This manual covers the models from the 2003 to 2006 production years. These motorcycles are renowned for their off-road and adventure motorcycles, with a strong racing heritage. The 950 Adventure marked a significant entry into the large-displacement adventure touring segment, featuring a V-twin, four-stroke LC8 engine. The 990 Adventure succeeded the 950, typically featuring fuel injection and engine refinements for improved performance and emissions. These motorcycles are engineered for durability and capability, offering a robust platform for both on-road touring and off-road exploration.
This Factory Service Repair Manual provides comprehensive English language documentation for the 950 and 990 Adventure. It offers detailed, step-by-step instructions, illustrations, drawings, and photos covering all aspects of maintenance, diagnostics, and repair. Key areas include the general information, fuel system, cooling system, engine top end, clutch, lubrication system, engine removal and installation, crankshaft and transmission, wheels and tires, final drive, brakes, suspension, steering, frame, and electrical system. Additionally, it includes advanced troubleshooting guides, common issue resolutions, and specific tuning procedures, empowering owners and technicians to maintain and repair these machines effectively.
Years Covered:
2003, 2004, 2005, 2006
Target Audience:
KTM 950/990 Adventure owners, DIY mechanics, professional technicians.
Value Proposition:
Saves $50-$60 per hour on shop labor costs by enabling owner self-servicing. Provides factory-level knowledge.
Feature Highlight 1:
COMPLETE official full factory service repair manual.
Feature Highlight 2:
Actual Genuine Repair Service Factory Manuals, NOT 3rd party.
Feature Highlight 3:
Highly detailed with hundreds of pages of comprehensive information.
Feature Highlight 4:
Step-by-step instructions with detailed illustrations, drawings, and photos.
Feature Highlight 5:
Advanced troubleshooting guide and diagnostic procedures.
Manual Type:
Factory Service Repair Manual
Page Count:
Hundreds of pages
Origin:
Official Factory Manuals
General Information:
True
Engine Lubrication System:
True
Engine Removal Installation:
True
Crankshaft Transmission:
True
Diagnostics:
Engine fault symptom diagnosis, troubleshooting guide, advanced troubleshooting
Maintenance:
Fundamental maintenance, common tips before problems escalate
Repair:
Step-by-step repair procedures, fixing problems, component testing, electrical system repair
Rebuild:
Complete rebuild procedures
Tuning:
Tuning procedures
Depth:
Comprehensive: From fundamental maintenance to advanced diagnostics and complete rebuilds.
Detail Level:
Extremely detailed, step-by-step instructions and photos.
Wiring Diagrams:
Detailed wiring diagrams for ease of use and tracing.
Special Techniques:
Secret techniques used by top mechanics for part testing.
Engine Management:
Understanding and analyzing engine management systems.
Compatibility:
All PC-based Windows operating systems and Mac.
Searchability:
Searchable PDF for easy information retrieval.
Printability:
Printable without any restriction (individual pages or entire manual).
Resolution:
High resolution.
Binding:
Downloadable (no physical binding).
Paper Type:
N/A (Digital Download)
Delivery Method:
Instant download link on checkout page after payment.
Software Requirements:
Adobe PDF Reader
Engine Type 950:
V-twin, four-stroke LC8 engine
Engine Type 990:
V-twin, four-stroke LC8 engine
Displacement 950:
942 cc (57.5 cu in)
Displacement 990:
999 cc (61.0 cu in)
Bore Stroke 950:
97.0 mm x 64.0 mm (3.82 in x 2.52 in)
Bore Stroke 990:
101.0 mm x 62.4 mm (3.98 in x 2.46 in)
Fuel Delivery:
Carbureted (950), Fuel Injection (990)
Carburetor Details:
Mikuni BSR-42 (typical for 950 models covered)
Throttle Body Size 990:
48 mm (typical for 990 models covered)
Ignition System:
Dual ignition system
Fuel Type:
Unleaded gasoline (minimum 95 RON / 91 AKI)
Transmission Type:
6-speed, claw-shifted
Optional Transmission:
N/A
Clutch Type:
Wet multi-plate clutch, hydraulically actuated
Gear Ratios:
Detailed in manual (specific ratios vary slightly between 950/990)
Transmission Fluid Type:
Manual specifies specific transmission oil grades and capacities.
Wheelbase 950 990:
Approx. 1550 mm (61.0 in) - specific variations exist
Dry Weight 950:
Approx. 202 kg (445 lbs)
Dry Weight 990:
Approx. 207 kg (456 lbs)
Fuel Tank Capacity:
Approx. 22 Liters (5.8 US gal)
Safety Rating:
N/A for motorcycle safety ratings in this context.
Brakes:
Dual front disc brakes, single rear disc brake, often with ABS on later models or optional.
Suspension Systems:
Inverted front forks and monoshock rear suspension with adjustable damping.
Lighting:
Halogen headlights, LED taillights (model dependent).
Infotainment System:
Basic dashboard instrumentation, no advanced infotainment systems typical of modern vehicles.
ABS:
Available as an option or standard on later models within this range, detailed in manual.
Connectivity Features:
N/A
Oil Change Interval:
Refer to manual for specific mileage/time intervals (typically 5,000-7,500 km / 3,000-5,000 miles).
Valve Check Interval:
Refer to manual for specific mileage/time intervals (typically 10,000-15,000 km / 6,000-9,000 miles).
Air Filter Cleaning:
Recommended at regular intervals, especially in dusty conditions.
Engine Oil Type:
Manual specifies specific API SG or higher, JASO MA-certified motorcycle oils (e.g., 10W-40 or 10W-50).
Engine Oil Capacity:
Refer to manual for exact capacity (typically around 2.5-3.0 liters with filter change).
Coolant Type:
Ethylene glycol-based antifreeze mixture with distilled water.
Brake Fluid Type:
DOT 4 brake fluid.
Common Issue 1:
Cam chain tensioner wear (early models).
Common Issue 2:
Water pump seal leaks.
Common Issue 3:
Starter motor issues on some units.
Common Issue 4:
Fuel pump relay failure (990 models).
Common Issue 5:
Carburetor jetting and tuning (950 models) for optimal performance.
Brand Focus:
KTM is renowned for its off-road and adventure motorcycles, with a strong racing heritage.
Model Introduction 950:
The 950 Adventure marked KTM's significant entry into the large-displacement adventure touring segment.
Transition To 990:
The 990 Adventure succeeded the 950, typically featuring fuel injection and engine refinements for improved performance and emissions.
Manufacturing Location:
Austria (KTM headquarters)
Award Details:
While specific awards for these model years are not directly listed in the product information, the KTM Adventure line is generally well-regarded in the adventure touring segment for its performance and off-road capability.
