2003-2007 Ktm 950 Adventure 990 Adventure 990 Super Duke 950 Supermoto 950 Super Enduro Engine Workshop Service Repair Manual
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This manual covers esteemed Adventure, Super Duke, and Supermoto models, specifically those produced between 2003 and 2007. These motorcycles are celebrated for their robust Austrian engineering, powerful V-twin engines, and...
This manual covers esteemed Adventure, Super Duke, and Supermoto models, specifically those produced between 2003 and 2007. These motorcycles are celebrated for their robust Austrian engineering, powerful V-twin engines, and versatility, catering to both on-road performance and off-road exploration. The 950 and 990 Adventure series, in particular, have earned recognition for their groundbreaking design and capability in the adventure touring segment, offering a unique blend of sportbike handling and long-distance comfort.
This comprehensive factory service repair manual, presented in English and over 500 pages, is an essential resource for maintaining and repairing your motorcycle. It provides detailed guidance on engine service and repair, including disassembly, assembly, and component-specific procedures for the V-twin engine, fuel systems, lubrication, and cooling. Additionally, the manual covers routine maintenance tasks, diagnostic procedures for common issues, and in-depth repair instructions, ensuring your motorcycle remains in optimal condition.
🏷️ Basic Information
Identification
Make:
KTM
Model:
950 Super Enduro
Codes
Applicable Years:
2003, 2004, 2005, 2006, 2007
👋 Introduction
Market Position
Target Audience:
DIY enthusiasts and professional mechanics servicing KTM 950/990 Adventure, Super Duke, and Supermoto models.
Over 500 pages (typical for comprehensive factory service manuals)
Manual Type
Type:
Factory Service Repair Manual
Language
Language:
English
Format
Format:
PDF (Digital Download)
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine disassembly and assembly, cylinder head, valve train, piston and connecting rod, crankshaft, lubrication system, cooling system, fuel system (carburetor/injection), ignition system, exhaust system
Procedures Included
Maintenance Procedures:
Oil changes, filter replacements, spark plug service, air filter cleaning/replacement, coolant checks and changes, chain maintenance, valve clearance adjustment
Diagnostic Procedures:
Troubleshooting common engine problems, fault code interpretation (if applicable to specific EFI models), diagnostic checks for various engine components
Repair Procedures:
Engine rebuilds, component replacement (e.g., seals, gaskets, bearings, clutch components, water pump), cylinder head repair, timing chain/belt service
Technical Depth
Depth:
Comprehensive, from basic maintenance to complete engine overhaul and rebuilding
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Printability:
Printable pages
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Quality:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, 4-stroke, V-twin cylinder
Displacement 950:
942 cc
Displacement 990:
999 cc
Performance
Bore Stroke 950:
98 x 62.4 mm
Bore Stroke 990:
101 x 62.4 mm
Compression Ratio 950:
11.5:1 (approx.)
Compression Ratio 990:
11.5:1 or 12.5:1 (depending on variant)
Fuel System
Fuel Delivery 950 Adventure Supermoto:
Dual Keihin CVK 40 carburetors
Fuel Delivery 990 Adventure Super Duke:
Electronic Fuel Injection (EFI) with dual throttle bodies (e.g., Mikuni or Keihin)
Fuel Type:
Unleaded gasoline
Ignition
Ignition System:
Digital electronic ignition
Lubrication
Oil Type:
Refer to manual for specific grades (e.g., JASO MA certified 10W-40 or 10W-50 motorcycle oil)
Cooling
Cooling System:
Liquid-cooled
Coolant Type:
Ethylene glycol based coolant with corrosion inhibitors (typically a 50/50 mix with distilled water)
🔧 Transmission
Standard
Transmission Type:
6-speed constant mesh
Clutch Type:
Hydraulically operated multi-plate wet clutch
Features
Final Drive:
O-ring sealed chain
Gearbox Oil Type:
Refer to manual for specific grades (e.g., SAE 80W/90 gear oil)
📐 Dimensions
Exterior
Frame Type:
CrMo steel trellis frame
Weights
Dry Weight 950 Adventure:
Approx. 199 kg (439 lbs)
Dry Weight 990 Adventure:
Approx. 200 kg (441 lbs)
Curb Weight 990 Adventure R:
Approx. 207 kg (456 lbs)
🛡️ Safety Features
Active Features
Braking System Front:
Dual disc, Brembo calipers, 300 mm rotor diameter (typically)
Braking System Rear:
Single disc, Brembo caliper, 240 mm rotor diameter (typically)
ABS:
Optional ABS available on some models/years
Passive Features
Lighting:
Halogen headlights, LED taillight
💡 Technology Features
Infotainment
Dash Features:
Analog tachometer, digital speedometer, odometer, trip meters, fuel gauge, clock, warning lights.
Driver Assistance
ABS System:
Bosch ABS system (on applicable models), often with rider-selectable modes.
Connectivity
Efi Diagnostics:
EFI models can be diagnosed using specialized KTM diagnostic tools, as detailed in the manual.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000-7,500 km or annually, refer to manual for exact interval.
Valve Adjustment Interval:
Typically every 10,000-15,000 km, refer to manual for exact interval.
Air Filter Cleaning:
Depending on riding conditions, often every 5,000-10,000 km.
Spark Plug Replacement:
Typically every 10,000-15,000 km, depending on spark plug type.
Fluid Specifications
Engine Oil Capacity 950:
Approx. 2.6 liters (with filter change)
Engine Oil Capacity 990:
Approx. 2.7 liters (with filter change)
Coolant Capacity:
Approx. 1.8 - 2.0 liters
Known Issues
Common Issues Mentioned In Manual:
Potential for oil consumption, water pump seal leaks, occasional electrical gremlins, clutch slave cylinder leaks (all typically addressed in factory service procedures).
Part Numbers
Oil Filter Part Number Example:
KTM part numbers are specific; examples include 75038005100 or compatible aftermarket filters.
Air Filter Part Number Example:
KTM part numbers are specific; examples include 75006015000 or compatible aftermarket filters.
📚 Vehicle History
Brand Heritage
Ktm Heritage:
KTM AG is an Austrian manufacturer renowned for its off-road motorcycles. The 'Adventure' line signifies their expansion into the dual-sport and adventure touring market.
Model Evolution
950 Introduction:
The 950 Adventure was introduced in 2003, featuring a revolutionary V-twin engine and excellent off-road capabilities for its class.
990 Introduction:
The 990 Adventure and Super Duke were introduced later, featuring a larger displacement engine and fuel injection for improved performance and emissions.
Production
Manufacturing Location:
Austria
🏆 Awards & Recognition
Recognitions
Motorcycle Of The Year:
The KTM Adventure series has consistently received accolades from motorcycle publications for its performance and versatility in adventure touring.
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