KTM 950 Service Manual

REPAIR MANUAL

REPARATURANLEITUNG

MANUALE DI RIPARAZIONE

MANUEL DE RÉPARATION

MANUAL DE REPARACIÓN

ART.NR.: 3.206.009-E

KTM Group Partner

950ADVENTURE2003

950ADVENTURE

REPAIR

MANUAL

1 SERVICE-INFORMATIONS

2 GENERAL INFORMATION

3 REMOVING AND REFITTING ENGINE

4 DISASSEMBLING ENGINE

5 SERVICING INDIVIDUAL COMPONENTS

6 ASSEMBLING ENGINE

7 ELECTRICAL

8 FUEL SYSTEM

9 TROUBLE SHOOTING

10 CHASSIS

11 TECHNICAL SPECIFICATIONS

12 PERIODIC MAINTENANCE SCHEDULE

13 WIRING DIAGRAMS

IMPORTANT

INFORMATION

KTM REPAIR MANUAL IN LOOSE-LEAF FORM

STORING THE REPAIR MANUAL IN THE BINDER

– Put the index into the binder. – Put the front page of the repair manual (210x297 mm) into the transparent pocket provided for

this purpose on the outside of the binder.

– Put the spine label (170x45 mm) into the transparent pocket provided for this purpose on the

spine of the binder.

– Put the summary list of contents (150x297 mm) into the transparent pocket provided for this

purpose on the inside of the binder or insert this page on the beginning of the manual.

– Then insert the individual chapters of the manual between the sheets of the index according to

the page number printed in the right bottom corner of each page. Example: page no. 3-5 3 = chapter 3 5 = page 5 All pages with a page number that begins with the digit 3, for example, must be put under the index heading „Chapter 3“.

– Index sheets that have not been marked with a certain chapter are for your personal convenience.

he respective headings can be entered in the list of contents.

INTRODUCTION

This repair manual offers extensiv repair-instructions and is an up-to-date version that describes the latest models of the series. However, the right to modifications in the interest of technical improvement is reserved without updating the current issue of this manual.

A description of general working modes common in work shops has not been included. Safety rules common in the work shop have also not been listed. We take it for granted that the repairs are made by qualified profesionally trained mechanics.

Read through the repair manual before beginning with the repair work.



WARNING



STRICT COMPLIANCE WITH THESE INSTRUCTIONS IS ESSENTIAL TO AVOID DANGER TO LIFE AND LIMB.

CAUTION

NON-COMPLIANCE WITH THESE INSTRUCTIONS CAN LEAD TO DAMAGE OF MOTORCYCLE COMPONENTS OR RENDER MOTORCYCLES UNFIT FOR TRAFFIC !

„NOTE” POINTS OUT USEFUL TIPS.

Use only ORIGINAL KTM SPARE PARTS when replacing parts. The KTM high performance engine is only able to meet user expectations if the maintenance work is

performed regularly and professionally.

KTM Austria’s certificate of achievement for its quality system ISO 9001 is the beginning of an ongoing total reengineered quality plan for a brighter tomorrow.

KTM Sportmotorcycle AG

5230 Mattighofen, Austria

All design and assembly modification rights reserved.

REPLY FAX FOR REPAIR MANUALS

We have made every effort to make our repair manuals as accurate as possible but it is always possible for a mistake or two to creep in.

To keep improving the quality of our repair manuals, we request mechanics and shop foremen to assist us as follows:

If you find any errors or inaccuracies in one of our repair manual – whether these are technical errors, incorrect or unclear repair procedures, tool problems, missing technical data or torques, inaccurate or incorrect translations or wording, etc. – please enter the error(s) in the table below and fax the completed form to us at 0043/7742/6000/5349.

NOTE to table:

– Enter the complete item no. for the repair manual in column 1 (e.g.: 3.206.009-E).

You will find the number on the cover page or in the left margin on each right page of the manual.

– Enter the corresponding page number in the repair manual (e.g.: 5-7c) in column 2. – Enter the current text (inaccurate or incomplete) in column 3 by quoting or describing the respective

passage of the text. If your text deviates from the text contained in the repair manual, please write your text in German or English if possible.

–

Enter the correct text in column 4.

Your corrections will be reviewed and incorporated in the next issue of our repair manual.

Item no. of repair manual Page Current text Correct text

Additional suggestions, requests or comments on our Repair Manuals (in German or English):

Name mechanic/shop foreman Company/work shop

GENERAL INFORMATION

Repair manual KTM LC8

Art.-Nr. 3.206.009-E

OIL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

AIR INTAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3

SLS-SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

SPECIALTOOLS – CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

SPECIALTOOLS – ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7

BLEEDING THE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9

INDEX

2-1

2-2

Repair manual KTM LC8 Art.-Nr. 3.206.009-E

Oil system

Pressure pump 1 draws engine oil from oil tank

2 through oil filter 3 and the oil return valve 4

and pumps it past the pressure relief valve 5 through the oil filter 6 into the annular groove

The main bearing

8, the conrod bearings 9 and

the spraying nozzle

bk (front timing chain) are

supplied with oil through holes in the crankshaft. An oil duct leads to spraying nozzle

bl (piston

cooling), the timing chain tensioner

bm, the

camshaft

bn and the oil pressure switch bo in the

front cylinder. Another oil duct leads from the annular groove to a distributor groove

bp in the clutch cover.

From there an oil duct leads to the spraying nozzle

bq (piston cooling). Another oil duct

supplies the timing chain tensioner

br, the

spraying nozzle

bs (timing chain) and the

camshaft

bt on the rear cylinder with oil.

Another oil duct leads to the oil line

ck that

lubricates the transmission gears. The suction pump

cl draws the oil from the oil sump cn

through the screen cm into the oil tank 2.

2-3

Intake system

Fresh air is drawn into the filter box through the intake snorkel 1, past the carburetors 2 and through the air filter 3. The cleaned air is conducted to the combustion chamber through the carburetors and intake ports.

2-4

Repair manual KTM LC8 Art.-Nr. 3.206.009-E

Secondary air system

The secondary air system supplies fresh air to the emissions in the exhaust port, resulting in the afterburning (oxidation) of the emissions. A line leads from the filter box

1 to the control valve 2 which opens as soon as the throttle valves 3 are opened. The

line continues to the reed valves

4 in the cylinder heads which are actuated by the pressure pulsation in the exhaust system. As a

result, cleansed fresh air arrives in the exhaust port. The oxygen content in the air and the high exhaust gas temperature cause the emissions to oxidize. If the throttle valves are closed and the engine goes into an overrun condition, the underpressure in the intake port will rise and the control valve will close. This prevents exhaust backfire (combustion of the unburned fuel/air mixture).

2-5

Closed thermostat

The thermostat is closed if the temperature of the cooling liquid drops below 75° C. The water pump 1 pumps the cooling liquid through the cylinder and cylinder heads

2 and the thermostat 2.

Open thermostat

The thermostat 3 opens at 75° C. The water pump 1 pumps the cooling liquid through the cylinder and cylinder heads 2, the aluminum cooler

4 and the thermostat. The pressure in the cooling system (max. 1.4 bar) is regulated by a valve in the radiator

cap

5. The cooling liquid level in the compensating tank 6 must be between the MIN and MAX marks when the engine is cold.

The fan

7 switches on at 102° C.

Cooling system

2-6

Repair manual KTM LC8 Art.-Nr. 3.206.009-E

SPECIALTOOLS

– CHASSIS

FIG PART NO DESCRIPTION

1 151.12.017.000 Gear puller 2 584.29.086.000 Pressing tool for swing arm bearing 3 584.29.089.000 Chassis tool holder 4 584.29.091.000 Press-in tool for

bearing seat / rear wheel bearing

5 584.29.092.000

Knock-out tool for bearing seat 6 600.03.022.000 Center stand 7 600.10.013.000 Sleeve for pressing tool for swim arm bearing 8 600.29.018.000 Internal gear puller 28 mm 9 600.29.020.000 Chain rivet tool

10 600.29.055.000 Center stand lock 11 600.29.055.100 Floor jack attachment 12 600.29.056.000 Anvil dolly (for 584.29.086.000) 13 600.29.057.000 Pliers for Öttiker clamps 14 600.29.057.100 Pliers for spring-loaded band-type clamp

2-7

648

LOCTITE

243

2-8

Repair manual KTM LC8 Art.-Nr. 3.206.009-E

SPECIAL TOOLS

– ENGINE

FIG PART NO DESCRIPTION

1 309098 Seal Three-Bond 2 0113 080802 Crankshaft locking bolt 3 151.12.017.000 Gear puller 4 503.29.050.000 Bleeding syringe for hydraulic clutch 5 560.12.001.000 Universal-engine work stand 6 584.29.059.000 Loctite 648 green 20 ml 7 585.29.005.000 Protection sleeve for shaft seal ring of water pump 8 590.29.019.000 Valve spring mounter 9 590.29.026.006 Limit plug gauge 6,05 mm

10 590.29.041.000 Feeler gauge for valve clearance 11 6 899 785 Loctite 243 blu 6 cm3 12 600.29.002.000 Engine holder for engine work stand 13 600.29.003.000 Clutch holder 14 600.29.005.000 Protection sleeve for shaft seal ring of output shaft 15 600.29.009.000 Magneto extractor 16 600.29.009.010 Protection bolt for magneto extractor 17 600.29.010.000 Degree wheel 18 600.29.011.000 Carburator synchronisation tool 19 600.29.012.000 Plastigauge-measuring strips 20 600.29.015.000 Piston ring mounting tool 21 600.29.016.000 Setting gauge for float level 22 600.29.018.000 Internal gear puller 28 mm 23 600.29.031.000 Protection sleeve for crankshaft (for pulling of the primary gear) 24 600.29.033.000 Puller for primary gear 25 600.29.041.000 Valve spring mounter insert 26 600.29.043.010 Pressing tool for seal of clutch release shaft 27 600.29.043.020 Pressing tool for seal of output shaft 28 600.29.043.030 Pressing tool for seal and bearing of shifting shaft 29 600.29.043.040 Pressing tool for seal of water pump 30 600.29.043.050 Pressing tool for seal of balancer shaft 31 600.29.044.050 Pressing tool for main bearings (In/out) 32 600.29.046.028 Pressing tool for supporting bearing (In) 33 600.29.073.000 Spark plug wrench 16 mm 34 600.29.075.000 Special nut for conrod 35 600.29.081.000 Special tool for cylinder head nuts 36 600.29.082.000 Holder for water pump wheel 37 600.29.083.000 Special nut for cylinder head nuts

2-9

Checking the oil level of the hydraulic clutch

To check the oil level in the master cylinder of the clutch remove the cover. For this purpose, remove bolts and cover together with the rubber boot

1. The oil level in the horizontal-standing master cylinder should

be 4 mm below the upper edge. If necessary add SAE 10 biodegradable hydraulic oil (e.g. Motorex Kupplungs-Fluid 75).

CAUTION

NLY USE SAE 10 BIODEGRADABLE HYDRAULIC OIL TO REFILL THE MASTER

CYLINDER

NEVER USE BRAKE FLUID NOR MIX BIODEGRADABLE HYDRAULIC OILS WITH

MINERAL OILS

Bleeding of the hydraulic clutch

For bleeding, the cover of the master cylinder of the clutch needs to be removed. For this purpose, remove bolts and take off cover together with rubber bellows

1. At the slave cylinder of the clutch, remove the

bleeder nipple. At its place, mount the bleeder syringe

2 which is filled

with biodegradable hydraulic oil (e.g. Motorex Kupplungs-Fluid 75).

Refill oil, until oil is discharged from the bore

A of the master cylinder in

a bubble-free state. Make sure that the oil does not overflow.

CAUTION

HAVING COMPLETED THE BLEEDING PROCEDURE, YOU HAVE TO VERIFY THAT THE OIL

LEVEL IN THE MASTER CYLINDER IS CORRECT

. FOR FILLING OF THE MASTER CYLINDER,

USE

SAE 10 BIODEGRADABLE HYDRAULIC OIL ONLY

(

EX. MOTOREX KUPPLUNGS-

LUID 75); NEVER USE BRAKE FLUID NOR MIX BIODEGRADABLE HYDRAULIC OILS WITH

MINERAL OILS

REMOVING AND REFITTING ENGINE

Repair manual KTM LC8

Art.-Nr. 3.206.009-E

REMOVING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

REFITTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7

INDEX

3-1

3-2

Repair manual KTM LC8 Art.-Nr. 3.206.009-E

Removing the engine

– Screw the center stand 600.03.022.000 onto the frame 1 and jack

up the motorcycle on a firm, even surface.

– Remove the left bump rubber and lock the center stand with the lock

600.29.055.000

NOTE: if available, use the center stand already on the bike. – Unlock the seat lock with the ignition key and remove.

– Remove the bolts

3 on the left and right of the front side covers,

disconnect the front turn signal, pull the tank vent hoses off of the fuel tank and remove the side covers.

– Open the tank cover, unscrew the fixing bolts

4 and remove the

upper tank compartment.

– Remove the bolts

5 on the lower tank compartment and the fuse

box, take the cover off the fuse box and dismount the lower tank compartment.

– Close the fuel cocks, disconnect the gasoline hoses, unscrew the

upper

6 and lower 7 fixing bolts on both fuel tanks and remove the

tanks together with the lower vent hoses.

NOTE: it is easier to disconnect the gasoline hoses if you remove the front bolts on the underride protection and fold the engine guard down.

– Drain the engine oil from the oil tank and the engine: see page 12-4.

– Remove the 4 bolts

8 on the underride protection and take off the

underride protection.

– Remove both bolts

9 on the front cover and take off the cover.

– Open the lid on the battery compartment and disconnect the battery

terminals

bk (starting with the negative pole).

– Take out the battery and remove the upper battery cover.

3-3

– Unscrew the bolts 1 and remove the intake snorkel 2 together with

the frame from the air filter box.

– Disconnect the vent hose and the EPC hose and remove the upper

half of the air filter box.

– Turn the intake trumpet

3 in a clockwise direction and remove.

Remove air filter.

– Unbolt both side covers on the lower air filter box and remove the

clamps on the carburetor connection boot.

– Detach the EPC hoses

4 from both carburetors and pull the hoses

out of the lower air filter box. – Remove both vent hoses from the carburetors. – Lift both carburetors, carefully draw the cable for the idle speed

adjustment and the gasoline hose through the openings in the lower

air filter box. – Detach the fuel hoses from the carburetors. – Pull the carburetor connection boots off of the intake manifolds.

– Detach the SLS valve

5 from the lower air filter box, pulling the thin

hose from the intake manifold and the thick hose from the valve.

Remove the valve. – Remove the EPC valve

6 from the lower air filter box and

disconnect. –Tilt up the carburetors and fasten to the handlebar with a wire or

rubber band. They do not need to be completely dismounted. – Take the lower air filter box out of the frame.

NOTE: cover the intake ports with a cloth to prevent any parts from falling inside.

– Unscrew both nuts

7 on the front exhaust manifold flange on the

cylinder head, loosen the exhaust clamp

8 on the front exhaust

manifold, pull the front exhaust manifold out of the rear exhaust pipe

and remove. – Unscrew the rear exhaust manifold from the cylinder head.

3-4

Repair manual KTM LC8 Art.-Nr. 3.206.009-E

– Disconnect the electric connections from the fan motor and the

temperature switch

– Drain the cooling liquid from the radiator and engine: see

page 12-16.

– Detach the water hoses from the radiator (special pliers

600.29.057.100) and unscrew the radiator

2 .

NOTE: fan and radiator shield do not need to be dismounted from the radiator.

– Pull off the oil lines from the oil tank to the valve covers

3 and the

return line

4 (special pliers 600.29.57.100), unscrew the oil lines

from the oil terminal

5 and pull out. Remove the O-rings.

– Loosen the fixing bolts

6 on the oil tank, remove the oil tank and

carefully pull out the oil line.

– Disconnect the side stand switch

7 and take the cable out of the

cable clips.

– Loosen the two bolts and the nut

8 and remove the side stand.

– Unscrew the clutch slave cylinder

9 and the chainguard bk and pull

the locking pin out of the pushrod.

– Dismount the chain roller and chain securing guide.

3-5

– Unscrew the nut on the wheel spindle, pull out the rear wheel

spindle, take the chain off of the rear sprocket and place over the side

of the bracket

1. Remove the chain from the engine sprocket.

– Detach the connector

– Remove the engine vent hose

3, discarding the hose clamp.

– Unscrew the positive starter engine cable and draw out the wiring

harness. – Detach connector

4 on the starter relay.

– Pull out the gasoline pump vent hose

5 towards the bottom.

– Unscrew the ground connection

– Disconnect the fuel hose

– Loosen the bolts on the side support

8 and the nut on the bolt 9,

pull out the bolt and remove support together with the battery case.

– Unscrew the front oil line

bk.

3-6

Repair manual KTM LC8 Art.-Nr. 3.206.009-E

– Use the trolley jack to position the attachment 600.29.055.100 on

the engine, insert the bolt

1 through the front of the engine bracket

and fasten with the nut. Screw one of the bolts

2 on the rear of the

side stand fixture and slightly lift the engine.

– Remove the bolt 3 and tilt the foot brake pedal to the side.

– Unscrew the ground wire connection

– Detach the connector from the pulse generator

– Detach the connector from the oil pressure switch

6, the

temperature sensor

7 and from the front 8 and rear ignition coil.

Remove any cable clips necessary.

– Pull the bolt

9 out of the lower support (if necessary, raise or lower

the engine slightly).

– Loosen the nut on the swing arm pivot

bk and knock out the swing

arm pivot with a suitable pipe.

– Pull the engine towards the front with the trolley jack, lower and pull

away towards the side.

– Disconnect all hoses and lines from the engine.

3-7

Refitting the engine

– Before mounting the engine, attach the water, SLS and vacuum hoses

(Öttiger clamps - special pliers 600.29.057.000 or spring-loaded

band-type clamps - special pliers 600.29.057.100) – Position the swing arm and fix with the swing arm pivot on the right

and a suitable pipe on the left.

– Lift the engine into the frame with the trolley jack, insert the sealing

washer in the rear exhaust flange and secure with copper paste if

necessary. – Guide the chain along the side of the pinion and insert the swing arm

pivot

1, screw on the nut but do not tighten yet.

– Insert the bolt

2 in the lower support (raise or lower the engine

slightly if necessary). – Remove the trolley jack attachment 600.29.055.100 from the engine.

– Plug the connector on the oil pressure switch

3, the temperature

sensor

4 and the front and rear ignition coil 5. Use cable clips to

fasten the wiring harnesses.

– Screw on the ground wire connection

– Attach the pulse generator connector

– Position the foot brake pedal, apply Loctite 243 to the bolt

8 and

tighten to 25 Nm.

+ 155 hidden pages

KTM 950 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

INTRODUCTION

REPLY FAX FOR REPAIR MANUALS

GENERAL INFORMATION

Oil system

Cooling system

REMOVING AND REFITTING ENGINE

Removing the engine

Refitting the engine