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KTM
Motorcycle
2003 950 Adventure
KTM 2003 950 Adventure User Manual
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13-63
Repair manual KTM LC8
Art.-No. 3.206.035-E
Connector CR
1-pole
1
Connector for
attachments:
Kl 15 (ignition)
Kl 31 (ground)
Under the seat next to
the fuse box
1
5
62
13
14
15
16
17
18
6
2
15
3
4
18
17
16
15
14
13
Connector DJ
20-pole
2
Connector for the alarm
system control unit
Under the seat
Connector DK
20-pole
3
Connector
(without alarm system)
Under the seat
1
2
3
314
316
Table of Contents
Table of Contents
5
Updating Instructions
7
Introduction
11
General Information Index
15
Oil System
17
Intake System
18
Secondary Air System
19
Cooling System
20
Closed Thermostat
20
Open Thermostat
20
ABS (Antilock Brake System)
21
ABS Warning Lamp
21
ABS Button
21
Special Tools - Engine
22
Chassis
24
Checking the Oil Level of the Hydraulic Clutch
25
Bleeding of the Hydraulic Clutch
25
Resetting the Control Unit after Replacing/Repairing the Engine
26
Adjusting the Throttle Cable for Models with Fuel Injection
27
ECU Software Update/Mapping
28
Downloading the Software
28
Starting the DMT (Data Maintenance Tool)
29
Starting the FAN (Flash Download System)
29
Checking the Oil Pressure
30
Removing and Refitting Engine Index
31
Removing the Engine
33
Refitting the Engine - 950 Adventure
38
Dismounting the Engine - 990 Super Duke
43
Mounting the Engine - 990 Super Duke
44
Dismounting/Mounting the Engine - 950 Supermoto
51
Removing the Tank
51
Disassembling the Engine Index
53
Table of Contents
53
Valve Covers
55
Spark Plug Shaft Inserts
55
Starter Motor
55
Camshafts Cylinder Rear
56
Setting Cylinder Rear to TDC
56
Timing Chain Cylinder Rear
57
Chain Tensioner Cylinder Rear
57
Cylinder Head Rear with Cylinder
58
Setting Cylinder Front to TDC
58
Double Timing Gear
58
Oil Pressure Switch
59
Chain Tensioner Cylinder Front
59
Camshafts Cylinder Front
59
Cylinder Head Front with Cylinder
60
Timing Chain Cylinder Front
60
Clutch Cover
61
Oil Screen
61
Water Pump
61
Clutch
62
Primary Pinion and Clutch
63
Rotor
64
Generator Cover
64
Balancer Shaft
65
Shift Mechanism
65
Freewheel
65
Engine Case Half
66
Transmission
67
Oil Pumps
68
Servicing Individual Components Index
69
Replacing the Roller Bearing
71
Replacing the Main Bearings-General Information
72
Replacing Bearing Shells, Output End
73
Replacing Bearing Shells, Generator End
73
Replacing the Conrod Bearings
74
Selecting the Bearing Shells
74
Replacing the Supporting Bearings in the Clutch Cover
75
Overhauling the Water Pump
76
Checking the Suction Pump for Wear
77
Checking the Pressure Pump for Wear
77
Bypass Valve
77
Valves
78
Sealing Area
78
Valve Seats/Guides/Springs
78
Disassembling the Cylinder Head and Checking Parts for Wear
78
Checking the Pistons
79
Checking the Piston Ring End Gap
79
Assembly Instructions for Piston Rings
79
Measuring Pistons/Cylinders, Establishing Piston Mounting Clearance
79
Piston and Cylinder Identification
80
Assembling the Cylinder Head
80
Torque Limiter
82
Valve Gear – Checking Parts for Wear
82
Preassembling the Spreader Drive
83
Clutch – Checking Parts for Wear
84
Shift Mechanism – Checking Parts for Wear
85
Preassembling the Shift Shaft
85
General Information on Servicing the Transmission
86
Assembling the Main Shaft
86
Assembling the Countershaft
87
Checking the Freewheel
88
Replacing the Freewheel Hub
88
Starter
88
Assembling the Engine Index
89
Axial Clearance of the Main Shaft
92
Case Half
94
Aligning the Return Spring
95
Freewheel
96
Timing Chain and Balancing Weight
97
Primary Pinion
98
Outer Clutch Hub
98
Clutch Disks
99
Clutch Cover
100
Cylinder Head Rear with Timing Chain
102
Cylinder Head Front with Cylinder and Timing Chain
106
Valve Cover
111
Electrical Index
113
Abs-System
113
Checking the Generator Coils
115
Checking the Charging Voltage / Rectifier Regulator
115
Charging the Battery
115
Checking for Loss of Current
115
Electric Starter System 950 Adventure
116
Starting System 990 Super Duke
117
950 Supermoto/950 Super Enduro Electric Starter System
118
990 Adventure Electric Starter System
119
Checking the Auxiliary Starter Relay
120
Functional Check of the Auxiliary Starter Relay
121
Functional Check of the Auxiliary Start Relay
121
Checking the Diodes
122
Checking the Starter Relay
123
Checking the Starter Motor
123
Checking the Clutch Switch
124
Checking the Tip Switch and Emergency off Switch
125
Troubleshooting in the Starter System
125
Ignition System, ECU 950 Adventure
126
Ignition System, ECU 950 Supermoto
127
Ignition System, ECU 950 Super Enduro
128
ECU 950 Adventure/Supermoto/Super Enduro
129
Checking the Pulse Generator 950 Adventure/950 Supermoto
129
Checking the Fuel Pump Relay 950 Adventure/950 Supermoto
130
Checking the Ignition Coils 950 Adventure/Supermoto/Super Enduro
130
Troubleshooting in the Ignition System 950 Adventure/950 Supermoto
131
The EPC System 950 Adventure
132
The EPC System 950 Supermoto
133
EPC System 950 Super Enduro
134
Checking the Solenoid Valve for the EPC 950
135
Checking the Gear Sensor 950
135
Adventure Carburetor Heater 950 Adventure
136
Checking the Heating Elements
136
Checking the Temperature Switch
136
Injection/Ignition System
137
Correction Sensors and Inputs
137
Establishing the Injection Period (Injection Volume)
137
System Diagram
138
Basic Description of the System
139
Wiring Diagram 990 Duke
140
Wiring Diagram 990 Adventure
141
Block Diagram
142
Description of the Electric System
143
Descriptiopn of the Components
144
Fuel Pump
144
Pressure Regulator
144
Injection Valves
144
Manifold Air Pressure Sensor
145
Ambient Air Pressure Sensor
145
Throttle Valve Sensor
145
Sensor for the 2Nd Throttle Valve
145
Pulse Generator (Crankshaft)
146
Lambda Probes
146
Servomotor for the 2Nd Throttle Valve
147
Catalytic Converter
147
Idle Speed Control Motor
147
Ignition Coils
148
Fuel Pump/Main Relay
148
Secondary Air Valve
148
Octane Selector Connections
148
Roll Angle Sensor
149
Diagnostics Connector
149
Side Stand Switch
149
Clutch/Gear Switch
149
Safety against Failure/Emergency Operation
150
Component Tests
151
Coolant Temperature Sensor
152
Air Temperature Sensor
152
Intake Pressure Sensors
153
Sensor for 2Nd Throttle Valve
154
Pulse Generator
155
Lambda Probe Heater
155
Control Motor for the 2Nd Throttle Valve
156
Ignition Coil
157
Fuel Pump Relay
157
Main Relay
158
Error Lamp
160
Gear Sensor (Neutral, 2, 3)
160
Clutch Switch
160
Speed Signal
161
Coolant Temperature Signal
161
Diagnostics Line
161
Error Codes
162
Abbreviations, Limit Values 990 Super Duke
163
Abbreviations, Limit Values 990 Adventure
164
Alarm System for 990 Super Duke
165
Order for Additional Hand-Held Transmitters
166
Adapting the Hand-Held Transmitter
166
Starting with the Emergency Code
167
Checking the ABS Fault Memory Using the KTM Diagnostics Tool
168
Checking the ABS Sensor with the KTM Diagnostics Tool
168
Checking the Fuses
168
ABS System 990 Adventure
168
Fuel System Index
169
Carburetor Exploded View
171
Description of the ACV (Air Cut Valve) System
172
Disassembling the Carburetor
173
Assembling the Carburetor
176
Adjusting the Float Level
179
Adjusting the Idle Mixture Control Screw
179
Checking the Throttle Sensor
180
Adjusting the Throttle Sensor
180
Adjusting the Choke Cable
180
Adjusting the Throttle Cable
180
Carburetor Heater
181
Replacing the Fuel Filter
182
Injection System
182
Dismounting/Mounting Fuel Pump with Pressure Regulator/Level Sensor
182
Dismounting/Mounting the Throttle Body
182
Checking the Fuel Pressure
183
Troubleshooting Index
185
Chassis Index
189
Dismounting/Mounting the Front Wheel
191
Dismounting/Mounting the Rear Wheel
192
Replacing the Front Wheel Bearing
193
Replacing the Rear Wheel Bearing
194
Replacing the Front Brake Pads
195
Replacing the Rear Brake Pads
196
Replacing the Fork Legs
197
Replacing the Shock Absorber
198
Replacing the Fork Leg
199
Replacing the Steering Head Bearing
200
Replacing the Swing Arm Bearing
201
Replacing the Chain, Pinion and Rear Sprocket
202
Opening the Chain with a Separating/Rivet Tool
203
Riveting the Chain
203
Replacing the ABS Unit
204
Replacing the Rear ABS Sensor
204
Technical Specifications Index
205
Engine 950 Adventure
207
Chassis Engine 950 Adventure/Adventure S
208
Engine 990 Super Duke
210
Chassis 990 Duke
211
Engine 950 Supermoto
213
Engine 990 Adventure
216
Chassis 990 Adventure/Adventure S
217
Engine 950 Super Enduro
219
Chassis 950 Super Enduro
220
Tolerance and Fitting Clearances
222
Tightening Torques
224
Periodic Maintenance Schedule Index
227
Cleaning the Oil Screens and Magnets on the Drain Plugs
238
Changing the Engine Oil and Filter
238
Lubrication and Maintenance Work - Engine
238
Engine Oil
239
Checking the Engine Oil Level
240
Replacing the Spark Plugs
240
Checking the Clutch Lining
244
Checking the Clutch Pressure Booster System
244
Cleaning the Oil Jet for the Clutch Lubrication
244
Lubrication and Maintenance Work - Carburetor
245
Check the Carburetor Synchronization with Vacuum Gauge and Adjust
245
Checking the Idle Setting
245
Replacing the O-Ring on the Fuel Hose Connector
246
Add-On Parts
246
Brakes
246
Injection
246
Changing the Front Brake Fluid
247
Changing the Rear Brake Fluid
248
Cleaning the Dust Boots
249
Checking the Swing Arm Support
249
Checking/Adjusting the Steering Head Bearing
249
Checking All Chassis Bolts for Force Fit
249
Wheels
250
Checking the Spoke Tension and Rim Run-Out
250
Checking the Chain and Chain Guides for Wear, Force Fit and Tension
250
Checking the Wheel Bearing and Jerk Damper for Clearance
250
Additional Work
251
Cleaning and Greasing the Steering Head Bearing and Sealing Elements
251
Changing the Cooling Liquid
252
Wiring Diagrams Index
253
Start System
262
Charging Circuit
264
Ecu
266
Turn Indicator System
268
Light-Brake System
270
Light System USA
272
Instruments Tachometer
274
Ground Connection
276
Positive Connection
277
Light/Turn Signal/Horn Switch
278
Multifunctional Digital Speedometer
278
Front Light
278
Start/Stop/Light Switch
278
Tachometer
279
Turn Signal Relay
279
Rear Brake Light Switch
279
Left/Right Front Turn Signal
279
Diode Neutral Switch
280
Diode Side Stand Switch
280
Rear Lighting
280
Right Front Turn Signal
280
Speed Sensor
281
Pick up
281
Carburetor Potentiometer
281
Fuel Sender
281
Tripmaster Switch
282
ECU (Control Unit)
282
Ignition Lock
282
Connector for Auxiliary Devices
282
Rear/Front Ignition Coil
283
Radiator Fan Motor
284
Regulator
284
Temperature Switch for the Radiator Fan
284
EPC Front/Rear Cylinder
284
Octane Selector
285
Temperature Sensor for the Multifunctional Digital Speedometer
285
Rear Turn Signal
285
Battery Generator Starter
290
Turn Signal, Horn, Fan
294
Instruments - Tachometer
298
Front Lighting
302
Turn Signal, Horn, High Beam Switch
302
Start Relay/Main Fuse
302
Auxiliary Starter Relay
303
Speedometer
303
Front Brake Light Switch
303
Diodes
304
Throttle Sensor for the 2Nd Throttle
305
Throttle Sensor
305
Gear Sensor
305
Side Stand
305
Ignition Switch
306
Diagnosis Connector
306
Rollover Sensor
306
Rear Ignition Coil
307
Front Ignition Coil
307
Temperature Switch
308
Fan Motor
308
Regulator Output
308
Rear Blinker
309
Pressure Sensor for Rear Cylinder
312
Manifold Air Pressure Sensor for Front Cylinder
312
Ambiant Air Pressure Sensor
312
Rear/Front Lambda Probe
312
Control Motor for 2Nd Throttle
313
Front Wiring Harness
313
Secondary Air System Valve
313
Rear Injection Valve
314
Front Injection Valve
314
Wiring Harness EFI
314
Connector
315
Connector for the Alarm System Control Unit
315
Connector for Attachments
315
Lighting Relay
331
Start Relay
331
Temperature Switch for Carburetor Heater
331
Neutral Switch Diode
332
Diode for Side Stand Switch
332
Diode for Turn Signal Control
332
Rear Lighting System
332
Controller Outlet
337
Front EPC
337
EPC Rear
337
Turn Signal/Horn/High Beam Switch
338
Radiator Fan
339
Alarm LED
339
Seat Switch
339
Headlight
340
Parking Light
341
Connector for the Alarm ECU
341
Dummy Plug
341
Battery, Generator, Starter
344
Efi
346
Abs
353
ABS Connection
358
Temperature Switch for Radiator Fan
362
Controller
362
Front Lambda Probe
365
Control Motor for the 2Nd Throttle
365
Rear Lambda Probe
365
EFI Wiring Harness
366
ABS-ECU (Control Unit)
367
Rear ABS Sensor
367
Front ABS Sensor
367
ABS Control Lamp
368
Manifold Air Pressure Sensor for the Rear Cylinder
368
Manifold Air Pressure Sensor for the Front Cylinder
368
Engine Stop Relay
384
Starter Relay
384
Light/Horn/Stop Switch
384
Temperature Switch for the Carburetor Heater
385
Flasher Relay
385
Diode for Neutral Switch
385
Diode for Side Stand
385
Flasher Switch
386
Control Unit
388
Controller Output
390
Front EPC Cylinder
391
Rear EPC Cylinder
391
Rear Flasher
391
Emergency off Switch
392
Tip Switch
393
5
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KTM 2003 950 Adventure Specifications
General
Brand
KTM
Model
2003 950 Adventure
Category
Motorcycle
Language
English
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