KTM 2003 950 SuperMoto Manuals

Manuals and User Guides for KTM 2003 950 SuperMoto. We have 1 KTM 2003 950 SuperMoto manual available for free PDF download: Repair Manual

KTM 2003 950 SuperMoto Repair Manual

KTM 2003 950 SuperMoto Repair Manual (395 pages)

Brand: KTM | Category: Motorcycle | Size: 25.58 MB

Table of Contents

Table of Contents
5
Updating Instructions
7
Introduction
11
General Information Index
15
Oil System
17
Intake System
18
Secondary Air System
19
Cooling System
20
Closed Thermostat
20
Open Thermostat
20
ABS (Antilock Brake System)
21
ABS Warning Lamp
21
ABS Button
21
Special Tools - Engine
22
Chassis
24
Checking the Oil Level of the Hydraulic Clutch
25
Bleeding of the Hydraulic Clutch
25
Resetting the Control Unit after Replacing/Repairing the Engine
26
Adjusting the Throttle Cable for Models with Fuel Injection
27
ECU Software Update/Mapping
28
Downloading the Software
28
Starting the DMT (Data Maintenance Tool)
29
Starting the FAN (Flash Download System)
29
Checking the Oil Pressure
30
Removing and Refitting Engine Index
31
Removing the Engine
33
Refitting the Engine - 950 Adventure
38
Dismounting the Engine - 990 Super Duke
43
Mounting the Engine - 990 Super Duke
44
Dismounting/Mounting the Engine - 950 Supermoto
51
Removing the Tank
51
Disassembling the Engine Index
53
Table of Contents
53
Valve Covers
55
- Spark Plug Shaft Inserts
  55
- Starter Motor
  55
- Camshafts Cylinder Rear
  56
Setting Cylinder Rear to TDC
56
Timing Chain Cylinder Rear
57
Chain Tensioner Cylinder Rear
57
- Cylinder Head Rear with Cylinder
  58
- Setting Cylinder Front to TDC
  58
Double Timing Gear
58
- Oil Pressure Switch
  59
- Chain Tensioner Cylinder Front
  59
Camshafts Cylinder Front
59
Cylinder Head Front with Cylinder
60
Timing Chain Cylinder Front
60
- Clutch Cover
  61
- Oil Screen
  61
Water Pump
61
Clutch
62
Primary Pinion and Clutch
63
Rotor
64
Generator Cover
64
- Balancer Shaft
  65
- Shift Mechanism
  65
Freewheel
65
Engine Case Half
66
Transmission
67
Oil Pumps
68
- Servicing Individual Components Index
  69
- Replacing the Roller Bearing
  71
- Replacing the Main Bearings-General Information
  72
- Replacing Bearing Shells, Output End
  73
- Replacing Bearing Shells, Generator End
  73
- Replacing the Conrod Bearings
  74
- Selecting the Bearing Shells
  74
- Replacing the Supporting Bearings in the Clutch Cover
  75
- Overhauling the Water Pump
  76
- Checking the Suction Pump for Wear
  77
- Checking the Pressure Pump for Wear
  77
- Bypass Valve
  77
- Valves
  78
- Sealing Area
  78
- Valve Seats/Guides/Springs
  78
- Disassembling the Cylinder Head and Checking Parts for Wear
  78
- Checking the Pistons
  79
- Checking the Piston Ring End Gap
  79
- Assembly Instructions for Piston Rings
  79
- Measuring Pistons/Cylinders, Establishing Piston Mounting Clearance
  79
- Piston and Cylinder Identification
  80
- Assembling the Cylinder Head
  80
- Torque Limiter
  82
- Valve Gear – Checking Parts for Wear
  82
- Preassembling the Spreader Drive
  83
- Clutch – Checking Parts for Wear
  84
- Shift Mechanism – Checking Parts for Wear
  85
- Preassembling the Shift Shaft
  85
- General Information on Servicing the Transmission
  86
- Assembling the Main Shaft
  86
- Assembling the Countershaft
  87
- Checking the Freewheel
  88
- Replacing the Freewheel Hub
  88
- Starter
  88
- Assembling the Engine Index
  89
- Axial Clearance of the Main Shaft
  92
- Case Half
  94
- Aligning the Return Spring
  95
- Freewheel
  96
- Timing Chain and Balancing Weight
  97
- Primary Pinion
  98
- Outer Clutch Hub
  98
- Clutch Disks
  99
- Clutch Cover
  100
- Cylinder Head Rear with Timing Chain
  102
- Cylinder Head Front with Cylinder and Timing Chain
  106
- Valve Cover
  111
- Electrical Index
  113
- Abs-System
  113
- Checking the Generator Coils
  115
- Checking the Charging Voltage / Rectifier Regulator
  115
- Charging the Battery
  115
- Checking for Loss of Current
  115
- Electric Starter System 950 Adventure
  116
- Starting System 990 Super Duke
  117
- 950 Supermoto/950 Super Enduro Electric Starter System
  118
- 990 Adventure Electric Starter System
  119
- Checking the Auxiliary Starter Relay
  120
- Functional Check of the Auxiliary Starter Relay
  121
- Functional Check of the Auxiliary Start Relay
  121
- Checking the Diodes
  122
- Checking the Starter Relay
  123
- Checking the Starter Motor
  123
- Checking the Clutch Switch
  124
- Checking the Tip Switch and Emergency off Switch
  125
- Troubleshooting in the Starter System
  125
- Ignition System, ECU 950 Adventure
  126
- Ignition System, ECU 950 Supermoto
  127
- Ignition System, ECU 950 Super Enduro
  128
- ECU 950 Adventure/Supermoto/Super Enduro
  129
- Checking the Pulse Generator 950 Adventure/950 Supermoto
  129
- Checking the Fuel Pump Relay 950 Adventure/950 Supermoto
  130
- Checking the Ignition Coils 950 Adventure/Supermoto/Super Enduro
  130
- Troubleshooting in the Ignition System 950 Adventure/950 Supermoto
  131
- The EPC System 950 Adventure
  132
- The EPC System 950 Supermoto
  133
- EPC System 950 Super Enduro
  134
- Checking the Solenoid Valve for the EPC 950
  135
- Checking the Gear Sensor 950
  135
- Adventure Carburetor Heater 950 Adventure
  136
- Checking the Heating Elements
  136
- Checking the Temperature Switch
  136
- Injection/Ignition System
  137
- Correction Sensors and Inputs
  137
- Establishing the Injection Period (Injection Volume)
  137
- System Diagram
  138
- Basic Description of the System
  139
- Wiring Diagram 990 Duke
  140
- Wiring Diagram 990 Adventure
  141
- Block Diagram
  142
- Description of the Electric System
  143
- Descriptiopn of the Components
  144
- Fuel Pump
  144
- Pressure Regulator
  144
- Injection Valves
  144
- Manifold Air Pressure Sensor
  145
- Ambient Air Pressure Sensor
  145
- Throttle Valve Sensor
  145
- Sensor for the 2Nd Throttle Valve
  145
- Pulse Generator (Crankshaft)
  146
- Lambda Probes
  146
- Servomotor for the 2Nd Throttle Valve
  147
- Catalytic Converter
  147
- Idle Speed Control Motor
  147
- Ignition Coils
  148
- Fuel Pump/Main Relay
  148
- Secondary Air Valve
  148
- Octane Selector Connections
  148
- Roll Angle Sensor
  149
- Diagnostics Connector
  149
- Side Stand Switch
  149
- Clutch/Gear Switch
  149
- Safety against Failure/Emergency Operation
  150
- Component Tests
  151
- Coolant Temperature Sensor
  152
- Air Temperature Sensor
  152
- Intake Pressure Sensors
  153
- Sensor for 2Nd Throttle Valve
  154
- Pulse Generator
  155
- Lambda Probe Heater
  155
- Control Motor for the 2Nd Throttle Valve
  156
- Ignition Coil
  157
- Fuel Pump Relay
  157
- Main Relay
  158
- Error Lamp
  160
- Gear Sensor (Neutral, 2, 3)
  160
- Clutch Switch
  160
- Speed Signal
  161
- Coolant Temperature Signal
  161
- Diagnostics Line
  161
- Error Codes
  162
- Abbreviations, Limit Values 990 Super Duke
  163
- Abbreviations, Limit Values 990 Adventure
  164
- Alarm System for 990 Super Duke
  165
- Order for Additional Hand-Held Transmitters
  166
- Adapting the Hand-Held Transmitter
  166
- Starting with the Emergency Code
  167
- Checking the ABS Fault Memory Using the KTM Diagnostics Tool
  168
- Checking the ABS Sensor with the KTM Diagnostics Tool
  168
- Checking the Fuses
  168
- ABS System 990 Adventure
  168
- Fuel System Index
  169
- Carburetor Exploded View
  171
- Description of the ACV (Air Cut Valve) System
  172
- Disassembling the Carburetor
  173
- Assembling the Carburetor
  176
- Adjusting the Float Level
  179
- Adjusting the Idle Mixture Control Screw
  179
- Checking the Throttle Sensor
  180
- Adjusting the Throttle Sensor
  180
- Adjusting the Choke Cable
  180
- Adjusting the Throttle Cable
  180
- Carburetor Heater
  181
- Replacing the Fuel Filter
  182
- Injection System
  182
- Dismounting/Mounting Fuel Pump with Pressure Regulator/Level Sensor
  182
- Dismounting/Mounting the Throttle Body
  182
- Checking the Fuel Pressure
  183
- Troubleshooting Index
  185
- Chassis Index
  189
- Dismounting/Mounting the Front Wheel
  191
- Dismounting/Mounting the Rear Wheel
  192
- Replacing the Front Wheel Bearing
  193
- Replacing the Rear Wheel Bearing
  194
- Replacing the Front Brake Pads
  195
- Replacing the Rear Brake Pads
  196
- Replacing the Fork Legs
  197
- Replacing the Shock Absorber
  198
- Replacing the Fork Leg
  199
- Replacing the Steering Head Bearing
  200
- Replacing the Swing Arm Bearing
  201
- Replacing the Chain, Pinion and Rear Sprocket
  202
- Opening the Chain with a Separating/Rivet Tool
  203
- Riveting the Chain
  203
- Replacing the ABS Unit
  204
- Replacing the Rear ABS Sensor
  204
- Technical Specifications Index
  205
- Engine 950 Adventure
  207
- Chassis Engine 950 Adventure/Adventure S
  208
- Engine 990 Super Duke
  210
- Chassis 990 Duke
  211
- Engine 950 Supermoto
  213
- Engine 990 Adventure
  216
- Chassis 990 Adventure/Adventure S
  217
- Engine 950 Super Enduro
  219
- Chassis 950 Super Enduro
  220
- Tolerance and Fitting Clearances
  222
- Tightening Torques
  224
- Periodic Maintenance Schedule Index
  227
- Cleaning the Oil Screens and Magnets on the Drain Plugs
  238
- Changing the Engine Oil and Filter
  238
- Lubrication and Maintenance Work - Engine
  238
- Engine Oil
  239
- Checking the Engine Oil Level
  240
- Replacing the Spark Plugs
  240
- Checking the Clutch Lining
  244
- Checking the Clutch Pressure Booster System
  244
- Cleaning the Oil Jet for the Clutch Lubrication
  244
- Lubrication and Maintenance Work - Carburetor
  245
- Check the Carburetor Synchronization with Vacuum Gauge and Adjust
  245
- Checking the Idle Setting
  245
- Replacing the O-Ring on the Fuel Hose Connector
  246
- Add-On Parts
  246
- Brakes
  246
- Injection
  246
- Changing the Front Brake Fluid
  247
- Changing the Rear Brake Fluid
  248
- Cleaning the Dust Boots
  249
- Checking the Swing Arm Support
  249
- Checking/Adjusting the Steering Head Bearing
  249
- Checking All Chassis Bolts for Force Fit
  249
- Wheels
  250
- Checking the Spoke Tension and Rim Run-Out
  250
- Checking the Chain and Chain Guides for Wear, Force Fit and Tension
  250
- Checking the Wheel Bearing and Jerk Damper for Clearance
  250
- Additional Work
  251
- Cleaning and Greasing the Steering Head Bearing and Sealing Elements
  251
- Changing the Cooling Liquid
  252
- Wiring Diagrams Index
  253
- Start System
  262
- Charging Circuit
  264
- Ecu
  266
- Turn Indicator System
  268
- Light-Brake System
  270
- Light System USA
  272
- Instruments Tachometer
  274
- Ground Connection
  276
- Positive Connection
  277
- Light/Turn Signal/Horn Switch
  278
- Multifunctional Digital Speedometer
  278
- Front Light
  278
- Start/Stop/Light Switch
  278
- Tachometer
  279
- Turn Signal Relay
  279
- Rear Brake Light Switch
  279
- Left/Right Front Turn Signal
  279
- Diode Neutral Switch
  280
- Diode Side Stand Switch
  280
- Rear Lighting
  280
- Right Front Turn Signal
  280
- Speed Sensor
  281
- Pick up
  281
- Carburetor Potentiometer
  281
- Fuel Sender
  281
- Tripmaster Switch
  282
- ECU (Control Unit)
  282
- Ignition Lock
  282
- Connector for Auxiliary Devices
  282
- Rear/Front Ignition Coil
  283
- Radiator Fan Motor
  284
- Regulator
  284
- Temperature Switch for the Radiator Fan
  284
- EPC Front/Rear Cylinder
  284
- Octane Selector
  285
- Temperature Sensor for the Multifunctional Digital Speedometer
  285
- Rear Turn Signal
  285
- Battery Generator Starter
  290
- Turn Signal, Horn, Fan
  294
- Instruments - Tachometer
  298
- Front Lighting
  302
- Turn Signal, Horn, High Beam Switch
  302
- Start Relay/Main Fuse
  302
- Auxiliary Starter Relay
  303
- Speedometer
  303
- Front Brake Light Switch
  303
- Diodes
  304
- Throttle Sensor for the 2Nd Throttle
  305
- Throttle Sensor
  305
- Gear Sensor
  305
- Side Stand
  305
- Ignition Switch
  306
- Diagnosis Connector
  306
- Rollover Sensor
  306
- Rear Ignition Coil
  307
- Front Ignition Coil
  307
- Temperature Switch
  308
- Fan Motor
  308
- Regulator Output
  308
- Rear Blinker
  309
- Pressure Sensor for Rear Cylinder
  312
- Manifold Air Pressure Sensor for Front Cylinder
  312
- Ambiant Air Pressure Sensor
  312
- Rear/Front Lambda Probe
  312
- Control Motor for 2Nd Throttle
  313
- Front Wiring Harness
  313
- Secondary Air System Valve
  313
- Rear Injection Valve
  314
- Front Injection Valve
  314
- Wiring Harness EFI
  314
- Connector
  315
- Connector for the Alarm System Control Unit
  315
- Connector for Attachments
  315
- Lighting Relay
  331
- Start Relay
  331
- Temperature Switch for Carburetor Heater
  331
- Neutral Switch Diode
  332
- Diode for Side Stand Switch
  332
- Diode for Turn Signal Control
  332
- Rear Lighting System
  332
- Controller Outlet
  337
- Front EPC
  337
- EPC Rear
  337
- Turn Signal/Horn/High Beam Switch
  338
- Radiator Fan
  339
- Alarm LED
  339
- Seat Switch
  339
- Headlight
  340
- Parking Light
  341
- Connector for the Alarm ECU
  341
- Dummy Plug
  341
- Battery, Generator, Starter
  344
- Efi
  346
- Abs
  353
- ABS Connection
  358
- Temperature Switch for Radiator Fan
  362
- Controller
  362
- Front Lambda Probe
  365
- Control Motor for the 2Nd Throttle
  365
- Rear Lambda Probe
  365
- EFI Wiring Harness
  366
- ABS-ECU (Control Unit)
  367
- Rear ABS Sensor
  367
- Front ABS Sensor
  367
- ABS Control Lamp
  368
- Manifold Air Pressure Sensor for the Rear Cylinder
  368
- Manifold Air Pressure Sensor for the Front Cylinder
  368
- Engine Stop Relay
  384
- Starter Relay
  384
- Light/Horn/Stop Switch
  384
- Temperature Switch for the Carburetor Heater
  385
- Flasher Relay
  385
- Diode for Neutral Switch
  385
- Diode for Side Stand
  385
- Flasher Switch
  386
- Control Unit
  388
- Controller Output
  390
- Front EPC Cylinder
  391
- Rear EPC Cylinder
  391
- Rear Flasher
  391
- Emergency off Switch
  392
- Tip Switch
  393

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