KTM 950 990 ADVENTURE 2003-2007 Service Repair Manual

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Typ: Motorcycle

Anbieter:

Art.-Nr: 157399

Stichworte: 2003 2004 2005 2006 2007 950 ADVENTURE 990 990 ADVENTURE KTM Motorcycle Motorcycles

Produktvarianten

Beschreibung

The KTM 950 Adventure and 990 Adventure, produced between 2003 and 2007, represent a significant offering in the adventure touring motorcycle segment. These models are distinguished by their robust LC8 V-twin engine, known for its potent torque and power delivery, and are engineered with long-travel WP suspension for exceptional off-road capability and rider comfort. The chassis is built for durability, making these machines versatile for both demanding off-road exploration and long-distance touring. KTM's heritage in off-road racing is evident in the design, creating a rugged and highly capable motorcycle that has garnered a dedicated following among riders who value performance and versatility. This comprehensive Factory Service Repair Workshop Manual provides essential information for the maintenance and repair of the KTM 950 Adventure and 990 Adventure. It covers a wide array of critical systems, including detailed engine mechanical procedures for the LC8 V-twin, fuel system and throttle body servicing, cooling and lubrication systems, chassis components, and the electrical system. The manual also includes periodic maintenance schedules, troubleshooting guides, and specific procedures for engine rebuilds, suspension overhauls, and electrical diagnostics. With detailed torque specifications and wiring diagrams, this manual serves as an indispensable resource for owners, technicians, and mechanics to ensure the optimal performance and longevity of these adventure motorcycles.

🏷️ Basic Information

Identification

Make:

Model:

990 Adventure

Year Range:

2003-2007

Codes

Platform Code:

👋 Introduction

Market Position

Segment:

Adventure Touring Motorcycle

Target Audience:

Off-road enthusiasts, long-distance tourers, riders seeking a rugged and capable machine.

Competitive Analysis

Competitors:

BMW R1150/1200GS, Triumph Tiger, Yamaha Super Ténéré (though later models), Honda Africa Twin (later models).

Key Features

Engine Architecture:

V-twin LC8 engine known for its torque and power delivery.

Suspension Design:

Long-travel WP suspension providing excellent off-road capability and comfort.

Chassis Durability:

Robust frame and components designed for demanding conditions.

Versatility:

Capable of handling both on-road touring and off-road exploration.

📋 Manual Details

Coverage Areas

General Information:

Included

Periodic Maintenance:

Included

Engine:

Included

Fuel System And Throttle Body:

Included

Cooling And Lubrication System:

Included

Chassis:

Included

Electrical System:

Included

Servicing Information:

Included

Emission Control Information:

Included

Wiring Diagrams:

Included

Page Count

Estimated Page Count:

Comprehensive (exact number not specified but implied by 'COMPLETE official full factory')

Manual Type

Manual Type:

Factory Service Repair Workshop Manual

Language

Language:

English

Format

File Format:

Digital Delivery:

Instant Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete disassembly, reassembly, overhaul procedures for the LC8 V-twin engine.

Engine Management:

Fuel injection, ignition system diagnosis and repair, emissions control systems.

Cooling System:

Radiator, coolant flow, pump, thermostat, fan operation and service.

Lubrication System:

Oil pump, oil passages, oil filter, oil change procedures, specifications.

Fuel System:

Fuel pump, fuel filters, fuel lines, fuel tank servicing, injector testing.

Throttle Body:

Adjustment, cleaning, synchronization, TPS (Throttle Position Sensor) diagnosis.

Transmission:

Clutch operation, gear shifting mechanisms, gearbox disassembly and reassembly.

Suspension:

Front fork (WP USD) service, rear shock absorber service, adjustment procedures.

Brakes:

Brake caliper service, master cylinder overhaul, hydraulic line maintenance, bleeding procedures, disc inspection.

Electrical System:

Battery, charging system (alternator/stator), starter motor, lighting, instrumentation, fuses, relays.

Chassis:

Frame inspection, steering head bearing service, swingarm maintenance, wheel bearings.

Exhaust System:

Component inspection, potential for aftermarket system compatibility considerations.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, chain adjustment, brake pad inspection, spark plug service.

Troubleshooting:

Diagnosis of common and uncommon issues based on symptoms.

Engine Rebuild:

Full top-end and bottom-end rebuild procedures, including piston, ring, valve, and crankshaft service.

Suspension Overhaul:

Fork seal replacement, damper rod service, shock absorber rebuilding.

Electrical Diagnosis:

Fault finding using wiring diagrams, component testing.

Wheel And Tire:

Tire replacement, wheel balancing, spoke tensioning (if applicable to spoke wheels).

Torque Specifications:

Detailed torque values for all critical fasteners.

Technical Depth

Depth Of Coverage:

Comprehensive, covering everything from basic maintenance to complete engine and chassis overhauls.

Diagnostic Capabilities:

Advanced diagnostic procedures for engine management and electrical systems.

Diagrams And Illustrations:

High-quality, detailed exploded views and schematics for clear understanding.

📊 Manual Specifications

File Format

File Format:

Print Quality

Printability:

Printable without restriction

Binding Type

Binding Type:

Digital Download (not applicable for physical binding)

Paper Type

Paper Type:

Digital (not applicable for physical paper type)

Software Requirements

Required Software:

Adobe PDF Reader

⚙️ Engine Specifications

Primary Engine

Engine Type:

Liquid-cooled, 75° V-twin, four-stroke (LC8)

Displacement:

950cc (950 Adventure), 990cc (990 Adventure)

Bore X Stroke:

950: 98 x 61.5 mm; 990: 101 x 62.4 mm (Typical for LC8)

Valve Train:

DOHC, 4 valves per cylinder

Performance

Horsepower:

Approx. 98-105 hp (depending on model variant and tuning)

Torque:

Approx. 90-95 Nm (depending on model variant and tuning)

Fuel System

Fuel Delivery:

Fuel Injection (EFI)

Ignition System:

Electronic Ignition

🔧 Transmission

Standard

Transmission Type:

6-speed, constant mesh

Clutch Type:

Wet multi-disc clutch, hydraulically operated

Features

Final Drive:

Chain drive

📐 Dimensions

Exterior

Seat Height:

Variable, typically around 880-900 mm (adjustable on some models)

Weights

Dry Weight:

Approx. 195-210 kg (depending on model and equipment)

Fuel Capacity:

Approx. 22-23 Liters (dual tanks on many models)

🛡️ Safety Features

Ratings

Safety Features:

ABS (available on some later models, not standard on all 2003-2007 variants)

Active Features

Braking System:

Dual front discs, single rear disc with radial calipers (typically Brembo).

Passive Features

Lighting:

Halogen headlight, LED taillight (model dependent).

💡 Technology Features

Infotainment

Instrumentation:

Analog tachometer and speedometer, LCD multi-function display for fuel level, odometer, trip meters, clock.

Driver Assistance

ABS Availability:

Optional on later models, not universally standard across the 2003-2007 range.

Connectivity

Charging Port:

Typically a 12V power outlet for accessory charging.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 5,000 - 10,000 km or annually, refer to manual for exact specs.

Valve Clearance Check:

Significant interval, often around 10,000 - 20,000 km, detailed in manual.

Chain Maintenance:

Regular cleaning, lubrication, and adjustment are critical for longevity.

Fluid Specifications

Engine Oil Type:

Synthetic motorcycle oil, e.g., Motul 5100 10W-50 or equivalent, check manual for specific viscosity and API ratings.

Coolant Type:

Ethylene glycol-based coolant, typically 50/50 mix with distilled water.

Brake Fluid:

DOT 4 brake fluid.

Known Issues

Water Pump Seals:

Can be a common wear item requiring replacement.

Carburetor Synchronization:

Crucial for smooth running on 950 models; may require periodic adjustment.

Starter Solenoid:

Can sometimes fail, especially with heavy use.

Rear Shock ABSorber:

Can require service or replacement over time due to extensive use.

📚 Vehicle History

Brand Heritage

Brand Focus:

KTM is renowned for its off-road racing heritage, translating into robust and capable adventure motorcycles.

Model Evolution

Introduction Of Lc8:

The LC8 platform, powering the Adventure models, was a significant step for KTM into the large-displacement adventure touring segment.

Key Variants:

950 Adventure (carbureted, off-road focus), 990 Adventure (fuel-injected, more road-biased options, ABS availability).

Production

Manufacturing Location:

Austria (KTM's primary manufacturing base)

🏆 Awards & Recognition

Recognitions

Reputation:

The KTM Adventure series is widely recognized for its off-road prowess and long-distance comfort, earning a strong following among adventure riders.