2003KTM 950 ADVENTURE Repair Manual – PDF DOWNLOAD
FILE DETAILS:
2003KTM 950 ADVENTURE Repair Manual – PDF DOWNLOAD
Language :English_German_Italian_French_Spanish
Pages :185
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
2003KTM 950 ADVENTURE Repair Manual – PDF DOWNLOAD
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 (210×297 mm) into the transparent pocket provided for
this purpose on the outside of the binder.
– Put the spine label (170×45 mm) into the transparent pocket provided for this purpose on the
spine of the binder.
– Put the summary list of contents (150×297 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.
The 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.
TABLE OF CONTENTS:
2003KTM 950 ADVENTURE Repair Manual – PDF DOWNLOAD
HOME 0
NOTES AND PREFACE 1
Title page and file spine 1
Important information 7
Introduction 9
Reply fax for repair manuals 11
TABLE OF CONTENTS 5
GENERAL INFORMATION 13
OIL SYSTEM 15
AIR INTAKE SYSTEM 16
SLS-SYSTEM 17
COOLING SYSTEM 18
SPECIALTOOLS – CHASSIS 19
SPECIALTOOLS – ENGINE 20
BLEEDING THE CLUTCH 22
REMOVING AND REFITTING ENGINE 23
REMOVING THE ENGINE 25
REFITTING THE ENGINE 30
DISASSEMBLING THE ENGINE 35
VALVE COVERS 37
SPARK PLUG SHAFT INSERTS 37
STARTER MOTOR 37
SETTING CYLINDER REAR TO TDC 38
CAMSHAFTS CYLINDER REAR 38
CHAIN TENSIONER CYLINDER REAR 39
TIMING CHAIN CYLINDER REAR 39
DOUBLE TIMING GEAR 40
CYLINDER HEAD REAR WITH CYLINDER 40
SETTING CYLINDER FRONT TO TDC 40
CAMSHAFTS CYLINDER FRONT 41
OIL PRESSURE SWITCH 41
CHAIN TENSIONER CYLINDER FRONT 41
TIMING CHAIN CYLINDER FRONT 42
CYLINDER HEAD FRONT WITH CYLINDER 42
WATER PUMP 43
OIL SCREEN 43
CLUTCH COVER 43
CLUTCH 44
PRIMARY PINION AND CLUTCH 45
GENERATOR COVER 46
ROTOR 46
FREEWHEEL 46
BALANCER SHAFT 46
SHIFT MECHANISM 47
ENGINE CASE HALF 47
TRANSMISSION 48
OIL PUMPS 49
SERVICING INDIVIDUAL COMPONENTS 51
ROLLER BEARING 53
MAIN BEARINGS – GENERAL INFORMATION 54
REPLACING BEARING SHELLS, OUTPUT END 55
REPLACING BEARING SHELLS, GENERATOR END 55
REPLACING THE CONROD BEARINGS 56
SELECTING THE BEARING SHELLS 56
REPLACING THE SUPPORTING BEARINGS IN THE CLUTCH COVER 57
OVERHAULING THE WATER PUMP 58
CHECKING THE SUCTION PUMP FOR WEAR 59
CHECKING THE PRESSURE PUMP FOR WEAR 59
BYPASS VALVE 59
DISASSEMBLING THE CYLINDER HEAD AND CHECKING PARTS FOR WEAR 60
CHECKING THE PISTONS 61
ASSEMBLY INSTRUCTIONS FOR PISTON RINGS 61
CHECKING THE PISTON RING END GAP 61
MEASURING PISTONS + CYLINDERS, ESTABLISHING THE PISTON MOUNTING CLEARANCE 61
PISTON AND CYLINDER IDENTIFICATION 62
ASSEMBLING THE CYLINDER HEAD 62
GENERATOR COVER 64
VALVE GEAR – CHECKING PARTS FOR WEAR 64
CLUTCH – CHECKING PARTS FOR WEAR 65
SHIFT MECHANISM – CHECKING PARTS FOR WEAR 66
PREASSEMBLING THE SHIFT SHAFT 66
GENERAL INFORMATION ON SERVICING THE TRANSMISSION 67
ASSEMBLING THE MAIN SHAFT 67
ASSEMBLING THE COUNTERSHAFT 68
CHECKING THE FREEWHEEL 69
REPLACING THE FREEWHEEL HUB 69
STARTER 69
ASSEMBLING ENGINE 71
OIL PUMPS 73
TRANSMISSION 75
CASE HALF 76
SHIFT MECHANISM 77
ALIGNING THE RETURN SPRING 77
BALANCER SHAFT 78
FREEWHEEL 78
ROTOR 78
GENERATOR COVER 79
TIMING CHAIN AND BALANCING WEIGHT 79
PRIMARY PINION 80
OUTER CLUTCH HUB 80
CLUTCH DISKS 81
CLUTCH COVER 82
OIL SCREEN 83
WATER PUMP 83
CYLINDER HEAD REAR WITH TIMING CHAIN 84
CHAIN TENSIONER CYLINDER REAR 86
CAMSHAFTS CYLINDER REAR 87
SETTING CYLINDER FRONT TO TDC 88
CYLINDER HEAD FRONT WITH TIMING CHAIN 88
CHAIN TENSIONER CYLINDER FRONT 90
OIL PRESSURE SWITCH 90
CAMSHAFTS CYLINDER FRONT 91
STARTER MOTOR 92
SPARK PLUG SHAFT INSERTS 93
VALVE COVER 93
ELECTRICAL 95
CHECKING FOR LOSS OF CURRENT 97
DISMOUNTING THE BATTERY 97
CHARGING THE BATTERY 97
JUMP START 97
CHECKING THE CHARGING VOLTAGE/ RECTIFIER REGULATOR 97
CHECKING THE GENERATOR COILS 97
ELECTRIC STARTER SYSTEM 98
CHECKING THE AUXILIARY STARTER RELAY 99
FUNCTIONAL CHECK OF THE AUXILIARY STARTER RELAY 99
CHECKING THE DIODES 99
CHECKING THE STARTER RELAY 100
CHECKING THE STARTER EINGINE 100
CHECKING THE CLUTCH SWITCH 100
CHECKING THE TIP SWITCH AND THE EMERGENCY OFF SWITCH 100
TROUBLESHOOTING IN THE STARTER SYSTEM 100
IGNITION SYSTEM, ECU 101
CHECKING THE ECU 102
CHECKING THE PULSE GENERATOR 102
CHECKING THE FUEL PUMP RELAY 102
CHECKING THE IGNITION COILS 102
TROUBLESHOOTING IN THE IGNITION SYSTEM 103
THE EPC SYSTEM 104
CHECKING THE SOLENOID VALVE FOR THE EPC 105
CHECKING THE GEAR SENSOR 105
FUEL SYSTEM 107
KEIHIN CVRD 43 109
DESCRIPTION OF THE ACV (AIR CUT VALVE) SYSTEM 110
DISASSEMBLING THE CARBURETOR 111
ASSEMBLING THE CARBURETOR 114
CHECKING THE FLOAT LEVEL 117
ADJUSTING THE MIXTURE CONTROL SCREW 117
CHECKING THE THROTTLE SENSOR 118
ADJUSTING THE THOTTLE SENSOR 118
ADJUSTING THE CHOKE CABLE 118
ADJUSTING THE THROTTLE CABLES 118
SYNCHRONIZING THE CARBURETOR 151
ADJUSTING THE IDLE SPEED 151
TROUBLE SHOOTING 119
CHASSIS 123
REPLACING THE FRONT WHEEL BEARING 125
REPLACING THE REAR WHEEL BEARING 126
REPLACING THE FORK LEGS 127
REPLACING THE SHOCK ABSORBER 128
REPLACING THE STEERING HEAD BEARING 129
REPLACING THE SWING ARM BEARING 130
REPLACING THE CHAIN, PINION AND REAR SPROCKET 131
CUTTING AND RIVETING THE CHAIN 132
TECHNICAL SPECIFICATIONS 133
LC8 ENGINE 135
950 ADVENTURE CHASSIS 136
TOLERANCES, MOUNTING CLEARANCES – ENGINE 138
TIGHTENING TORQUES – ENGINE 140
TIGHTENING TORQUES – CHASSIS 141
PERIODIC MAINTENANCE SCHEDULE 143
PERIODIC MAINTENANCE SCHEDULE 950 ADVENTURE 144
MAINTENANCE WORK 143
Changing the engine oil and the oil filter 146
Cleaning the oil screens in the engine and oil tank 146
Cleaning the magnets on the drain plug for the engine and oil tank 146
Replacing the spark plugs 148
Checking and adjusting the valve clearance 149
Checking the clutch lining 150
Checking the clutch pressure booster system 150
Carburetor synchronization 151
Idle adjustment 151
Checking the cooling system for leakage and antifreeze 152
Checking the radiator fan for proper functioning 152
Lubricating the cables 152
Checking the air filter, replacing if necessary, cleaning the air filter box 152
Checking the brake fluid level, lining thickness, brake disks 152
Changing the brake fluid 153
Checking the bolts on the brake system for force fit 155
Cleaning the dust boots 155
Bleeding the fork legs 155
Checking the swing arm support 155
Checking/adjusting the steering head bearing 155
Checking all chassis bolts for force fit 155
Checking the spoke tension and rim run-out 156
Checking the chain and chain guides for wear, force fit and tension 156
Checking the nuts/bolts on the engine sprocket and the rear sprocket for the securing agent and a tight fit 156
Checking the wheel bearing and jerk damper for clearance 156
Servicing the fork 157
Servicing the shock absorber 157
Cleaning and greasing the steering head bearing and sealing elements 157
Cleaning and adjusting the carburetor 158
Changing the cooling liquid 158
WIRING DIAGRAMS 159
WIRING DIAGRAMS 160
START SYSTEM 162
CHARGING SYSTEM 164
ECU 166
FLASHER, HORN, COOLING FAN 168
LIGHTS 170
LIGHTS USA 172
INSTRUMENTS 174
GROUND CONNECTION 176
POSITIVE CONNECTION 177
CONNECTOR LIST 159
Connector AA – AF 178
Connector AG – AJ 179
Connector AK – AM 180
Connector AN – AR 181
Connector AS – AW 182
Connector AX – AZ, BA 183
Connector BB – BG 184
Connector BH – BK 185
S.M 13/3/2025
