KTM 950 ADVENTURE 2003 Manuel utilisateur

950 ADVENTURE

2003 to 2006

1SERVICE-INFORMATIONS

2GENERAL INFORMATION

3REMOVING AND REFITTING ENGINE

4DISASSEMBLING ENGINE

5 SERVICING INDIVIDUAL COMPONENTS

6ASSEMBLING ENGINE

7ELECTRICAL

8FUEL SYSTEM

9TROUBLE SHOOTING

10 CHASSIS

11 TECHNICAL SPECIFICATIONS

12 PERIODIC MAINTENANCE SCHEDULE

13 WIRING DIAGRAMS

2-2

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

Oil system

Pressure pump 1draws engine oil from oil tank

2through oil filter 3and the oil return valve 4

and pumps it past the pressure relief valve 5

through the oil filter 6into the annular groove

The main bearing 8, the conrod bearings 9and

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

line continues to the reed valves 4in 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 1pumps the cooling liquid

through the cylinder and cylinder heads 2and the thermostat 2.

Open thermostat

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

aluminum cooler 4and 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 6must be between the MIN and MAX marks when the engine is cold.

The fan 7switches on at 102° C.

Cooling system

2-6

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

SPECIALTOOLS – CHASSIS

FIG PART NO DESCRIPTION

1151.12.017.000 Gear puller

2584.29.086.000 Pressing tool for swing arm bearing

3584.29.089.000 Chassis tool holder

4584.29.091.000 Press-in tool for

bearing seat / rear wheel bearing

5584.29.092.000

Knock-out tool for bearing seat

6600.03.022.000 Center stand

7600.10.013.000 Sleeve for pressing tool for swim arm bearing

8600.29.018.000 Internal gear puller 28 mm

9600.29.020.000 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

12345

bn bo

2-7

648

LOCTITE

243

9bk

6bl

bn bo bp bq

cm cn co cp cq cr cs ct dk

dn do

dp dq

2-8

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

SPECIAL TOOLS – ENGINE

FIG PART NO DESCRIPTION

1309098 Seal Three-Bond

20113 080802 Crankshaft locking bolt

3151.12.017.000 Gear puller

4503.29.050.000 Bleeding syringe for hydraulic clutch

5560.12.001.000 Universal-engine work stand

6584.29.059.000 Loctite 648 green 20 ml

7585.29.005.000 Protection sleeve for shaft seal ring of water pump

8590.29.019.000 Valve spring mounter

9590.29.026.006 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

ONLY 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 2which is filled

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

Refill oil, until oil is discharged from the bore Aof 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-

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

MINERAL OILS.

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