This manual covers the KTM 950 Adventure and 990 Adventure models produced between 2003 and 2007. These motorcycles are renowned for their robust construction, off-road capabilities, and suitability for long-distance touring, drawing on KTM's extensive heritage in off-road racing. The 950 Adventure, powered by a 942 cc V-twin LC8 engine, features a carbureted fuel system and delivers approximately 98-103 horsepower. The later 990 Adventure offers a larger 999 cc V-twin LC8 engine with electronic fuel injection and produces around 105-115 horsepower, representing an evolution in performance and refinement. Both models are built upon a strong steel trellis frame, feature a hydraulically operated wet multi-disc clutch, and a 6-speed manual gearbox, making them versatile machines for various riding conditions.
This comprehensive workshop service repair manual is designed to provide detailed guidance for the maintenance and repair of your KTM 950 or 990 Adventure. It covers all major systems, including the engine (mechanical and electrical), emission control, fuel system, suspension, clutch, transmission, driveshaft, steering, brakes, and bodywork, both interior and exterior. Within its pages, you will find essential procedures for routine maintenance, troubleshooting, diagnostics, and repair, complete with detailed illustrations, diagrams, and wiring schematics. This manual aims to empower owners and technicians with the knowledge needed to keep these capable motorcycles in optimal working condition, ensuring reliability and performance through clear, step-by-step instructions.
Production Years:
2003-2007
Purpose:
Essential resource for maintaining and repairing KTM 950/990 Adventure motorcycles, catering to both DIY enthusiasts and professional mechanics.
Value Proposition:
Provides an inexpensive way to keep vehicles working properly, offering a comprehensive alternative to costly dealership services.
Content Highlights:
Detailed illustrations, diagrams, wiring schematics, specifications, and step-by-step instructions for all major systems and procedures.
Usability:
Printable pages, numbered table of contents, bold figure numbers for quick reference, and combined troubleshooting/electrical diagrams.
Vehicle Models Covered:
KTM 950 Adventure, KTM 990 Adventure
Model Years Covered:
2003, 2004, 2005, 2006, 2007
Estimated Page Count:
Comprehensive (specific count not provided, but described as 'complete' and covering 'every detail')
Type:
Workshop Service Repair Manual / Factory Service Repair Manual
Automatic Transaxle:
Yes (likely refers to optional transmission variants or components within the broader system)
Body Interior Exterior:
Yes
Body Electrical System:
Yes
Restraint System:
Yes (likely refers to safety systems, possibly including seat belts if applicable to the Adventure models)
Rebuild:
Yes (implied by 'complete' and detailed instructions)
Depth:
Comprehensive, covering detailed substeps, notes, cautions, warnings, and step-by-step instructions for both general and experienced users.
Digital Features:
Zoom IN/OUT capability
Printability:
Fully Printable
Binding:
N/A (Digital PDF format)
Paper Type:
N/A (Digital PDF format)
Delivery:
Instant Download
Software Required:
Adobe PDF Reader, WinZip
Operating Systems:
All Versions of Windows & Mac
Engine Type 950:
V-twin, four-stroke (LC8 engine)
Engine Type 990:
V-twin, four-stroke, fuel-injected (LC8 engine)
Displacement 950:
942 cc (57.5 cu in)
Displacement 990:
999 cc (61.0 cu in)
Horsepower 950:
Approx. 98-103 hp (specific figures vary by market and tuning)
Horsepower 990:
Approx. 105-115 hp (specific figures vary by market and tuning)
Torque 950:
Approx. 95 Nm (70 lb-ft) (specific figures vary)
Torque 990:
Approx. 99-100 Nm (73-74 lb-ft) (specific figures vary)
Fuel Delivery 950:
Carbureted (Mikuni BSR 37)
Fuel Delivery 990:
Electronic Fuel Injection (EFI) with twin injectors per cylinder
Type:
6-speed sequential manual gearbox
Options:
N/A (standard manual transmission across the range)
Clutch Type:
Hydraulically operated, wet multi-disc clutch
Wheelbase:
Approx. 1550 mm (61.0 in) - Varies slightly by model/year
Seat Height:
Approx. 880-910 mm (34.6-35.8 in) - Adjustable on some models
Dry Weight 950:
Approx. 192 kg (423 lbs)
Dry Weight 990:
Approx. 196 kg (432 lbs)
Wet Weight Estimated:
Approx. 212 kg (467 lbs) (with fluids, varies)
Safety Certifications:
Complies with relevant motorcycle safety standards for its production era (specific ratings like Euro NCAP are not applicable to motorcycles in this manner).
Braking System:
Dual front discs with multi-piston calipers, single rear disc with caliper. ABS was an optional feature on later models.
Lighting:
Halogen headlights, LED taillights and indicators (model dependent).
Frame Construction:
Lightweight, high-strength steel trellis frame.
Ergonomics:
Designed for long-distance touring and off-road capability, with upright riding position and adjustable components.
Dashboard:
Analog tachometer, digital speedometer, trip meters, fuel gauge, and warning lights. Some models may have more advanced displays.
ABS Availability:
Optional Anti-lock Braking System (ABS) available on select models and years within the 2003-2007 range.
Charging Port:
Accessory power socket (cigarette lighter style) often present for GPS or device charging.
Oil Change Interval:
Typically every 5,000 - 10,000 km (3,000 - 6,000 miles) or annually. Consult manual for specifics.
Valve Clearance Check:
Typically every 10,000 - 20,000 km (6,000 - 12,000 miles). Consult manual for specifics.
Engine Oil Type:
SAE 10W-50 or 15W-50 JASO MA/MA2 certified motorcycle oil (consult manual for exact specification).
Coolant Type:
Ethylene glycol-based coolant with anti-corrosion additives. Typically a 50/50 mix with distilled water.
Brake Fluid Type:
DOT 4 (or DOT 5.1 as per some specifications) hydraulic brake fluid.
Common Wear Items:
Clutch plates, wheel bearings, steering head bearings, exhaust valve cable (on some models), fuel pump (EFI models).
Potential Concerns:
Some owners report potential issues with the wiring harness, charging system components, and occasional water pump seal leaks. Regular maintenance is key.
Ktm Offroad Legacy:
KTM has a strong heritage in off-road racing, particularly Enduro and Dakar Rally, which heavily influences the design and capability of the Adventure models.
950 Introduction:
The 950 Adventure was introduced in 2003, building on KTM's off-road expertise to create a capable adventure touring motorcycle.
990 Introduction:
The 990 Adventure, featuring fuel injection and an updated engine, was introduced to supersede and complement the 950, offering improved performance and refinement.
Manufacturing Location:
Austria (primarily KTM's headquarters)
Motorcycle Journalist Reviews:
Consistently praised by motorcycle publications for its off-road prowess, long-distance comfort, and robust build quality. Often cited as a benchmark in the adventure touring segment.
Owner Satisfaction:
High owner satisfaction due to its capability and durability, though maintenance requires a certain level of commitment.
