KTM 950 ADVENTURE 2003 Manual
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KTM 950 ADVENTURE 2003 Manual

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950 ADVENTURE
2003 to 2006

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Summary of Contents for KTM 950 ADVENTURE 2003

  • Page 1 950 ADVENTURE 2003 to 2006...

  • Page 2: Service-Informations

    1 SERVICE-INFORMATIONS 2 GENERAL INFORMATION 3 REMOVING AND REFITTING ENGINE 4 DISASSEMBLING ENGINE 5 SERVICING INDIVIDUAL COMPONENTS 6 ASSEMBLING ENGINE 7 ELECTRICAL 8 FUEL SYSTEM 9 TROUBLE SHOOTING 10 CHASSIS 11 TECHNICAL SPECIFICATIONS 12 PERIODIC MAINTENANCE SCHEDULE 13 WIRING DIAGRAMS...

  • Page 3: 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 the spraying nozzle (front timing chain) are supplied with oil through holes in the crankshaft.

  • Page 4: Intake System

    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.

  • Page 5: Secondary Air System

    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 6: 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 7: Specialtools - Chassis

    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 8 cm cn cs ct dk...

  • Page 9: Special Tools - Engine

    SPECIAL TOOLS – ENGINE PART NO DESCRIPTION 309098 Seal Three-Bond 0113 080802 Crankshaft locking bolt 151.12.017.000 Gear puller 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 590.29.026.006...

  • Page 10: Checking The Oil Level Of The Hydraulic Clutch

    Checking the oil level of the hydraulic clutch 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 . The oil level in the horizontal-standing master cylinder should be 4 mm below the upper edge.

  • Page 11: Removing And Refitting Engine

    REMOVING AND REFITTING ENGINE INDEX REMOVING THE ENGINE ........3-2 REFITTING THE ENGINE .
  • Page 12 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 13 – 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 14 – Disconnect the electric connections from the fan motor and the temperature switch – Drain the cooling liquid from the radiator and engine: see page 12-16. – 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 15 – 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 16 – 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 17: Refitting The Engine

    Refitting the engine – 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 18 – Mount the front oil line inserting new O-rings. Tighten the bolts. – Align the side supports and battery case against the engine, insert the bolt and mount the nut. – Mount the bolts ( M10x23), lifting the engine slightly if necessary. Tighten the nut and bolts to 40 Nm.
  • Page 19 – 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 110 Nm. –...
  • Page 20 3-10 – Screw on the radiator together with the fan and the radiator shield , tighten the bolts to 10 Nm. – Connect the water hoses on the radiator (special pliers 600.29.057.100) – Attach the electric connections for the fan motor and the temperature switch –...
  • Page 21 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 22 DISASSEMBLING THE ENGINE INDEX VALVE COVERS ..........4-2 SPARK PLUG SHAFT INSERTS .

  • Page 23: 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 24: 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 25 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 26: 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 the cylinder-head nuts crosswise. Special nut 600.29.083.000 is required for the inside nuts –...

  • Page 27: Camshafts Cylinder Front

    Camshafts cylinder front – Check and note down the valve clearance before you dismount the camshafts. Valve clearance: intake 0.125 - 0.175 mm exhaust 0.225 - 0.275 mm – Loosen the bolts on the camshaft bearing bridge from the front cylinder and carefully remove the camshaft bearing bridge.

  • Page 28: 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 29: 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 30 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.
  • Page 31 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 32: Generator Cover

    4-11 Generator cover – Loosen all of the bolts on the generator cover except the bolt on the starter idler shaft and remove the generator cover, being careful not to lose the dowel pins. Discard the gasket. NOTE: the rotor's magnetic retaining force will prevent the cover from being removed easily.

  • Page 33: Shift Mechanism

    4-12 Shift mechanism – Push the shift rail away from the shift locating drum and pull out the shift shaft – Remove the bolt from the shift locating drum. – Press the locking lever down to relieve the shift locating drum remove the shift locating drum.
  • Page 34 4-13 Transmission – Remove the oil rail for the transmission lubrication. It is secured at the bottom to keep it from twisting. – Pull out the shift rails together with the upper shift rail springs. – Tilt the shift forks to the side;...

  • Page 35: Oil Pumps

    4-14 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 36 SERVICING INDIVIDUAL COMPONENTS INDEX ROLLER BEARING ..........5-2 MAIN BEARINGS - GENERAL INFORMATION .
  • Page 37 Replacing the roller bearing – Remove all bearing locking screws from both case halves. – Remove all shaft seal rings and the dowel pins from the case halves. Heat both case halves evenly in an oven at 150° C; the roller bearings will fall out of the case by themselves.
  • Page 38 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. –...

  • Page 39: Replacing Bearing Shells, Output End

    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 40: Replacing The Conrod Bearings

    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 41 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 42: Overhauling The Water Pump

    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 43: Checking The Suction Pump For Wear

    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 44 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 45: Checking The Piston Ring End Gap

    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 46: Piston And Cylinder Identification

    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 47 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 48: Generator Cover

    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 49 5-14 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. Clutch springs must have a minimum length of 29.0 mm (new 30.77 mm). If necessary, replace all 6 at the same time. The clutch disks must be even.

  • Page 50: Shift Mechanism - Checking Parts For Wear

    5-15 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 51: General Information On Servicing The Transmission

    5-16 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 52: Assembling The Countershaft

    5-17 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 53: Checking The Freewheel

    5-18 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 54 ASSEMBLING THE ENGINE INDEX OIL PUMPS ..........6-2 TRANSMISSION .
  • Page 56 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 57 – 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 58 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 59 – Insert the crankshaft in the friction bearing. NOTE: – The crankshaft and 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 60: Aligning The Return Spring

    Shift mechanism – Mount the locking lever with the spring. Apply Loctite 243 to the M5x20 bolt and tighten to 8 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 61 – 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 62: Timing Chain And Balancing Weight

    Generator cover M6x30 – 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 10 Nm (see illustration for bolt lengths). M6x30 M6x35 M6x30 M6x35 M6x30 M6x30...

  • Page 63: Primary Pinion

    Primary pinion – Mount the woodruff key for the primary pinion in the shaft groove (if dismounted). – Mount the primary pinion with the longer collar facing the back. The pin for the ring gear must face outside. – Mount the gear wheel of the balancer shaft with the collar facing the back.

  • Page 64: Clutch Disks

    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 65 6-11 Clutch cover – Mount the dowel pins on the engine case and put M6x30 a new clutch cover gasket in place. M6x85 NOTE: remove the locking bolt to make it easier to M6x35 mount the clutch cover. M6x30 M6x30 M6x30 M6x30 M6x30...
  • Page 66 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 67: Cylinder Head Rear With Timing Chain

    6-13 Cylinder head rear with timing chain – Mount a new base gasket. NOTE: make sure the crankshaft is blocked in the cylinder rear TDC position. – Fit the timing chain and chain tensioning rail in the cylinder. NOTE: – The chain guide is mounted on the exhaust side of cylinder rear. –...
  • Page 68 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 69: Chain Tensioner Cylinder Rear

    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 70 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 71 6-17 Setting cylinder front to TDC – Loosen the crankshaft locking bolt and turn the 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 72 6-18 – Push the cylinder head and cylinder down. Mount the cylinder head nuts. 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 CAUTION...
  • Page 73 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 74 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 75 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 will point towards the inside and rest against the bucket tappet. The cams on the intake camshaft also point towards the inside, the bucket tappets are not actuated.
  • Page 76 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 77 ELECTRICAL INDEX CHECKING FOR LOSS OF CURRENT ......7-2 DISMOUNTING THE BATTERY ........7-2 CHARGING THE BATTERY .
  • Page 78 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 79: Electric Starter System

    start/stop switch start-relay orange 1 fuse C_BB/9 C_AB/9 10 A 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 NOTE: the starter system is equipped with a safety feature. You will only be able to start under the following conditions: –...
  • Page 80 Checking the auxiliary starter relay – Dismount the auxiliary starter relay NOTE: orange, yellow, red and white/red cable colors. – Connect the auxiliary starter relay (see drawing) to a 12 V battery, making sure you hear the relay switch (nonrecurring "click"). NOTE: the 12 V battery must be connected to the two terminals to which the orange and yellow cable colors are connected when the plug is connected.
  • Page 81 Checking the starter relay – Disconnect the negative pole from the battery and dismount the start relay. NOTE: white/red and brown cable colors. – 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 same terminals to which the 3 white/red and the brown cable are connected when the connector is attached.
  • Page 82 orange 1 start/stop switch pick up throttle position sensor orange 1 fuse fuse 5 A 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           B yellow-blue 0.5 page 2/9 yellow-white 0.5 blue 0.5 yellow 0.5 black 0.5           C blue-grey 0.5 page 7/9 pink 0.5 blue-white 0.5 black-brown 0.5 yellow-brown 0.5 grey 0.5 violet-white 0.5 brown-white 0.5 red-green 0.5 orange 0.5 C_AT/2 C_AR/3 C_AM2/3 C_AS1/2 C_AS/2...

  • Page 83: Checking The Fuel Pump Relay

    Check the cables and socket connectors on the ECU 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 on the lower photo).
  • Page 84 Troubleshooting in the ignition system Before checking the ignition, make sure: – the ignition lock is in the ON position – the emergency OFF switch is in the ON position – the battery is charged – the main fuse is OK –...
  • Page 85 orange 1 start/stop switch pick up throttle position sensor orange 1 fuse fuse 10 A 5 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           B yellow-blue 0.5 page 2/9 yellow-white 0.5 blue 0.5 yellow 0.5 black 0.5           C blue-grey 0.5 page 7/9 pink 0.5 blue-white 0.5 black-brown 0.5 yellow-brown 0.5 grey 0.5 violet-white 0.5 brown-white 0.5 red-green 0.5 orange 0.5 C_AT/2 C_AR/3 C_AM2/3 C_AS1/2 C_AS/2...
  • Page 86 7-10 Checking the solenoid valve for the EPC – 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 87: Fuel System

    FUEL SYSTEM INDEX KEIHIN CVRD 43 DESCRIPTION OF THE ACV (AIR CUT VALVE) SYSTEM ....8-3 DISASSEMBLING THE CARBURETOR ......8-4 ASSEMBLING THE CARBURETOR .
  • Page 88 CARBURATOR - KEIHIN CVRD 43...

  • Page 89: Description Of The Acv (Air Cut Valve) System

    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 90: Disassembling The Carburetor

    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 91 – 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 92 – 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 93: Assembling The Carburetor

    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 94 – 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 95 – 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 96 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 97 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 blue and yellow cables at the connector AM (under the fuse box).

  • Page 98: Troubleshooting

    TROUBLE SHOOTING INDEX TROUBLE SHOOTING ........10-2...
  • Page 99 REMEDY ERROR CAUSE Engine does not start when Operating error Switch on the ignition, switch the transmission to neutral, switch on the emergency OFF switch the starter button is actuated Battery is dead Charge battery and look for cause of discharging; replace defective parts IGNITION fuse is blown Replace the IGNITION fuse in the fuse box...
  • Page 100 REMEDY ERROR CAUSE Engine does not switch on EPC valve is not mounted correctly, Check the position of the EPC valve (near the oil dipstick): may not rest against the frame opens through vibrations Engine stalls while driving No fuel Refuel Open the fuel taps Operating error...
  • Page 101 10-1 CHASSIS INDEX REPLACING THE FRONT WHEEL BEARING ......10-2 REPLACING THE REAR WHEEL BEARING ......10-3 REPLACING THE FORK LEGS .

  • Page 102: Replacing The Front Wheel Bearing

    10-2 Replacing the front wheel bearing – 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. – Put a load on the vehicle tail to lift the front wheel off of the ground. –...

  • Page 103: Replacing The Rear Wheel Bearing

    10-3 Replacing the rear wheel bearing – 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. – Dismount the rear wheel (see Owner's Manual, page 31). –...

  • Page 104: Replacing The Fork Legs

    10-4 Replacing the fork legs – 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. – Put a load on the vehicle tail to lift the front wheel off of the ground. –...

  • Page 105: Replacing The Shock Absorber

    10-5 Replacing the shock absorber – 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 106: Replacing The Steering Head Bearing

    10-6 Replacing the steering head bearing – Dismount the fork legs (see page 10-4). – Unscrew the brake hose guides from the top and bottom triple clamp. – Remove the handlebar clamps and lay the handlebar back. NOTE: if the tanks and the tank compartment have not been removed, protect these parts from being damaged.

  • Page 107: Replacing The Swing Arm Bearing

    10-7 Replacing the swing arm bearing – 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. – Dismount the rear wheel (see Owner's Manual, page 31). –...

  • Page 108: Replacing The Chain, Pinion And Rear Sprocket

    10-8 Replacing the chain, pinion and rear sprocket – Jack up the motorcycle on the center stand 600.03.022.000, unscrew the left bump rubber and the lock the center stand with the locking device 600.29.055.000. – Unscrew the engine sprocket cover , bend up the lock washer and loosen the engine sprocket nut –...
  • Page 109 10-9 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 ADVENTURE model. 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 110: Technical Specifications

    11-1 TECHNICAL SPECIFICATIONS INDEX TECHNICAL SPECIFICATIONS –LC8 ENGINE ..... . .11-2 TECHNICAL SPECIFICATIONS –950 ADVENTURE CHASSIS ... .11-3 TOLERANCES, MOUNTING CLEARANCES –...
  • Page 111 11-2 TECHNICAL SPECIFICATIONS – LC8 2003 ENGINE Engine 950 LC8 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 112 11-3 TECHNICAL SPECIFICATIONS CHASSIS – 950 ADVENTURE/ADVENTURE S 2003 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 ADVENTURE = 230 mm, ADVENTURE S = 265 mm Rear suspension WP Progressive Damping System shock absorber with hydraulic preload adjuster, aluminum rear wheel swinging fork supported by needle bearings...
  • Page 113 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 114: Tolerances And Fitting Clearances

    11-5 TOLERANCES AND FITTING CLEARANCES COMPONENT MEASUREMENT/TEST ......SETPOINT VALUE . .TOLERANCE LIMIT Valves Valve shaft runout ...........max. 0.1mm Sealing seat width, intake .
  • Page 115 11-6 TOLERANCES AND FITTING CLEARANCES COMPONENT MEASUREMENT/TEST ......SETPOINT VALUE . . .TOLERANCE LIMIT Clutch Total height of disk package ....50.20 mm – 51.20 mm ..min. 48.0 mm Thickness of lining disks .

  • Page 116: Tightening Torques - Engine

    11-7 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 cylinder head 25 Nm /43 Nm AH bolts on cylinder head 18 Nm/23 Nm...

  • Page 117: Tightening Torques - Chassis

    11-8 TIGHTENING TORQUES – CHASSIS Collar bolt on front wheel spindle M24x1.5 60 Nm Collar nut wheel spindle rear M25x1.5 110 Nm AH bolt shock absorber top M14x1.5 100 Nm AH bolt shock absorber bottom M14x1.5 Loctite 243 + 45 Nm Collar nut for swing arm bolt M19x1.5 130 Nm...
  • Page 118 12-1 PERIODIC MAINTENANCE SCHEDULE INDEX PERIODIC MAINTENANCE SCHEDULE 950 ADVENTURE ... .12-2 MAINTENANCE WORK Changing the engine oil and the oil filter ......12-4 Cleaning the oil screens in the engine and oil tank .
  • Page 119 12-2 PERIODIC MAINTENANCE SCHEDULE 2003 950 ADVENTURE 7500 km 15000 1. Service km or after A washed motorcycle can be checked more quickly which saves money! once a every 2 1000 km year 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...
  • Page 120 12-3 PERIODIC MAINTENANCE SCHEDULE 2003 MPORTANT ECOMENDED AINTENANCE ROCEDURES ERFORMED ASED EPARATE UPPLEMENT RDER at least every 2 years or once a year 15000 km Perform complete fork maintenance Perform complete suspension strut 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 121 12-4 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 performing the following greasing and maintenance work, remove the engine guard, the seat and both tanks (see page 3-2).
  • Page 122 (see information on the can). 5W/40 10W/50 KTM recommends Motorex Power Synt 4T in the 10W/50 viscosity (for temperatures over 0°C) or 5W/40 (for temperatures under 0°C). – Fill approx. 2.7 liters of engine oil into the oil tank. The oil tank will be filled up to the top.

  • Page 123: Replacing The Spark Plugs

    12-6 Replacing the spark plugs NOTE: the carburetors are dismounted during the 15000 km inspection to check/adjust the valve clearance. This work is described in Chapter 3 and will not be described in detail at this point. – Disconnect the cable connectors ( ) from both ignition coils.

  • Page 124: Checking And Adjusting The Valve Clearance

    12-7 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 125: Checking The Clutch Lining

    12-8 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 126 12-9 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 127 12-10 LUBRICATION AND MAINTENANCE WORK – ADD-ON PARTS Checking the cooling system for leakage and the antifreeze concentration – Check the cooling liquid level in the radiator and in the compensating tank. Fill up if necessary (see Owner's Manual, page 37). –...

  • Page 128: Changing The Front Brake Fluid

    12-11 Changing the front brake fluid – Unscrew the cover on the brake fluid reservoir and remove together with the diaphragm – Use a syringe to extract the used brake fluid and add fresh DOT 5.1 brake fluid (Motorex Brake Fluid DOT 5.1). –...

  • Page 129: Changing The Rear Brake Fluid

    12-12 Changing the rear brake fluid – Unscrew the cover on the brake fluid reservoirs and remove together with the diaphragm – Use a syringe to extract the used brake fluid and add fresh DOT 5.1 brake fluid (Motorex Brake Fluid DOT 5.1). –...

  • Page 130: Cleaning The Dust Boots

    12-13 LUBRICATION AND MAINTENANCE WORK - CHASSIS Cleaning the dust boots – See Owner's Manual, page 25 Bleeding the fork legs – See Owner's Manual, page 25 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 131: Checking The Spoke Tension And Rim Run-Out

    12-14 LUBRICATION AND MAINTENANCE WORK - WHEELS Checking the spoke tension and rim run-out – Spoke nipple: 4 Nm +2/-1 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 132: Cleaning And Greasing The Steering Head Bearing And Sealing Elements

    12-15 LUBRICATION AND MAINTENANCE WORK – ADDITIONAL WORK Completely servicing the fork – Dismounting the fork legs: see page 10-4 – Maintenance: see WP-documentation Completely servicing the shock absorber – Dismounting the shock absorber: see page 10-5 – Maintenance: see WP-documentation Cleaning and greasing the steering head bearing and sealing elements –...

  • Page 133: Cleaning And Adjusting The Carburetor

    12-16 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 134 13-1 WIRING DIAGRAMS INDEX WIRING DIAGRAMS ........12-2 START SYSTEM .
  • Page 135 13-2...

  • Page 136: Cable Colours

    13-3 NOTE to the connector designations: The connector designations are comprised of letters and numbers - e.g.: C_AA/20 The 1st position C stands for connector (connector). The 2nd and 3rd positions AA stand for the connector type. The 4th and 5th positions 20 specify the number of pins in the connector, in this case 20 poles.
  • Page 137 13-4...
  • Page 138 13-5 start/stop switch cable harness cable switch START STOP clutch switch switch position pulled unpulled sidestand switch cable harness cable switch folded up folded down...
  • Page 139 13-6...
  • Page 140 13-7 ignition switch LOCKED...
  • Page 141 13-8...
  • Page 142 13-9 ignition switch LOCKED start/stop switch cable harness cable switch START STOP...
  • Page 143 13-10...
  • Page 144 13-11 ignition switch LOCKED flasher switch cable harness cable bu- bu- switch TURN L TURN R horn switch cable harness cable switch HORN...
  • Page 145 13-12...
  • Page 146 13-13 brake light switch cable harness cable switch pushed unpushed light switch cable harness cable wh wh switch LIGHT OFF P. LIGHT LIGHT high/low beam switch cable harness cable switch passing light cable harness cable switch P. HORN...
  • Page 147 13-14...
  • Page 148 13-15 brake light switch cable harness cable switch pushed unpushed light switch cable harness cable wh wh switch LIGHT OFF P. LIGHT LIGHT high/low beam switch cable harness cable switch passing light cable harness cable switch P. HORN...
  • Page 149 13-16...
  • Page 150 13-17 brake light switch cable harness cable switch pushed unpushed...
  • Page 151 13-18...
  • Page 152 13-19...
  • Page 153 13-20 Connector AA 20-pole Multifunctional digital speedometer Behind multi- functional digital speedometer 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 connector support under...
  • Page 154 13-21 Connector AG 3-pole Tachometer connector support under multifunctional digital speedometer Connector AH 2-pole Turn signal relay connector support under multifunctional digital speedometer Rear brake light switch Under the right rear side cover Left front turn signal Under the left front side cover Right front turn signal Under the right front...
  • Page 155 13-22 Connector AK 2-pole Rear brake light switch Under the right rear side cover Left front turn signal Under the left front side cover Right front turn signal Under the right front side cover Connector AL 2-pole Clutch switch Behind the headlight under connector support...
  • Page 156 13-23 Connector AN 4-pole Tripmaster switch Near connector support under multifunctional digital speedometer Connector AO 26-pole ECU (control unit) Under the fuse box behind the 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)
  • Page 157 13-24 Connector AS 2-pole Front ignition coil Behind the radiator Rear ignition coil Behind the air filter box Connector AT 2-pole Clutch switch Behind the headlight under connector support Pick up Between the water pipe and the front cylinder head Fuel sender Between the left tank and the frame...
  • Page 158 13-25 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 the air filter Connector AZ 4-pole Rear turn signal Under the right rear side cover...
  • Page 159 13-26 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 160 13-27 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 Regulator On the right side of the battery case under the starter relay Connector BJ 1-pole Oil pressure switch On the left frame under...

This manual is also suitable for:

950 adventure 2004950 adventure 2005950 adventure 2006

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