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Ktm 950-990 complete technical Manual

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This manual covers the series, along with variants such as the Super Duke, Supermoto, SMR, and SMT. These models, powered by the robust LC8 V-twin engine, were renowned for their...
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Type: Motorcycle
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Sku: 145011
Ktm 950-990 complete technical Manual
This manual covers the series, along with variants such as the Super Duke, Supermoto, SMR, and SMT. These models, powered by the robust LC8 V-twin engine, were renowned for their performance, handling prowess, and versatility, appealing to riders seeking adventure touring capabilities and spirited street riding. The models were produced from approximately 2003 to 2006, with the series following from 2006 to 2013. Key features include premium WP suspension, powerful braking systems, and a strong trellis frame, all contributing to their reputation for dynamic performance and rider engagement. This comprehensive technical service and repair manual provides detailed guidance for all aspects of maintenance, repair, and diagnostics for the and series motorcycles. It encompasses in-depth information on engine mechanicals, fuel and ignition systems, transmission, brakes, suspension, and electrical systems. The manual includes routine maintenance schedules, troubleshooting procedures, and component overhaul instructions, designed to assist both experienced technicians and owner-operators. With approximately 800-1200 pages of expert-level content, this manual serves as an essential resource for ensuring the optimal performance and longevity of your motorcycle.
🏷️ Basic Information
Identification
Make:
KTM
Model:
950 Adventure / 990 Adventure / 990 Super Duke / 990 Supermoto / 990 SMR / 990 SMT
Model Variant Details:
Covers multiple variants within the 950 and 990 platform, including Adventure (Standard, S, SE), Super Duke, Supermoto, SMR, and SMT.
Codes
Engine Code Designation:
LC8 (V-Twin)
👋 Introduction
Market Position
Positioning:
The KTM 950/990 series (LC8 V-twin platform) occupied a niche in the adventure and supermoto segments, known for performance, off-road capability (for Adventure models), and aggressive styling.
Competitive Analysis
Competitors 950 990 Adv:
BMW R1200GS, Triumph Tiger, Yamaha Super Tenere, Honda Africa Twin, Suzuki V-Strom.
Competitors 990 Super Duke:
Ducati Monster, Triumph Speed Triple, Yamaha MT-09/MT-10, Aprilia Tuono.
Key Features Vehicle
Lc8 Engine:
High-performance 75-degree V-twin engine, known for torque and character.
Wp Suspension:
Premium WP suspension components offering excellent adjustability and performance.
Off Road Bias Adv:
Long travel suspension, spoked wheels (often), and rider ergonomics suitable for adventure touring and light off-roading.
Key Features Manual
Completeness:
Promises 'everything you need to service your KTM', indicating a high degree of comprehensiveness for DIY and professional mechanics.
Technical Accuracy:
Derived from official KTM documentation, ensuring accuracy in specifications, procedures, and part identification.
📋 Manual Details
Coverage Areas
Primary Coverage:
Complete service, repair, and maintenance for KTM 950 and 990 series motorcycles.
Secondary Coverage:
Includes diagnostic procedures, electrical systems, troubleshooting, and component overhauls.
Page Count
Estimated Page Count:
Approximately 800-1200 pages (highly variable based on specific edition and included appendices/supplements).
Manual Type
Type:
Comprehensive Technical Service Manual / Repair Manual.
Language
Language:
English (typically). May also be available in other languages depending on the specific publication.
Format
Format:
Digital (PDF) is common. Printed versions also exist.
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Detailed disassembly, inspection, reassembly of engine components including crankshaft, pistons, cylinders, valves, camshafts, timing.
Engine Management:
Fuel injection system (EFI), ignition system, sensors (TPS, MAP, IAT, ECT, O2), ECU diagnostics, EFI tuning basics.
Transmission:
Clutch assembly (hydraulic actuation), gearbox internal inspection and repair, shift mechanism, final drive (chain and sprockets).
Fuel System:
Fuel pump, fuel filters, fuel injectors, throttle bodies, fuel tank maintenance.
Cooling System:
Radiator, coolant hoses, water pump, thermostat, fan operation, coolant type and capacity.
Exhaust System:
Catalytic converters, mufflers, exhaust header pipes, lambda sensors (O2 sensors).
Electrical System:
Wiring diagrams, starter motor, alternator, battery, lighting (headlight, taillight, indicators), fuses, relays, ignition switch.
Braking System:
Front and rear brake calipers, master cylinders, brake lines, brake fluid specifications, ABS (if equipped) troubleshooting.
Suspension:
Front forks (WP USD), rear monoshock (WP), preload, compression, rebound adjustment, oil types and capacities.
Chassis And Frame:
Frame integrity, steering head bearings, swingarm, rear linkage (if applicable).
Wheels And Tires:
Wheel bearing inspection and replacement, spoke tensioning (for spoked wheels), tire pressure recommendations, wheel balancing.
Bodywork And Plastics:
Fairing removal and installation, seat, fuel tank cover, fender components.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements (oil, air), spark plug replacement, chain adjustment and lubrication, brake fluid flush.
Diagnostic Troubleshooting:
Step-by-step guides for identifying and resolving common and uncommon issues, using diagnostic tools where applicable.
Engine Rebuild:
Comprehensive instructions for complete engine teardown, inspection, component replacement, and reassembly.
Suspension Service:
Fork seal replacement, fork oil changes, shock absorber service and adjustments.
Electrical Troubleshooting:
Locating shorts, open circuits, diagnosing sensor failures, using wiring diagrams for fault finding.
Efi Calibration And Tuning:
Basic guidelines for adjusting fuel mixture and ignition timing, although advanced tuning often requires specialized software.
ABS System Maintenance:
Troubleshooting ABS faults, sensor checks, bleed procedures (if applicable).
Technical Depth
Depth:
Expert level. Covers everything from basic user maintenance to complete engine and gearbox overhauls, and complex electrical diagnostics.
Diagnostic Tools:
Mentions diagnostic connectors and basic diagnostic procedures, often referring to dealer-level tools for advanced EFI diagnostics.
📊 Manual Specifications
File Format
Digital Format:
PDF (Portable Document Format). Typically searchable text and high-resolution diagrams.
Print Quality
Print Quality Digital:
High resolution for clear viewing of diagrams, schematics, and photographs.
Binding Type
Printed Binding:
Spiral-bound or saddle-stitched for easy lay-flat viewing during work. Perfect-bound for larger volumes.
Paper Type
Printed Paper:
Durable, often glossy or semi-gloss paper stock to withstand shop environment and provide clarity for illustrations.
⚙️ Engine Specifications
Primary Engine
Engine Type:
4-stroke, V-twin, liquid-cooled, DOHC, 8 valves per cylinder (LC8)
Displacement 950:
942 cc (94 x 68 mm bore x stroke)
Displacement 990:
999 cc (101 x 62.4 mm bore x stroke)
Performance
Horsepower 950 Adv:
Approx. 98 HP @ 8000 RPM
Torque 950 Adv:
Approx. 98 Nm (72 lb-ft) @ 6500 RPM
Horsepower 990 Adv:
Approx. 115 HP @ 9000 RPM
Torque 990 Adv:
Approx. 100 Nm (74 lb-ft) @ 7000 RPM
Horsepower 990 Super Duke:
Approx. 120-130 HP @ 9000 RPM
Torque 990 Super Duke:
Approx. 100 Nm (74 lb-ft) @ 7000 RPM
Fuel System
Fuel Delivery:
Fuel Injection (EFI) with dual throttle bodies.
Fuel Type:
Unleaded gasoline, 95 RON (91 AKI) or higher recommended.
Ignition System:
Digital ignition with dual spark plugs per cylinder.
Lubrication
Oil Type:
Fully synthetic motorcycle oil, SAE 10W-50 or 15W-50, meeting JASO MA/MA2 specifications. (e.g., Motorex Power Synt 4T 10W-50)
Oil Capacity W Filter:
Approx. 3.0 - 3.5 Liters (depending on model and filter).
🔧 Transmission
Standard
Type:
6-speed, claw-shifted constant mesh gearbox.
Optional
Optional Transmissions:
None; all models featured a 6-speed manual transmission.
Features
Clutch Type:
Wet multi-plate clutch with hydraulic actuation.
Final Drive:
O-ring sealed chain, 525 pitch (typically).
📐 Dimensions
Exterior
Length Adv:
Approx. 2250 mm (950/990 Adventure).
Width Adv:
Approx. 900 mm (950/990 Adventure, excluding mirrors).
Height Adv:
Approx. 1450 mm (950/990 Adventure, screen height).
Seat Height Adv:
Adjustable, approx. 860 mm - 880 mm (950/990 Adventure).
Weights
Dry Weight 950 Adv:
Approx. 200-210 kg (441-463 lbs).
Wet Weight 950 Adv:
Approx. 230-240 kg (507-529 lbs).
Dry Weight 990 Adv:
Approx. 205-215 kg (452-474 lbs).
Wet Weight 990 Adv:
Approx. 235-245 kg (518-540 lbs).
Dry Weight 990 Super Duke:
Approx. 182 kg (401 lbs).
Wet Weight 990 Super Duke:
Approx. 200 kg (441 lbs).
Cargo
Fuel Capacity Adv:
22 Liters (5.8 US gal).
Fuel Capacity 990 Sd:
15 Liters (4.0 US gal).
🛡️ Safety Features
Ratings
Safety Ratings:
Motorcycles are not subject to traditional automotive crash test ratings. Safety is assessed through design features and handling dynamics.
Active Features
ABS Availability:
Optional ABS (Anti-lock Braking System) on certain Adventure and Super Duke models. Can often be disabled.
Braking System:
Powerful dual front disc brakes with radial-mount calipers, single rear disc. High-performance braking components.
Passive Features
Frame Design:
Strong trellis frame providing excellent rigidity and rider feedback.
Lighting:
Halogen or LED lighting systems depending on model year and variant. High-visibility indicators.
💡 Technology Features
Infotainment
Infotainment Systems:
These models predated sophisticated integrated infotainment systems. Features were limited to basic instrumentation (speedometer, tachometer, odometer, fuel gauge, basic diagnostics warning lights).
Driver Assistance
ABS:
Optional ABS on select models, as mentioned in safety features. This is the primary electronic rider aid.
Connectivity
Connectivity Features:
No modern smartphone integration or Bluetooth connectivity. Diagnostic port for ECU communication.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 7,500 km (4,600 miles) or annually, whichever comes first. Check manual for exact specifications.
Air Filter Check:
Inspect every 7,500 km (4,600 miles), replace as needed or every 15,000 km (9,200 miles).
Spark Plug Replacement:
Typically every 15,000 km (9,200 miles) or as recommended by the manual for the specific spark plug type.
Valve Clearance Check:
Critical check usually at 15,000 km (9,200 miles) or 30,000 km (18,000 miles) intervals, depending on the model year and specific recommendation.
Brake Fluid Flush:
Recommend every 2 years to maintain braking performance and prevent corrosion.
Chain Maintenance:
Clean and lubricate chain every 1,000 km (600 miles) and adjust tension as needed.
Fluid Specifications
Coolant Type:
Ethylene glycol based coolant, 50% mixture with distilled water. Anti-corrosion and anti-freeze properties. (e.g., Motorex Coolant M3.0).
Brake Fluid Type:
DOT 4 or DOT 5.1 recommended for optimal performance and compatibility.
Fork Oil Type:
WP recommends specific viscosity oils, often around SAE 5W or 7.5W, depending on the model and desired damping characteristics. Check manual for exact type and capacity.
Known Issues
Water Pump Seals:
Early models could experience water pump seal leaks. Regular inspection is advised.
Starter Clutch:
Some models may exhibit starter clutch wear or noise. The manual would detail inspection and replacement procedures.
Fuel Pump Reliability:
Occasional reports of fuel pump issues, particularly with aged units. The manual covers its testing and replacement.
Rear Shock Bushings:
Wear on rear shock linkage bushings can occur with high mileage, affecting handling. Manual would cover inspection and replacement.
📚 Vehicle History
Brand Heritage
Ktm Heritage:
KTM, founded in Austria in 1934, has a rich history in off-road motorsports, particularly motocross and rally raid (Dakar).
Model Evolution
Lc8 Introduction:
The LC8 V-twin engine platform debuted with the 950 Adventure in 2003, revolutionizing KTM's presence in the large-displacement adventure market.
Model Expansion:
The platform was expanded to include the 950 Super Enduro, 950 Supermoto, and subsequently the 990 Adventure, 990 Super Duke, and 990 SMR/SMT variants, showcasing versatility.
Major Updates:
The transition from 950 to 990 saw increases in displacement, fuel injection adoption, and chassis refinements. Later 990 models received updates like revised suspension, electronics, and styling.
Production
Production Years:
950 models: approx. 2003-2006. 990 models: approx. 2006-2013.
Manufacturing Location:
Austria (primarily).
🏆 Awards & Recognition
Recognitions
Industry Acclaim:
The 950/990 platform received significant praise for its performance, handling, and versatility, particularly the Adventure models, winning numerous 'best adventure bike' comparisons in their era.
Motorcycle Press Reviews:
Consistently lauded for its powerful LC8 engine, capable WP suspension, and distinctive 'Ready to Race' KTM character.
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