-pole Connector for attachments: Ground, continuous positive polarity, positive ignition Behind headlight mask Connector DI 2-pole Parking light On the headlight...

KTM 2003 950 Adventure Repair Manual

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