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KTM Manuals
Motorcycle
950 Supermoto/R
Repair manual
KTM 950 Supermoto/R Repair Manual
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Table Of Contents
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Important Information/Updating Instructions
Storing the Repair Manual in the Binder
General Information
Oil System
Intake System
Secondary Air System
Cooling System
Closed Thermostat
Open Thermostat
ABS (Antilock Brake System)
ABS Warning Lamp
ABS Button
Special Tools – Engine
Special Tools – Chassis
Checking the Oil Level of the Hydraulic Clutch
Bleeding of the Hydraulic Clutch
Resetting the Control Unit after Replacing/Repairing the Engine
Adjusting the Throttle Cable for Models with Fuel Injection
ECU Software Update/Mapping
Starting the DMT (Data Maintenance Tool)
Starting the FAN (Flash Download System)
Checking the Oil Pressure
Table of Contents
Removing and Refitting Engine
Removing the Engine - 950 Adventure
Refitting the Engine - 950 Adventure
Removing the Engine - 990 Adventure
Refitting the Engine
Dismounting the Engine - 990 Super Duke
Mounting the Engine - 990 Super Duke
Dismounting the Engine - 990 Super Duke R
Removing the Engine - 990 Supermoto
Refitting the Engine - 990 Supermoto
Disassembling the Engine
Valve Covers
Spark Plug Shaft Inserts
Starter Motor
Setting Cylinder Rear to TDC
Camshafts Cylinder Rear
Chain Tensioner Cylinder Rear
Timing Chain Cylinder Rear
Setting Cylinder Front to TDC
Double Timing Gear
Cylinder Head Rear with Cylinder
Camshafts Cylinder Front
Oil Pressure Switch
Chain Tensioner Cylinder Front
Timing Chain Cylinder Front
Cylinder Head Front with Cylinder
Water Pump
Oil Screen
Clutch Cover
Clutch
Primary Pinion and Clutch
Rotor
Freewheel
Balancer Shaft
Shift Mechanism
Engine Case Half
Transmission
Oil Pumps
Servicing Individual Components
Replacing the Roller Bearing
Replacing the Main Bearings-General Information
Replacing Bearing Shells, Output End
Replacing Bearing Shells, Generator End
Replacing the Conrod Bearings
Selecting the Bearing Shells
Replacing the Supporting Bearings in the Clutch Cover
Overhauling the Water Pump
Checking the Pressure Pump for Wear
Checking the Suction Pump for Wear
Disassembling the Cylinder Head and Checking Parts for Wear
Sealing Area
Valve Seats
Valve Guides
Checking the Pistons
Checking the Piston Ring End Gap
Assembly Instructions for Piston Rings
Measuring Pistons and Cylinders, Establishing the Piston Mounting Clearance
Assembling the Cylinder Head
Piston and Cylinder Identification
Generator Cover
Torque Limiter
Valve Gear – Checking Parts for Wear
Preassembling the Spreader Drive
Clutch – Checking Parts for Wear
Shift Mechanism – Checking Parts for Wear
Preassembling the Shift Shaft
Assembling the Main Shaft
General Information on Servicing the Transmission
Assembling the Countershaft
Checking the Freewheel
Replacing the Freewheel Hub
Starter
Assembling the Engine
Axial Clearance of the Main Shaft
Case Half
Aligning the Return Spring
Timing Chain and Balancing Weight
Outer Clutch Hub
Primary Pinion
Clutch Disks
Water Pump
Cylinder Head Rear with Timing Chain
Electrical
Abs-System
Checking for Loss of Current
Checking the Charging Voltage / Rectifier Regulator
Checking the Generator Coils
Electric Starter System 950 Adventure
Electric Starter System 990 Super Duke/R
Electric Starter System 950 Supermoto/R, 950 Super Enduro
Electric Starter System 990 Adventure -2007
Starting System 990 Adventure 2007-
Starting System 990 Supermoto
Checking the Auxiliary Starter Relay
Functional Check of the Auxiliary Starter Relay (950 Adventure)
Functional Check of the Auxiliary Start Relay (990 Adventure/ 990 Super Duke/R)
Functional Check of the Auxiliary Start Relay (950 Supermoto/R, 990 Supermoto)
Checking the Diodes
Checking the Starter Relay
Checking the Starter Motor
Checking the Clutch Switch
Checking the Tip Switch and Emergency off Switch
Troubleshooting in the Starter System
Ignition System, ECU 950 Adventure
Ignition System, ECU 950 Supermoto
Ignition System, ECU 950 Super Enduro
Checking the Pulse Generator 950 Adventure/950 Supermoto
ECU 950 Adventure/Supermoto/Super Enduro
Checking the Fuel Pump Relay 950 Adventure/950 Supermoto
Checking the Ignition Coils 950 Adventure/Supermoto/Super Enduro
Troubleshooting in the Ignition System 950 Adventure/950 Supermoto
The EPC System 950 Adventure
The EPC System 950 Supermoto/R
EPC System 950 Super Enduro
Checking the Solenoid Valve for the EPC 950 Adventure, 950 Supermoto/R, 950 Super Enduro
Checking the Gear Sensor 950 Adventure, 950 Supermoto/R, 950 Super Enduro
Checking the Temperature Switch
Checking the Heating Elements
Adventure Carburetor Heater 950 Adventure, 950 Supermoto/R, 950 Super Enduro
Injection/Ignition System
Establishing the Injection Period (Injection Volume)
Correction Sensors and Inputs
System Diagram
Wiring Diagram 990 Super Duke
Schaltplan 990 Super Duke R
Wiring Diagram 990 Supermoto
Wiring Diagram 990 Adventure -2007
Wiring Diagram 990 Adventure 2007-
Block Diagram
Description of the Electric System
Fuel Pump Relay
Main Relay
Sensors
Description of the Components
Fuel Pump
Pressure Regulator
Injection Valves
Sensor for the 2Nd Throttle Valve
Manifold Air Pressure Sensor
Throttle Valve Sensor
Ambient Air Pressure Sensor
Pulse Generator (Crankshaft)
Lambda Probes
Catalytic Converter
Idle Speed Control Motor
Servomotor for the 2Nd Throttle Valve
Octane Selector Connections (990 Adventure Only)
Secondary Air Valve
Ignition Coils
Roll Angle Sensor
Diagnostics Connector
Side Stand Switch
Clutch Switch
Safety against Failure/Emergency Operation
Component Tests
Coolant Temperature Sensor
Air Temperature Sensor
Intake Pressure Sensors
Sensor for 2Nd Throttle Valve
Pulse Generator
Control Motor for the 2Nd Throttle Valve
Gear Sensor (Neutral, 2, 3)
Error Lamp
Speed Signal
Coolant Temperature Signal
Diagnostics Line
Abbreviations, Limit Values 990 Super Duke/R
Abbreviations, Limit Values 990 Adventure / 990 Supermoto
Alarm System for 990 Super Duke/R (Optional)
Order for Additional Hand-Held Transmitters
Adapting the Hand-Held Transmitter
Starting with the Emergency Code
ABS System 990 Adventure
Checking the Fuses
Checking the ABS Fault Memory Using the KTM Diagnostics Tool
Checking the ABS Sensor with the KTM Diagnostics Tool
Fuel System
Carburator - Keihin Cvrd 43
Description of the ACV (Air Cut Valve) System
Disassembling the Carburetor
Assembling the Carburetor
Adjusting the Float Level
Adjusting the Idle Mixture Control Screw
Checking the Throttle Sensor
Adjusting the Throttle Sensor
Adjusting the Choke Cable
Adjusting the Throttle Cable (Carburetor Models Only)
Carburetor Heater
Replacing the Fuel Filter
Dismounting/Mounting the Throttle Body
Dismounting/Mounting the Fuel Pump with Pressure Regulator
Checking the Fuel Pressure
Trouble Shooting
Chassis
Dismounting/Mounting the Front Wheel
Dismounting/Mounting the Rear Wheel
Replacing the Front Wheel Bearing
Replacing the Rear Wheel Bearing
Replacing the Front Brake Pads (950/990 Adventure)
Replacing the Rear Brake Pads (990 Super Duke/R)
Replacing the Fork Legs
Replacing the Shock Absorber (950/990 Adventure)
Replacing the Steering Head Bearing
Replacing the Swing Arm Bearing
Replacing the Chain, Pinion and Rear Sprocket
Opening the Chain with a Separating/Rivet Tool
Riveting the Chain
Replacing the Rear ABS Sensor
Replacing the Front ABS Sensor
Replacing the ABS Unit
Technical Specifications
Technical Specifications – Engine 950 Adventure
Basic Carburetor Setting
Technical Specifications – Chassis 950 Adventure/Adventure S
Technical Specifications – Engine 990 Super Duke / Super Duke R
Technical Specifications – Chassis 990 Duke / Super Duke R
Technical Specifications – Engine 950 Supermoto / Supermoto R
Technical Specifications – Chassis 950 Supermoto / Supermoto R
Technical Specifications – Engine 990 Adventure
Technical Specifications – Chassis 990 Adventure/Adventure S
Technical Specifications – Engine 990 Supermoto
Technical Specifications – Chassis 990 Supermoto
Technical Specifications – Engine 950 Super Enduro
Technical Specifications – Chassis 950 Super Enduro
Tolerances and Fitting Clearances
Tightening Torques – Engine
Tightening Torques – Chassis
Periodic Maintenance Schedule
Lubrication and Maintenance Work - Engine
Engine Oil
Checking the Engine Oil Level
Replacing the Spark Plugs
Checking and Adjusting the Valve Clearance
Number/Thickness of the Demounted Compensating Washer (Shim) in MM
Checking the Clutch Lining
Checking the Clutch Pressure Booster System
Cleaning the Oil Jet for the Clutch Lubrication
Checking the Idle Setting (950 Adventure)
Check the Carburetor Synchronization with an Vacuum Gauge and Adjust if Necessary
Lubrication and Maintenance Work – Carburetor
Lubricating the Cables
Checking the Idle Setting (950 Supermoto/Super Enduro)
Lubrication and Maintenance Work – Add-On Parts
Lubrication and Maintenance Work - Injection
Changing the Front Brake Fluid
Changing the Rear Brake Fluid
Lubrication and Maintenance Work - Chassis
Checking/Adjusting the Steering Head Bearing
Lubrication and Maintenance Work - Wheels
Checking the Spoke Tension and Rim Run-Out
Completely Servicing the Shock Absorber
Lubrication and Maintenance Work – Additional Work
Changing the Cooling Liquid
Wiring Diagrams
Multifunctional Digital Speedometer
Start/Stop/Light Switch
Front Light
Light/Turn Signal/Horn Switch
Left Front Turn Signal
Tachometer
Rear Brake Light Switch
Turn Signal Relay
Diode Neutral Switch
Diode Side Stand Switch
Rear Lighting
Right Front Turn Signal
Gear Sensor
Carburetor Potentiometer
Pick up
Tripmaster Switch
ECU (Control Unit)
Ignition Lock
Connector for Auxiliary Devices
Speed Sensor
Rear Ignition Coil
Fuel Sender
EPC Front Cylinder
Temperature Switch for the Radiator Fan
Regulator
Radiator Fan Motor
Temperature Sensor for the Multifunctional Digital Speedometer
Rear Turn Signal
Octane Selector
990 Super Duke 2005/06 Wiring Diagram
Battery Generator Starter Diagram
ECU Diagram
Turn Signal, Horn, Fan Diagram
Light-Brake System Diagram
Instruments-Tachometer Diagram
Ground Connection
Positive Connection
Controller Outlet
Temperature Switch
Front EPC
950 Super Enduro 2006/07 Diagram
950 Super Enduro 2007-2008 Wiring Diagram
990 Supermoto 2008 Diagram
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See also:
Owner's Manual
REPAIRMANUAL2003-2008
950/990 ADVENTURE
990 SUPER DUKE/R
950/990 SUPERMOTO/R
950 SUPER ENDURO
REPARATURANLEITUNG
MANUALE DI RIPARAZIONE
MANUEL DE RÉPARATION
MANUAL DE REPARACIÓN
Table of
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Table of Contents
Troubleshooting
Checking the tip switch and emergency OFF switch
153
Troubleshooting in the ignition system 950 Adventure/950 Supermoto
159
Trouble shooting
216
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