KTM 950 Adventure 990 Super Duke Motorcycle Workshop Service Repair Manual 2003-2005 (En-De-Fr-It-Es) (203MB 2 500+ Pages Searchable Bookmarked iPad-ready)

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Art.-Nr: 136274

Stichworte: 2003 2004 2005 500 950 Adventure 990 Super Duke KTM Motorcycle Motorcycles

Produktvarianten

Beschreibung

This workshop service repair manual covers the KTM 950 Adventure and 990 Super Duke motorcycles produced between 2003 and 2005. These Austrian-engineered machines are renowned for their powerful LC8 V-twin engines, offering robust performance for both adventure touring and street riding. The 950 Adventure, introduced in 2003, established KTM in the adventure segment with its off-road prowess, while the 2005 990 Super Duke built on this foundation, delivering exceptional naked streetfighter dynamics. This manual provides comprehensive information to ensure these motorcycles are maintained and repaired to the highest standards. This extensive manual, presented in a digital format and available in English, German, French, Italian, and Spanish, offers over 2500 pages of detailed guidance. It covers all essential systems, including complete engine mechanicals, fuel delivery, ignition, cooling, transmission, chassis, suspension, brakes, and electrical systems. Included are routine maintenance procedures, in-depth troubleshooting guides, step-by-step repair instructions, critical technical specifications, and detailed wiring diagrams. The manual's completeness, along with its searchable and bookmarked structure, makes it an invaluable resource for owners and professional mechanics alike, ensuring accurate and efficient upkeep of the KTM 950 Adventure and 990 Super Duke.

🏷️ Basic Information

Identification

Make:

Model:

950 Adventure / 990 Super Duke

Product Name:

KTM 950 Adventure 990 Super Duke Motorcycle Workshop Service Repair Manual 2003-2005

Codes

Production Years Covered:

2003, 2004, 2005

👋 Introduction

Market Position

Target Audience:

Owners and mechanics of KTM 950 Adventure and 990 Super Duke motorcycles from 2003-2005, seeking detailed repair and maintenance information.

Competitive Analysis

Manual Advantage:

Provides the same level of detail as dealer-used manuals, ensuring accurate and efficient repairs. Multilingual support enhances accessibility.

Key Features

Searchability:

Fully searchable text allows for quick access to specific information.

Bookmarked:

Bookmarked structure facilitates easy navigation through chapters and sections.

Illustrations:

Includes detailed illustrations, drawings, and photos to guide repairs.

Completeness:

100% complete and intact, with no missing or corrupt pages/sections.

📋 Manual Details

Coverage Areas

Languages:

English, German, French, Italian, Spanish

Page Count

Total Pages:

2500+

Manual Type

Type:

Workshop Service Repair Manual

Format

File Format:

Compatibility:

Compatible with Windows, Mac, and Linux operating systems.

Protection

Drm Free:

DRM-free, allowing unrestricted use and printing.

📖 Manual Coverage

Systems Covered

Engine:

Complete engine mechanicals, including disassembly, assembly, and overhaul of internal components (pistons, rings, valves, camshafts, crankshafts, connecting rods).

Fuel System:

Carburetor (950 Adventure) and Fuel Injection (990 Super Duke) systems, including fuel pump, injectors, regulators, and troubleshooting.

Ignition System:

Ignition timing, spark plugs, coils, ECU, and troubleshooting.

Cooling System:

Radiator, coolant, thermostat, water pump, fan operation, and maintenance.

Transmission:

Gearbox overhaul, clutch system (including hydraulic actuation), lubrication, and troubleshooting.

Chassis And Suspension:

Front forks (including internal components and adjustments), rear shock absorber, swingarm, linkage, wheel bearings, and steering head bearings.

Brakes:

Front and rear brake systems, including calipers, master cylinders, brake lines, pads, rotors, bleeding procedures, and ABS (if applicable).

Electrical System:

Comprehensive wiring diagrams, battery, alternator, starter motor, lighting, instrumentation, sensors, and troubleshooting diagnostic procedures.

Bodywork And Frame:

Frame inspection, fairings, plastics, seat, fuel tank, and related components.

Exhaust System:

Information on exhaust system components, maintenance, and potential modifications.

Frame And Suspension Linkages:

Details on frame integrity checks, swingarm pivot, and linkage bearing maintenance for optimal suspension performance.

Procedures Included

Maintenance:

Routine maintenance tasks such as oil changes, filter replacements, chain adjustment, valve clearance checks, and lubrication schedules.

Troubleshooting:

Detailed diagnostic procedures for identifying and resolving common mechanical and electrical issues.

Repair:

Step-by-step instructions for disassembling, repairing, and reassembling all major vehicle components.

Technical Specifications:

Torque specifications for all fasteners, fluid capacities and types, electrical component data, and engine build specifications.

Wiring Diagrams:

Detailed, color-coded wiring diagrams for all electrical systems.

Engine Rebuild:

Detailed procedures for complete engine teardown, component inspection, measurement, and reassembly, including piston ring installation, valve lapping, and timing chain setup.

Suspension Adjustment:

Instructions on adjusting front and rear suspension for preload, compression, and rebound damping to suit rider preference and riding conditions.

Carburetor Rebuild 950:

Step-by-step guide for cleaning, rebuilding, and synchronizing the Mikuni BSR-42 carburetors.

Fuel Injection Diagnosis 990:

Troubleshooting guidance for the electronic fuel injection system, including sensor checks and basic ECU diagnostics.

Wheel And Tire Service:

Procedures for wheel removal, tire mounting/dismounting, balancing, and spoke adjustment (for spoked wheels).

Electrical Troubleshooting:

Systematic approach to diagnosing electrical faults using wiring diagrams and test equipment.

Torque Specifications:

Extensive list of torque values for critical fasteners across all systems.

Technical Depth

Depth:

Comprehensive, covering complete disassembly and reassembly of all major components, suitable for both DIY enthusiasts and professional mechanics.

Diagnostic Tools:

Guidance on using basic diagnostic tools and understanding system feedback.

📊 Manual Specifications

File Format

Quality:

High-quality PDF, searchable and bookmarked for easy navigation.

Print Quality

Printability:

Fully printable, allowing users to print specific sections or the entire manual.

Binding Type

Binding:

Digital (PDF format)

Paper Type

Digital Format:

iPad-ready

⚙️ Engine Specifications

Primary Engine

Engine Type:

V-Twin, 4-stroke, LC8 (Liquid Cooled Boxer Engine)

Displacement 950 Adventure:

942 cc (57.5 cu in)

Displacement 990 Super Duke:

999 cc (61.0 cu in)

Valve Train:

DOHC, 4 valves per cylinder, chain driven camshafts

Performance

Bore X Stroke 950 Adventure:

98 x 62.4 mm (3.86 x 2.46 in)

Bore X Stroke 990 Super Duke:

101 x 62.4 mm (3.98 x 2.46 in)

Compression Ratio 950 Adventure:

11.1:1

Compression Ratio 990 Super Duke:

12.5:1

Fuel System

Fuel Delivery 950 Adventure:

Carburetor (Mikuni BSR-42)

Fuel Delivery 990 Super Duke:

Fuel Injection (ECU controlled)

🔧 Transmission

Standard

Transmission Type:

6-speed, claw-shifted, constant mesh

Features

Clutch Type:

Hydraulic actuation, wet multi-plate clutch

📐 Dimensions

Weights

Dry Weight 950 Adventure Approx:

200 kg (441 lbs)

Dry Weight 990 Super Duke Approx:

174 kg (383.6 lbs)

Wet Weight 950 Adventure Approx:

227 kg (500 lbs)

Wet Weight 990 Super Duke Approx:

194 kg (427.7 lbs)

💡 Technology Features

Infotainment

Instrumentation:

Digital/analog combination meter with tachometer, speedometer, odometer, trip meters, and warning lights.

Driver Assistance

ABS Availability:

Available on some later models or as an option on certain variants within this period (refer to specific model details).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Refer to manual for specific mileage/time intervals based on riding conditions.

Valve Clearance Interval:

Refer to manual for specific mileage/time intervals.

Fluid Specifications

Engine Oil Type:

Refer to manual for specific viscosity (e.g., Motorex Power Synt 10W-50 or equivalent).

Coolant Type:

Ethylene glycol based coolant with corrosion inhibitors (refer to manual for specific type and mixture).

Brake Fluid Type:

DOT 4

Clutch Fluid Type:

DOT 4 (shared with brake system)

Chain Lube:

Refer to manual for recommended chain lubricant type and application frequency.

Known Issues

Common Wear Items:

Clutch plates, steering head bearings, wheel bearings, fork seals, and chain/sprockets.

Lc8 Engine Notes:

Known for its strong performance but can be sensitive to maintenance, particularly oil changes and cooling system upkeep. Some early models had cam chain tensioner improvements.

Cooling System Leaks:

Potential for coolant leaks at hose connections or water pump seal, requiring regular inspection.

📚 Vehicle History

Brand Heritage

Manufacturer Origin:

Austria

Model Evolution

950 Adventure Introduction:

Introduced for the 2003 model year, the 950 Adventure established KTM's presence in the large-displacement adventure touring segment with its potent LC8 V-twin engine and off-road capabilities.

990 Super Duke Introduction:

Launched in 2005, the 990 Super Duke built upon the success of the LC8 platform, focusing on naked streetfighter performance with a more powerful engine and refined chassis.

Production

Manufacturing Location:

Austria