KTM 950 Adventure Super Enduro Supermoto 990 Super Duke Workshop Repair Service Manual 2003-2007 PDF - MKTM950990OPES.zip
A full workshop repair and service manual, complete with electrical wiring diagrams, covering the 2003-2007 KTM 950 Adventure, 950 Super Enduro, 950 Supermoto, 990 Adventure, and 990 Super Duke — packed with every technical detail needed to service, troubleshoot, fix, and rebuild your bike the way professional technicians do.
The workshop service and repair manual for the KTM 950 Adventure/Super Enduro/Supermoto and 990 Adventure/Super Duke contains:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
KTM 950 ADVENTURE, 990 SUPER DUKE REPAIR MANUAL 2003-2005
KTM 950 Adventure (S) REPAIR MANUAL 2003 (DE).pdf
KTM 950, 990 ADVENTURE, 990 SUPER DUKE, 950 SUPERMOTO, 950 SUPER ENDURO REPAIR MANUAL 2003-2006.pdf
KTM 950_990 ADVENTURE, 990 SUPER DUKE, 950 SUPERMOTO, 950 SUPER ENDURO REPAIR MANUAL 2003-2007.pdf
KTM 950 ADVENTURE 2003 Owners Manual.pdf
KTM 950 ADVENTURE 2003 Repair Manual.pdf
PRODUCT DETAILS:
Total Pages: 1,221 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
"'03-'07 950-990.pdf"
394 pages; 2003-2007 Repair manual for
950/990 ADVENTURE
990 SUPER DUKE
950 SUPERMOTO
950 SUPER ENDURO
"'03-'06 950-990.pdf"
394 pages; 2003-2006 Repair manual for
950/990 ADVENTURE
990 SUPER DUKE
950 SUPERMOTO
950 SUPER ENDURO
"'03-'05 950-990"
203 MB PDF; 2003-2005 Service manual for 950 Adventure, 990 Super Duke
LANGUAGE: EN/DE/FR/IT/ES
"'03 950 Adventure (S) (EN).pdf"
185 pages; 2003 Service manual for 950 Adventure, Adventure S
"'03 950 Adventure (S) (DE).pdf"
386 pages, German; 2003 Service manual for 950 Adventure, Adventure S
"'03 950 Adventure Owners Manual.pdf"
55 pages; 2003 Owners manual for 950 Adventure
TABLE OF CONTENTS
HOME...0
NOTES AND PREFACE ...1
Title page and file spine...1
Important information...7
Introduction...9
Reply fax for repair manuals...11
TABLE OF CONTENTS...5
GENERAL INFORMATION...13
OIL SYSTEM...15
AIR INTAKE SYSTEM...16
SLS-SYSTEM...17
COOLING SYSTEM...18
SPECIALTOOLS – CHASSIS...19
SPECIALTOOLS – ENGINE...20
BLEEDING THE CLUTCH...22
REMOVING AND REFITTING ENGINE...23
REMOVING THE ENGINE...25
REFITTING THE ENGINE...30
DISASSEMBLING THE ENGINE...35
VALVE COVERS...37
SPARK PLUG SHAFT INSERTS...37
STARTER MOTOR...37
SETTING CYLINDER REAR TO TDC...38
CAMSHAFTS CYLINDER REAR...38
CHAIN TENSIONER CYLINDER REAR...39
TIMING CHAIN CYLINDER REAR...39
DOUBLE TIMING GEAR...40
CYLINDER HEAD REAR WITH CYLINDER...40
SETTING CYLINDER FRONT TO TDC...40
CAMSHAFTS CYLINDER FRONT...41
OIL PRESSURE SWITCH...41
CHAIN TENSIONER CYLINDER FRONT...41
TIMING CHAIN CYLINDER FRONT...42
CYLINDER HEAD FRONT WITH CYLINDER...42
WATER PUMP...43
OIL SCREEN...43
CLUTCH COVER...43
CLUTCH...44
PRIMARY PINION AND CLUTCH...45
GENERATOR COVER...46
ROTOR...46
FREEWHEEL...46
BALANCER SHAFT...46
SHIFT MECHANISM...47
ENGINE CASE HALF...47
TRANSMISSION...48
OIL PUMPS...49
SERVICING INDIVIDUAL COMPONENTS...51
ROLLER BEARING...53
MAIN BEARINGS - GENERAL INFORMATION...54
REPLACING BEARING SHELLS, OUTPUT END...55
REPLACING BEARING SHELLS, GENERATOR END...55
REPLACING THE CONROD BEARINGS...56
SELECTING THE BEARING SHELLS...56
REPLACING THE SUPPORTING BEARINGS IN THE CLUTCH COVER...57
OVERHAULING THE WATER PUMP...58
CHECKING THE SUCTION PUMP FOR WEAR...59
CHECKING THE PRESSURE PUMP FOR WEAR...59
BYPASS VALVE...59
DISASSEMBLING THE CYLINDER HEAD AND CHECKING...60
CHECKING THE PISTONS...61
ASSEMBLY INSTRUCTIONS FOR PISTON RINGS...61
CHECKING THE PISTON RING END GAP...61
MEASURING PISTONS + CYLINDERS, ESTABLISHING THE PISTON...61
PISTON AND CYLINDER IDENTIFICATION...62
ASSEMBLING THE CYLINDER HEAD...62
GENERATOR COVER...64
VALVE GEAR – CHECKING PARTS FOR WEAR...64
CLUTCH – CHECKING PARTS FOR WEAR...65
SHIFT MECHANISM – CHECKING PARTS FOR WEAR...66
PREASSEMBLING THE SHIFT SHAFT...66
GENERAL INFORMATION ON SERVICING THE TRANSMISSION...67
ASSEMBLING THE MAIN SHAFT...67
ASSEMBLING THE COUNTERSHAFT...68
CHECKING THE FREEWHEEL...69
REPLACING THE FREEWHEEL HUB...69
STARTER...69
ASSEMBLING ENGINE...71
OIL PUMPS...73
TRANSMISSION...75
CASE HALF...76
SHIFT MECHANISM...77
ALIGNING THE RETURN SPRING...77
BALANCER SHAFT...78
FREEWHEEL...78
ROTOR...78
GENERATOR COVER...79
TIMING CHAIN AND BALANCING WEIGHT...79
PRIMARY PINION...80
OUTER CLUTCH HUB...80
CLUTCH DISKS...81
CLUTCH COVER...82
OIL SCREEN...83
WATER PUMP...83
CYLINDER HEAD REAR WITH TIMING CHAIN...84
CHAIN TENSIONER CYLINDER REAR...86
CAMSHAFTS CYLINDER REAR...87
SETTING CYLINDER FRONT TO TDC...88
CYLINDER HEAD FRONT WITH TIMING CHAIN...88
CHAIN TENSIONER CYLINDER FRONT...90
OIL PRESSURE SWITCH...90
CAMSHAFTS CYLINDER FRONT...91
STARTER MOTOR...92
SPARK PLUG SHAFT INSERTS...93
VALVE COVER...93
ELECTRICAL...95
CHECKING FOR LOSS OF CURRENT...97
DISMOUNTING THE BATTERY...97
CHARGING THE BATTERY...97
JUMP START...97
CHECKING THE CHARGING VOLTAGE/ RECTIFIER REGULATOR...97
CHECKING THE GENERATOR COILS...97
ELECTRIC STARTER SYSTEM...98
CHECKING THE AUXILIARY STARTER RELAY...99
FUNCTIONAL CHECK OF THE AUXILIARY STARTER RELAY...99
CHECKING THE DIODES...99
CHECKING THE STARTER RELAY...100
CHECKING THE STARTER EINGINE...100
CHECKING THE CLUTCH SWITCH...100
CHECKING THE TIP SWITCH AND THE EMERGENCY OFF SWITCH...100
TROUBLESHOOTING IN THE STARTER SYSTEM...100
IGNITION SYSTEM, ECU...101
CHECKING THE ECU...102
CHECKING THE PULSE GENERATOR...102
CHECKING THE FUEL PUMP RELAY...102
CHECKING THE IGNITION COILS...102
TROUBLESHOOTING IN THE IGNITION SYSTEM...103
THE EPC SYSTEM...104
CHECKING THE SOLENOID VALVE FOR THE EPC...105
CHECKING THE GEAR SENSOR...105
FUEL SYSTEM...107
KEIHIN CVRD 43...109
DESCRIPTION OF THE ACV (AIR CUT VALVE) SYSTEM...110
DISASSEMBLING THE CARBURETOR...111
ASSEMBLING THE CARBURETOR...114
CHECKING THE FLOAT LEVEL...117
ADJUSTING THE MIXTURE CONTROL SCREW...117
CHECKING THE THROTTLE SENSOR...118
ADJUSTING THE THOTTLE SENSOR...118
ADJUSTING THE CHOKE CABLE...118
ADJUSTING THE THROTTLE CABLES...118
SYNCHRONIZING THE CARBURETOR...151
ADJUSTING THE IDLE SPEED...151
TROUBLE SHOOTING...119
CHASSIS...123
REPLACING THE FRONT WHEEL BEARING...125
REPLACING THE REAR WHEEL BEARING...126
REPLACING THE FORK LEGS...127
REPLACING THE SHOCK ABSORBER...128
REPLACING THE STEERING HEAD BEARING...129
REPLACING THE SWING ARM BEARING...130
REPLACING THE CHAIN, PINION AND REAR SPROCKET...131
CUTTING AND RIVETING THE CHAIN...132
TECHNICAL SPECIFICATIONS...133
LC8 ENGINE...135
950 ADVENTURE CHASSIS...136
TOLERANCES, MOUNTING CLEARANCES – ENGINE...138
TIGHTENING TORQUES - ENGINE...140
TIGHTENING TORQUES - CHASSIS...141
PERIODIC MAINTENANCE SCHEDULE...143
PERIODIC MAINTENANCE SCHEDULE 950 ADVENTURE...144
MAINTENANCE WORK...143
Changing the engine oil and the oil filter...146
Cleaning the oil screens in the engine and oil tank...146
Cleaning the magnets on the drain plug for the engine and oil tank...146
Replacing the spark plugs...148
Checking and adjusting the valve clearance...149
Checking the clutch lining...150
Checking the clutch pressure booster system...150
Carburetor synchronization...151
Idle adjustment...151
Checking the cooling system for leakage and antifreeze...152
Checking the radiator fan for proper functioning...152
Lubricating the cables...152
Checking the air filter, replacing if necessary, cleaning the air filter box...152
Checking the brake fluid level, lining thickness, brake disks...152
Changing the brake fluid...153
Checking the bolts on the brake system for force fit...155
Cleaning the dust boots...155
Bleeding the fork legs...155
Checking the swing arm support...155
Checking/adjusting the steering head bearing...155
Checking all chassis bolts for force fit...155
Checking the spoke tension and rim run-out...156
Checking the chain and chain guides for wear, force fit and tension...156
Checking the nuts/bolts on the engine sprocket and...156
Checking the wheel bearing and jerk damper for clearance...156
Servicing the fork...157
Servicing the shock absorber...157
Cleaning and greasing the steering head bearing and sealing elements...157
Cleaning and adjusting the carburetor...158
Changing the cooling liquid...158
WIRING DIAGRAMS...159
WIRING DIAGRAMS...160
START SYSTEM...162
CHARGING SYSTEM...164
ECU...166
FLASHER, HORN, COOLING FAN...168
LIGHTS...170
LIGHTS USA...172
INSTRUMENTS...174
GROUND CONNECTION...176
POSITIVE CONNECTION...177
CONNECTOR LIST...159
Connector AA - AF...178
Connector AG - AJ...179
Connector AK - AM...180
Connector AN - AR...181
Connector AS - AW...182
Connector AX - AZ, BA...183
Connector BB - BG...184
Connector BH - BK...185
NOTES AND PREFACE ...1
Title page and file spine...1
Important information...7
Updating instruction...7
Explanation update...9
Introduction...11
Reply fax for repair manuals...13
TABLE OF CONTENTS...5
GENERAL INFORMATION...15
OIL SYSTEM...17
AIR INTAKE SYSTEM...18
SLS-SYSTEM...19
COOLING SYSTEM...20
ABS-SYSTEM...21
SPECIAL TOOLS - ENGINE...22
SPECIAL TOOLS - CHASSIS...24
BLEEDING THE 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
BLEEDING THE COOLING SYSTEM...15
CHECKING THE OIL PRESSURE...30
REMOVING AND REFITTING ENGINE...31
950 ADVENTURE...31
REMOVING THE ENGINE...33
REFITTING THE ENGINE...38
990 SUPER DUKE...31
REMOVING THE ENGINE...43
REFITTING THE ENGINE...44
950 SUPERMOTO...31
REMOVING THE ENGINE...51
REFITTING THE ENGINE...51
DISASSEMBLING THE ENGINE...53
VALVE COVERS...55
SPARK PLUG SHAFT INSERTS...55
STARTER MOTOR...55
SETTING CYLINDER REAR TO TDC...56
CAMSHAFTS CYLINDER REAR...56
CHAIN TENSIONER CYLINDER REAR...57
TIMING CHAIN CYLINDER REAR...57
DOUBLE TIMING GEAR...58
CYLINDER HEAD REAR WITH CYLINDER...58
SETTING CYLINDER FRONT TO TDC...58
CAMSHAFTS CYLINDER FRONT...59
OIL PRESSURE SWITCH...59
CHAIN TENSIONER CYLINDER FRONT...59