Segment:
High-performance adventure touring and sport motorcycles.
Target Audience:
Owners and independent repair shops seeking comprehensive repair and maintenance information.
Comparable Models:
BMW R1200GS series, Triumph Tiger series, Ducati Multistrada series (of the same era).
Powertrain:
Powerful LC8 V-twin engine, known for its torque and performance.
Adventure Capability:
Designed for long-distance touring and off-road capability, with robust suspension and chassis.
Sport Performance:
The Super Duke and Supermoto models leverage the LC8 platform for exhilarating road performance.
Owner Empowerment:
Enables owners to perform maintenance and repairs themselves, saving costs and increasing understanding of their machine.
Professional Resource:
Provides the same level of detail and accuracy used by professional technicians.
Engine Electrical Injection:
Yes
Periodic Maintenance:
Yes
Technical Specifications:
Yes
Bodywork:
Implied within general repair procedures
Estimated Page Count:
High (typical workshop manuals for this era are several hundred pages)
Type:
Workshop Service Repair Manual
Languages Covered:
English (primary), German (REPARATURANLEITUNG), Italian (MANUALE DI RIPARAZIONE), French (MANUEL DE RÉPARATION), Spanish (MANUAL DE REPARACIÓN)
Engine Disassembly Assembly:
Comprehensive, from basic removal and refitting to detailed component servicing and reassembly.
Fuel Delivery Management:
Includes carburetors (for 950 models) or fuel injection systems (for 990 models), fuel pump, lines, and filters.
Ignition And Charging:
Covers stator, ignition coil, spark plugs, battery, and charging system components.
Cooling System:
Radiator, cooling fan, coolant flow, and related components.
Lubrication System:
Oil pump, oil filter, oil passages, and oil change procedures.
Clutch System:
Clutch operation, hydraulic system, and clutch plate servicing.
Transmission Gearbox:
Gear selection, internal components, and lubrication.
Suspension Front Rear:
Fork servicing, rear shock absorber adjustment and maintenance.
Braking System Front Rear:
Brake caliper, master cylinder, brake lines, pads, and rotor servicing.
Wheel And Tire Assembly:
Wheel bearing replacement, tire fitting and balancing.
Exhaust System:
Exhaust pipe and muffler inspection and replacement.
Control Systems:
Throttle control, clutch lever, brake lever, and cable routing.
Electrical Components:
Lights, horn, starter motor, instruments, and switches.
Routine Maintenance:
Oil changes, filter replacements, chain adjustment, lubrication points, spark plug replacement.
Diagnostic Troubleshooting:
Step-by-step guides for identifying and resolving common mechanical and electrical issues.
Engine Rebuilding:
Detailed instructions for engine disassembly, cleaning, inspection of components (pistons, rings, valves, crankshaft), and reassembly with torque specifications.
Suspension Overhaul:
Front fork seal replacement, oil level checks, rear shock absorber servicing.
Brake System Service:
Brake fluid bleeding, pad and rotor replacement, caliper and master cylinder rebuild.
Electrical Troubleshooting:
Use of wiring diagrams to diagnose faults in lighting, starting, ignition, and accessory circuits.
Fuel System Adjustment:
Carburetor synchronization and jetting (950 models), fuel injector diagnostics (990 models).
Valve Adjustment:
Procedure for checking and adjusting valve clearance (shims or screw adjusters depending on specific engine variant).
Depth:
Comprehensive: Covers everything from basic maintenance checks and adjustments to complete engine and chassis rebuilds, including electrical system diagnostics.
Diagnostic Capability:
Advanced: Utilizes troubleshooting flowcharts and detailed explanations of system functions.
Rebuild Detail:
Detailed step-by-step instructions with required torque specifications and critical measurements for engine and component rebuilds.
Engine Family:
LC8 V-Twin
950 Adventure/Supermoto/Super Enduro Engine:
72° V-twin, liquid-cooled, DOHC, 4 valves per cylinder
950 Engine Displacement:
942 cc (57.5 cu in)
950 Engine Power Output:
Approx. 98-105 hp (72-77 kW) at 8000 rpm (varies slightly by model and year)
950 Engine Torque:
Approx. 95-100 Nm (70-74 lb-ft) at 6000 rpm
990 Adventure/Super Duke Engine:
75° V-twin, liquid-cooled, DOHC, 4 valves per cylinder
990 Engine Displacement:
999 cc (61.0 cu in)
990 Engine Power Output:
Approx. 105-115 hp (77-85 kW) at 8000 rpm (varies slightly by model and year)
990 Engine Torque:
Approx. 98-105 Nm (72-77 lb-ft) at 6500 rpm
950 Models Fueling:
Dual Keihin CV carburetors (e.g., 38mm)
990 Models Fueling:
Electronic Fuel Injection (EFI)
Compression Ratio 950:
10.4:1
Compression Ratio 990:
11.5:1 (approx.)
Seat Height 950 Adventure:
Approx. 880-900 mm (34.6-35.4 in) adjustable
Ground Clearance 950 Adventure:
Approx. 265 mm (10.4 in)
Dry Weight 950 Adventure:
Approx. 198 kg (436.5 lbs)
Dry Weight 990 Adventure:
Approx. 203 kg (447.5 lbs)
Dry Weight 990 Super Duke:
Approx. 183 kg (403.4 lbs)
Oil And Filter Change:
Typically every 7,500 km (4,660 miles) or annually.
Valve Clearance Check:
Typically every 15,000 km (9,320 miles).
Spark Plug Replacement:
Refer to manual, often around 15,000-20,000 km (9,320-12,430 miles).
Air Filter Service:
Recommended at regular intervals, more frequently in dusty conditions.
Engine Oil Type 950:
SAE 10W-40, API SJ or higher, JASO MA compatible (e.g., Motorex Power Synt 4T 10W-40)
Engine Oil Type 990:
SAE 10W-50, API SJ or higher, JASO MA compatible (e.g., Motorex Power Synt 4T 10W-50)
Coolant Type:
Ethylene glycol-based coolant with corrosion inhibitors (e.g., Motorex Coolant M5.0)
Brake Fluid Type:
DOT 4 hydraulic fluid
Clutch Fluid Type:
DOT 4 hydraulic fluid
Carburetor Sync 950:
Carburetors may require periodic synchronization for optimal performance.
Starter Clutch Wear:
Some early models reported potential wear on the starter clutch mechanism.
Water Pump Seals:
Potential for water pump seal leaks, especially with age.
Fuel Pump Reliability 990:
Early EFI models sometimes experienced fuel pump issues, though often addressed by KTM service bulletins.
Brand Focus:
KTM is renowned for its off-road prowess and performance-oriented motorcycles, often referred to as 'Ready to Race'.
Lc8 Platform Introduction:
The LC8 engine platform was a significant development for KTM, moving into larger displacement street-legal and adventure bikes.
950 Adventure Debut:
Introduced in 2003, it established KTM as a major player in the adventure touring segment.
990 Series Introduction:
The 990 models, featuring fuel injection and larger displacement, followed, offering further refinement and performance.
Manufacturing Origin:
Austria
