KTM 950 SUPER ENDURO R 950 Owner's Manual
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KTM 950 SUPER ENDURO R 950 Owner's Manual

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OWNER'S MANUAL
2006
950 SUPER ENDURO R
ART. NR. 3.211.172 EN

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Summary of Contents for KTM 950 SUPER ENDURO R 950

  • Page 1 OWNER’S MANUAL 2006 950 SUPER ENDURO R ART. NR. 3.211.172 EN...

  • Page 2: Introduction

    INTRODUCTION We would like to congratulate you on your purchase of a KTM motorcycle. You are now the owner of a state-of-the-art sport motorcycle that guarantees to bring you lots of fun and enjoyment, provided that you clean and maintain it appropriately.

  • Page 3: Important Information

    IMPORTANT INFORMATION INTENDED PURPOSE The KTM 950 Super Enduro R is designed to resist the usual wear and tear of onor off-road service, providing maximum perform- ance in competitive racing or private use. OWNER'S MANUAL Carefully read the entire Owner's Manual before you start riding your motorcycle, even if this will take a little time. It contains use- ful tips and information on the best way to handle the motorcycle and how to protect yourself from injuries.
  • Page 4 SPARE PARTS, ACCESSORIES For your own safety, only use spare parts and accessories approved by KTM. KTM shall not assume any liability for other products or consequential damage resulting from the use of such products.

  • Page 5: Table Of Contents

    GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE .......20 Instructions for initial operation ....20 Running in the LC8 engine .
  • Page 6 » INDEX Checking of brake fluid level - front brake ... . .42 Checking the front brake pads .....42 Checking rear brake fluid level .

  • Page 7: Serial Number Locations

    » SERIAL NUMBER LOCATIONS Chassis number, Type label The chassis number is stamped on the right side of the steering head tube. Enter this num- ber in the field on page no 1. The type label is located next to the chassis number. Engine number, engine type The engine number and the engine type are stamped into the left side of the engine below the engine sprocket.

  • Page 8: Operation Instruments

    » OPERATION INSTRUMENTS Clutch lever The clutch lever [1] is fitted on the left hand side of the handle bar. The adjusting screw [A] is used to change the original position of the clutch lever (see maintenance work on chassis and engine). The clutch is hydraulically actuated and adjusts itself automatically.

  • Page 9: Multi-Functional Digital Speedometer

    Use the MODE and SET [1] button to change the display and the basic settings in the dis- play. Display [2] shows all of the information that may be of interest to you. 5 display modes can be selected with the MODE button. The indicator lamps [3] provide additional information on the motorcycle's running condition. Display TEST...
  • Page 10 OPERATION INSTRUMENTS CLOCK TRIP 1 TRIP 2 TRIP F » CLOCK You will recognize the CLOCK display by the blinking dots between the hours and minutes. It displays the speed, temperature of the cooling liquid and the clock. To switch to the next display mode, press the MODE button. The speed, temperature of the cooling liquid and the total kilometers or miles traveled are shown in the ODO mode.

  • Page 11: Setting Options In The Display

    OPERATION INSTRUMENTS 10 sec » Setting options in the display KILOMETERS OR MILES. You can have the speed and distance shown in kilometers or miles in the display. The dis- play can be adapted to the respective country on long-distance trips. To switch from kilometers to miles, switch on the ignition and press the MODE [1] button for approx.
  • Page 12 » OPERATION INSTRUMENTS RESETTING TRIP 2 The trip meter 2 runs continuously and counts up to 999.9. It can be used similarly to TRIP 1 or together with a switch available as an accessory (see below) for trips according to a roadbook.

  • Page 13: Cooling Liquid Temperature Display

    OPERATION INSTRUMENTS 120°C (248°F) 110°C (230°F) 100°C (212°F) 70°C (158°F) 60°C (140°F) 50°C (122°F) 40°C (104°F) » Cooling liquid temperature display The temperature display [1] is shown in 7 bars. The more bars that light up, the hotter the cooling liquid. When the lowest bar lights up, the cooling liquid has reached a temperature of approx.

  • Page 14: Ignition Lock

    OPERATION INSTRUMENTS » Ignition lock The ignition lock [1] has 3 switching positions. Ignition off, (engine can't be started) Ignition on, light on, (engine can be started) Ignition off, handlebar blocked To switch the ignition to position turn the ignition key to position into the lock.

  • Page 15: Starter Tip Switch

    Fuel taps 2 fuel taps [4] are mounted on the fuel tank that must be open when the motorcycle is run- ning. The level in the fuel tanks is equalized by means of a connecting hose. The fuel pump stops running when the engine is switched off and fuel cannot flow to the carburetors so the fuel taps do not need to be closed when the motorcycle is switched off.

  • Page 16: Grips

    » OPERATION INSTRUMENTS Grips The grips [1] are used to maneuver the motorcycle. If carrying a passenger, the passenger can hold on to the grip during the ride. Removal of seat Actuate the lever [2] while lifting the back of the seat [3].

  • Page 17: Tool Set

    » OPERATION INSTRUMENTS Tool set The tool set [1] is located in the storage compartment under the seat. Shift lever The shift lever is mounted on the left side of the engine. The position of the gears is shown in the illustration. Neutral, or the idle speed, is located between first and second gear. 2,3,4,5,6 Side stand Fold the side stand [2] forward to the stop with your foot and put the weight of the motor-...

  • Page 19: Compression Damping Of Fork

    » OPERATION INSTRUMENTS Compression damping of fork The fork's damping action during compression travel (compression damping) can be adjusted. This allows you adjust the damping behavior to match your driving style and the payload. The adjusting screws [2] are located under the cap [1] on the lower end of the fork legs. More information is provided in the chapter "Adjusting the fork and shock absorber.“...

  • Page 20: Damping Action During Compression Of Shock Absorber

    The damping rate can be adjusted in the low and high-speed range (Dual Compression Control). The designation low and high-speed refers to the movement of the shock absorber and not to the motorcycle's driving speed. The adjusting screw [1] for the low-speed range can be adjusted with a screwdriver.

  • Page 21: General Tips And Warnings For Starting The Motorcycle

    GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE Instructions for initial operation – Make sure the work for the „pre-delivery inspection“ was performed by your author- ized KTM workshop. The DELIVERY CER- TIFICATE and SERVICE MANUAL will be handed over when you pick up your vehicle.

  • Page 22: Accessories And Payload

    – A passenger may only ride on the motor- cycle if passenger footrests are mounted. A passenger footrest system is available from your authorized KTM workshop as an accessory. The motorcycle is already approved for two seats. – Never leave your motorcycle without super- vision if the engine is running.

  • Page 23: Driving Instructions

    Arrange for the braking system to be checked by a KTM specialist, as com- plete failure of the braking system can be avoided.
  • Page 24 Insufficient oil results in premature wear and consequently to engine damage. 9 BAGGAGE, PAYLOAD Never exceed the maximum total weight (400 kg, 883 lbs) and the motorcycle's wheel loads. The maximum total weight is comprised of: – the motorcycle in a running condition and refueled (200 kg, 442 lbs) –...

  • Page 25: Starting When The Engine Is Cold

    If the engine is not switched off, engine damage will occur within a short period of time. Check the engine oil level or contact a ktm workshop. – Maximum period for continuous starting: 5 seconds. Wait at least 5 seconds before try- ing again.

  • Page 26: Starting When The Engine Is Warm Or Hot

    – If this is not the case, refill the tank – If sufficient fuel is in the tank, proceed as described in the „Trouble-shooting“ section or contact a KTM dealer. NOTE: This motorcycle is equipped with a safety start- ing system. The engine can only be started if the transmission is in neutral or the clutch lever is pulled.

  • Page 27: Braking

    Check the engine oil level or con- tact an authorized KTM workshop. – Never have the throttle wide open when changing down to a lower gear. The engine will overspeed, damaging the valves.

  • Page 28: Foot Brake Pedal

    DRIVING INSTRUCTIONS – In the rain, or after the motorcycle has been washed, braking action may be delayed due to wet brake discs. First, the brakes must be braked dry. – On salt-sprayed or dirty roads brake action may be delayed as well. First, the brakes must be braked clean.
  • Page 29 – Use unleaded fuel with at least RON 95 (USA = Premium RON 91). If using lower octane fuel, the ignition curve must be changed, otherwise engine damage will occur. – This motorcycle is equipped with a catalytic converter that will be destroyed if you use leaded fuel. Always use unleaded fuel.

  • Page 30: Periodic Maintenance Schedule

    IF MOTORCYCLE IS USED FOR COMPETITION 7500 KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE! Service intervalls should never be exceeded by more than 500 km (300 miles). Maintenance work performed by an authorized KTM workshop is not a substitute for care and maintenance by the driver!
  • Page 31 IF MOTORCYCLE IS USED FOR COMPETITION 7500 KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE! Service intervalls should never be exceeded by more than 500 km (300 miles). Maintenance work performed by an authorized KTM workshop is not a substitute for care and maintenance by the driver!
  • Page 32 IF MOTORCYCLE IS USED FOR COMPETITION 7500 KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE! Service intervalls should never be exceeded by more than 500 km (300 miles). Maintenance work performed by an authorized KTM workshop is not a substitute for care and maintenance by the driver!
  • Page 33 PERIODIC MAINTENANCE SCHEDULE 950 SUPER ENDURO R 2006 VITAL CHECKS AND CARE PROCEDURES TO CONDUCTED BY THE OWNER OR THE MECHANIC Check oil level Check brake fluid level Check brake pads for wear Check lighting system for proper operation Check horn for proper operation Lubricate and adjust actuating cables and nipples Bleed fork legs in regular intervals Clean chain...

  • Page 34: Maintenance Work On Chassis And Engine

    – Use special KTM screws with the correct thread length to fasten the spoiler to the tank. Mounting other screws or longer screws could puncture the tank and cause fuel to leak out.

  • Page 35: Adjusting The Fork And Shock Absorber

    There are a number of ways to adjust the fork and shock absorber to match the chassis to your driving style and the payload. We have provided a table with pragmatical values to help you tune up your motorcycle. These tune-up specifications are reference values only and should serve as a basis for your per- sonal chassis and suspension tuning.

  • Page 36: Adjusting Rebound Damping Of Fork

    MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting rebound damping of fork Hydraulic rebound damping determines the reaction when the fork is rebound. By turning the adjusting screw [1] (REB), the degree of damping of the rebound can be adjusted. Turn the knob clockwise to increase damping, turn it counterclockwise to reduce damping dur- ing rebounding.

  • Page 37: Compression Damping Of Shock Absorber

    (Dual Compression Control). Low and high speed refers to the movement of the shock absorber during compression and not to the speed of the motorcycle. The low and high-speed technology overlaps. The low-speed setting is primarily for slow to normal shock absorber compression rates.

  • Page 38: Rebound Damping Of Shock Absorber

    Breathing the fork legs Breath the fork legs regularly (see Maintenance Schedule). To breath, place the motorcycle on the side stand and briefly remove the bleeder screws [2] to allow any overpressure to escape from the fork. Excessive pressure in the interior of the fork can cause leaks in the fork. If your fork is leak- ing, it is recommended to open the breather plugs before having the seals replaced.

  • Page 39: Checking The Chain Tension

    If you don’t happen to have a torque wrench at hand, make sure you have the tightening torque corrected by a KTM dealer as soon as possible. A loose wheel spindle can cause the motorcycle's handling performance to become instable and cause it to crash.

  • Page 40: Chain Maintenance

    – The chain does not have a chain joint for safety reasons. Always have the chain replaced in an authorized KTM workshop where the service technicans have the required riveting tool. – Never mount a normal chain joint.

  • Page 41: General Informations About Ktm Disc Brakes

    Brake pads available in the accessory trade are often not authorized for operation of your KTM motorcycle in road traffic. The brake pads design and friction factor and therefore the braking power can deviate significantly from original KTM brake pads. If you use different brake pads than those provided with the original equipment, it cannot be warranted that they are authorized for use in road traffic.
  • Page 42 In this case, consult an authorized KTM dealer immediately. BRAKE FLUID: KTM fills the brake systems with Motorex Brake Fluid DOT 5.1 brake fluid, one of the best brake fluids that is currently available. We recommend that you continue to use it. DOT 5.1 brake fluid is based on glycol ether and of an amber color.

  • Page 43: Adjusting Of Free Travel At The Hand Brake Lever

    – If the brake fluid level drops below the minimum either the brake system has a leak or the brake pads are completely worn down. In this case, consult an authorized KTM dealer immediately.

  • Page 44: Checking Rear Brake Fluid Level

    – If the brake fluid level drops below the minimum either the brake system has a leak or the brake pads are completely worn down. In this case, consult an authorized KTM dealer immediately.

  • Page 45: Dismounting And Mounting The Front Wheel

    MAINTENANCE WORK ON CHASSIS AND ENGINE Dismounting and mounting the front wheel Jack the motorcycle up at the underride protection until the front wheel no longer touches the ground. Loosen the 2 clamping screws [2] on the left side of the fork fists.
  • Page 46 – If you do not have a torque wrench to mount the wheel, have the torques corrected by an authorized KTM workshop as soon as possible. A loose wheel spindle can cause the motorcycle's handling performance to become instable and cause it to crash.

  • Page 47: Dismounting And Mounting The Rear Wheel

    MAINTENANCE WORK ON CHASSIS AND ENGINE Dismounting and mounting the rear wheel Jack the motorcycle up at the underride protection until the rear wheel no longer touches the ground. Unscrew the collar nut [1], remove the chain tensioner [2], hold on to the rear wheel while you pull out the axle passage [3].
  • Page 48 – If you don’t happen to have a torque wrench at hand, make sure you have the tighten- ing torque corrected by a KTM dealer as soon as possible. A loose wheel spindle can cause the motorcycle's handling performance to become instable and cause it to crash.

  • Page 49: Tires, Air Pressure

    Proper pressure ensures optimum driving comfort and extends the life of your tires. – Do not mount tires which have not been approved by KTM. Other tires could have adverse effects on the way your motorcycle rides.

  • Page 50: Checking Spoke Tension

    A clear tone must be the result. Dull tones indicate loose spokes. If necessary, have the spokes retightened and the wheel centered by a KTM dealer. – If you continue to drive with loose spokes, the spokes can tear and lead to an instable handling performance.

  • Page 51: Battery

    The charge condition and type of charge are very important for the battery's service life. Never operate the motorcycle with a run-down battery or without the battery. This can dam- age the electronic components or safety equipment in either caseand the motorcycle will no longer be roadworthy.

  • Page 52: Charging The Battery

    Always use special charging devices to charge maintenance-free batteries, e.g. the KTM charg- ing device (item no. 58429074000). You can also use this charging device to test the off- load voltage and startability of the battery and generator.

  • Page 53: Main Fuse

    If a new fuse that has just been set in gets blown again, you are strongly advised to have it inspected by a KTM dealer. The fuse capacity is 30 Ampere. – Under no circumstances is a stronger fuse allowed to be set in or a fuse allowed to be „repaired“.

  • Page 54: Fuses For Individual Power Consumers

    Replace a blown fuse only with an equivalent one. If a new fuse that has just been set in gets blown again, you are strongly advised to have it inspected by a KTM dealer. Under no circumstances is a stronger fuse allowed to be set in or a fuse allowed to be “repaired”.

  • Page 55: Replacing The Headlight Lamp

    » MAINTENANCE WORK ON CHASSIS AND ENGINE Replacing the headlight lamp Remove the screws [1], tilt the headlight mask up towards the front and detach at the bottom. Never touch the glass of the bulb with your fingers. The glass of the bulb must remain absolutely free from grease.

  • Page 56: Adjusting The Headlight Range

    Position your motorcycle loaded ready for the trip 5 meters (16,4 ft) away from the wall and switch on the low beam. The light/dark cut-off line should be 5 cm (2 in) under the mark (see drawing).

  • Page 57: Replacing The Brake Light And Taillight Bulbs

    » MAINTENANCE WORK ON CHASSIS AND ENGINE Replacing the brake light and taillight bulbs Remove the seat. Remove the screws on the grips [1] and the upper rear [2] and take off the parts. BULB FOR BRAKE LIGHT: Turn the bulb socket [3] approx. 30° in a counterclockwise direction and pull it out of the taillight housing.

  • Page 58: Activating The Ignition Curve For Low-Octane Fuel

    » MAINTENANCE WORK ON CHASSIS AND ENGINE Activating the ignition curve for low-octane fuel If you are traveling to a country where fuel having at least 95 octane (RON) is not available, you can easily activate the corresponding ignition curve. A socket connector [1] is located on a brown-black cable under the fuse box.

  • Page 59: Cooling System

    If the fan is not working, and there appears to be sufficient cool- ing liquid, the only thing you can do is to drive on to your nearest authorized KTM work- shop at the least possible engine load.

  • Page 60: Checking The Cooling Liquid Level In The Compensating Tank

    If you need to add cooling liquid quite often, the cooling system may leak. If the compen- sating tank is empty, also check the cooling liquid level in the radiator. Have the cooling system checked by an authorized KTM workshop. »...

  • Page 61: Checking The Cooling Liquid Level In The Radiator

    – Only continue to drive if there is enough cooling liquid in the system. Contact an author- ized KTM workshop to have the error eliminated. You will damage the engine if you con- tinue to drive when the cooling liquid temperature warning lamp is on.

  • Page 62: Bleeding The Cooling System

    » MAINTENANCE WORK ON CHASSIS AND ENGINE Bleeding the cooling system To completely bleed the cooling system, the motorcycle must be raised approx. 50 cm (20 in) in the front. Remove the radiator cap [1] and bleeder screw [2]. Add cooling liquid until it runs out of the vent holes without bubbles and immediately mount the screw to prevent air from entering the radiator.

  • Page 63: Changing The Original Position Of The Clutch Lever

    KTM uses biodegradable, hydraulic mineral oil to actuate the hydraulic clutch. Do not mix this oil with any other hydraulic oil. Always use original KTM hydraulic oil (available from your authorized KTM workshop) to make sure your clutch operates smoothly. Never refill with...

  • Page 64: Checking And Adjusting The Throttle Cable Play

    » MAINTENANCE WORK ON CHASSIS AND ENGINE Checking and adjusting the throttle cable play You should feel 3-5 mm free travel on the throttle grip when you start to turn it. To adjust, loosen the counternut [2], turn the adjusting screw [3] as required and tighten the counternut again.

  • Page 65: Engine Oil

    Only use fully synthetic engine oils that meet the JASO MA quality requirements (see infor- mation on the can). KTM recommends Motorex Power Synt 4T in the 10W/50 viscosity (for temperatures over 0°C, 32°F) or 5W/40 (for temperatures under 0°C, 32°F).

  • Page 66: Changing The Engine Oil And The Oil Filter Cleaning The Oil Screen

    Since many parts must be demounted for an oil change, we recommend having the engine oil changed by an authorized KTM workshop. During the guaranty period, the oil change must be performed by an authorized KTM mechanic. Otherwise, the guarantee will become void.
  • Page 67 » MAINTENANCE WORK ON CHASSIS AND ENGINE Remove the drain plug [1] from the oil tank and allow the oil to drain into a vessel. Remove the screws [2] and tilt the connector [3] to the side. Carefully pull the oil screen [4] out of the oil tank. Thoroughly clean the drain plugs, the cover and both oil screens.
  • Page 68 O-ring. Tighten the screws to 6 Nm. Only use original ktm oil filters. The engine can be damaged if other filters are used. Mount the oil drain plug on the oil tank with a new seal ring and tighten to 20 Nm.

  • Page 69: Troubleshooting

    We would like to point out that many operations cannot be performed by oneself. In case of uncertainty, please contact a KTM-dealer.
  • Page 70 Check vacuum hoses and venting hoses of carburetors for correct position (no kinks) Have the air filter replaced at an authorized KTM workshop. Activate the ignition curve for 95 octane, if fuel with at least RON 95 (USA = Premium PON 91) is being used...
  • Page 71 Time is not displayed or not cor- Blown fuse, thus no continuous rectly displayed power supply REMEDY Contact an authorized KTM workshop. Refuel Open fuel taps Replace fuse FUEL PUMP Replace fuse ACC2 Check engine oil level when the engine is warm; correct if necessary Use thicker engine oil;...
  • Page 72 Recharge the battery according to the relevant instructions. Voltage regulator and generator should be checked by an authorized KTM workshop. Replace fuse HORN BRAKELIGHT SPEEDO. Check the pickup cable for damage, remove the headlight mask and check the cable connectors. Contact an authorized KTM workshop.

  • Page 73: Cleaning

    (e.g. Motorex 900) and cleaned with a brush. – After the motorcycle has been rinsed with a soft water jet, it should be dried by air pressure and a cloth. Then take a short drive until the engine has reached the working temperature and also use the brakes.

  • Page 74: Conservation For Winter Operation

    CONSERVATION FOR WINTER OPERATION In the event that the motorcycle is also used in winter and on roads where one has to expect salt spraying, you will have to take precautions against the aggressive road salt. – clean motorcycle thoroughly and let it dry –...

  • Page 75: Storage

    – Take a short, careful test ride first. NOTE: Before you put your motorcycle away for the winter, you have to check all parts for their function and wear. Should any service jobs, repairs, or any refitting be necessary, you should have them carried out during the off-season (lower workload a mechanics’ shops). This...

  • Page 76: Technical Specifications – Chassis

    TECHNICAL SPECIFICATIONS – CHASSIS CHASSIS 950 SUPER ENDURO R Frame tubular chrome-molybdenum-steel space frame Fork WP Suspension – Up Side Down 4860 MXMA PA Wheel travel front 250 mm (9.8 in) WP Suspension - Progressive Damping System shock absorber 4618 BAVP Rear suspension Wheel travel rear 255 mm (10 in)
  • Page 77 TECHNICAL SPECIFICATIONS – CHASSIS CHASSIS 950 SUPER ENDURO R Battery 12V 11.2 Ah maintenance-free Steering head angle 64.4° Wheel base 1577 ± 10 mm (62 in) Seat height, unloaded 965 mm (38 in) Ground clearance, unloaded 330 mm (13 in) Dry weight 190 kg (419.4 lbs) Max.
  • Page 78 TECHNICAL SPECIFICATIONS – CHASSIS TIGHTENING TORQUES – CHASSIS 950 SUPER ENDURO R 2006 Collar bolt on front wheel spindle Collar nut wheel spindle rear AH bolt shock absorber top/bottom Collar nut for swing arm bolt AH bolts on subframe AH bolts on back of footrest support Engine carrier bolts HH clamp bolts on top triple clamp HH clamp bolts on bottom triple clamp...
  • Page 79 TECHNICAL SPECIFICATIONS – CHASSIS TIGHTENING TORQUES – CHASSIS 950 SUPER ENDURO R 2006 Bolt for side stand switch Drain plug on oil tank Exhaust nuts on manifold Exhaust clamp Senkschraube Hitzeschutzblech HH bolt on fuel level indicator HH bolts fuel taps Collar screw for underride protection Spoke nipple Jerk damper bolt rear wheel...

  • Page 80: Technical Specifications – Engine

    TECHNICAL SPECIFICATIONS – ENGINE ENGINE 950 LC8 Design liquid-cooled, 2-cylinder 4-stroke engine with 75° V arrangement with balancer shaft and electric starter Displacement 942 cc Bore / Stroke 100/60 mm Compression ratio 11.5:1 Fuel unleaded fuel with at least RON 95 (USA: Premium PON 91*) Valve timing 4 valves controlled over bucket tappet and 2 camshafts, camshaft drive with gears/chain Valve diameter...

  • Page 81: Engine Oil

    Only use fully synthetic engine oils that meet the JASO MA quality requirements (see infor- mation on the can). KTM recommends Motorex Power Synt 4T in the 10W/50 viscosity (for temperatures over 0°C, 32°F) or 5W/40 (for temperatures under 0°C, 32°F).

  • Page 82: Head Word Index

    Fuses for individual power consumers ....53 General informations about KTM disc brakes ... . .40 General tips and warnings for starting the motorcycle .
  • Page 83 » HEAD WORD INDEX Ignition lock ........13 Important information .
  • Page 86 04/2006 FOTO: MITTERBAUER KTM Group Partner KTM Sportmotorcycle AG A–5230 Mattighofen www.ktm.at...

This manual is also suitable for:

950 super enduro r 2006

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