KTM 950 ADVENTURE 2003 Page 22 Manual Download

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DISASSEMBLING THE ENGINE

Repair manual KTM LC8

Art.-Nr

. 3.206.009-E

VALVE COVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

SPARK PLUG SHAFT INSERTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

SETTING CYLINDER REAR TO TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

CAMSHAFTS CYLINDER REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

CHAIN TENSIONER CYLINDER REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

TIMING CHAIN CYLINDER REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

DOUBLE TIMING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

CYLINDER HEAD REAR WITH CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

SETTING CYLINDER FRONT TO TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

CAMSHAFTS CYLINDER FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

OIL PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

CHAIN TENSIONER CYLINDER FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

TIMING CHAIN CYLINDER FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7

CYLINDER HEAD FRONT WITH CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . .4-7

WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

OIL SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

CLUTCH COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9

PRIMARY PINION AND CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10

GENERATOR COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11

ROTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11

FREEWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11

BALANCER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11

SHIFT MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12

ENGINE CASE HALF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12

TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13

OIL PUMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14

INDEX

4-1

Summary of Contents for 950 ADVENTURE 2003

Page 1: ...950 ADVENTURE 2003 to 2006...

Page 2: ...OVING 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...

Page 3: ...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 t...

Page 4: ...sh 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...

Page 5: ...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 i...

Page 6: ...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...

Page 7: ...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...

Page 8: ...2 7 648 LOCTITE 243 1 2 3 4 5 7 8 9 bk 6 bl bm bn bo bp bq br bs bt cl cm cn co cp cq cr cs ct dk dl dm dn do dp dq dr ck...

Page 9: ...1 000 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 Inter...

Page 10: ...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 bleed...

Page 11: ...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...

Page 12: ...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 fixi...

Page 13: ...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 inta...

Page 14: ...ines 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...

Page 15: ...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 Un...

Page 16: ...ound wire connection 4 Detach the connector from the pulse generator 5 Detach the connector from the oil pressure switch 6 the temperature sensor 7 and from the front 8 and rear ignition coil Remove a...

Page 17: ...r 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 eng...

Page 18: ...ositive starter cable to the starter and screw on the starter engine Run the starter ground to the battery case Attach both starter relay connectors 5 Run the gasoline pump vent hose 6 upwards along t...

Page 19: ...the clutch slave cylinder 2 Screw on the chainguard 3 Position the side stand and tighten the two bolts and the nut 4 to 45 Nm Mount the side stand switch 5 and fasten the cable with the cable clips...

Page 20: ...ilter box and connect Mount the secondary air system valve 6 on the lower air filter box connecting the thin hose to the intake manifold and the thick hose directly to the valve Attach the carburetor...

Page 21: ...into the radiator compensating tank and engine see page 12 16 Add engine oil see page 12 5 Connect the fuel sender to the right tank Connect the gasoline and vent hoses and mount the tanks Screw in t...

Page 22: ...5 CYLINDER HEAD REAR WITH CYLINDER 4 5 SETTING CYLINDER FRONT TO TDC 4 5 CAMSHAFTS CYLINDER FRONT 4 6 OIL PRESSURE SWITCH 4 6 CHAIN TENSIONER CYLINDER FRONT 4 6 TIMING CHAIN CYLINDER FRONT 4 7 CYLIND...

Page 23: ...valve covers Dismount the gaskets of the bolts the valve covers and the spark plug shafts 2 Spark plug shaft inserts Pull the spark plug shaft inserts out of the spark plug shafts pry out carefully w...

Page 24: ...ses for cylinder rear and the circles for cylinder front Remove the case bolt and screw in the special tool 0113 080802 3 to block the crankshaft Camshafts cylinder rear Check and note down the valve...

Page 25: ...g washer Pull out the chain tensioner element 2 NOTE the housing and the tensioning piston on the chain tensioner element are compression molded If they fall apart during disassembly the chain tension...

Page 26: ...inue to turn the engine towards the front cylinder s TDC position keeping the timing chain on the rear cylinder slightly tensioned and holding the conrod in the center of the opening in the case CAUTI...

Page 27: ...and unscrew Discard sealing washer Chain tensioner cylinder front Remove the bolt on the chain tensioner 2 NOTE measure the preload on the chain tensioner element before dismounting Apply the chain te...

Page 28: ...by inserting your finger through the hole in the bearing bolt Lift the double timing gear out of the cylinder head letting the chain fall into the slot Cylinder head front with cylinder Remove the out...

Page 29: ...er pump shaft and the water pump wheel can be pressed out from the inside later CAUTION IF YOU TRY TO LOOSEN THE BOLT ON THE WATER PUMP WITHOUT USING SPECIAL TOOL 600 29 082 000 YOU MAY BREAK THE DRIV...

Page 30: ...inner clutch hub together with the clutch pressure booster and the underlying washer which usually adheres to the inner clutch hub NOTE you do not need to dismount the primary pinion if you are only r...

Page 31: ...er with the needle bearing NOTE The gear for the oil pump drive is located on the back of the outer clutch hub and can easily fall down Remove the spacing washer inserted between the gear for the oil...

Page 32: ...shaft using the puller 600 29 009 000 6 remove the pressure bolt and the engine locking bolt Freewheel Remove the freewheel lock 7 and lift the freewheel 8 of the crankshaft Pull the lower starter idl...

Page 33: ...f Remove the gear shift sensor 6 with the pin and spring Unscrew the oil filter cover 7 discarding the gasket on the oil filter cover and the oil filter Unscrew all HH bolts accessible from the genera...

Page 34: ...e watch the shift rollers 4 while you remove the shift drum 5 Remove the shift forks and the lower springs of the shift rails Bring the engine into a vertical position mounting position and remove the...

Page 35: ...emove the oil pump housing NOTE the centering pins are usually retained in the oil pump housing if they are retained pull them out with pliers Remove the inner oil pump 6 suction pump Remove the sucti...

Page 36: ...YLINDER HEAD AND CHECKING PARTS FOR WEAR 5 9 CHECKING THE PISTONS 5 10 ASSEMBLY INSTRUCTIONS FOR PISTON RINGS 5 10 CHECKING THE PISTON RING END GAP 5 10 MEASURING PISTONS CYLINDERS ESTABLISHING THE PI...

Page 37: ...he roller bearings The new roller bearings can be inserted by hand until flush as soon as the case temperature has reached approx 150 C The roller bearings should fit tightly after cooling down Use a...

Page 38: ...e crankshaft web of the new crankshaft NOTE there are 2 types of bearings for each bearing color the grooved bearing shell with the lubricating groove and oil bore is pressed into the top of the case...

Page 39: ...e top with the assembling sleeve 600 29 044 050 same procedure as for the bearing shells output end see above Position the bearing sleeves at the generator end of the case with the bearing shell end g...

Page 40: ...strip A 600 29 012 000 on top and mount the conrod caps with the old bolts as described below CAUTION INSERT THE PLASTIGAUGE MEASURING STRIPS AT A 90 ANGLE TO THE BEARING END GAP DO NOT TURN THE CONR...

Page 41: ...The crankshaft must be replaced if the measurement falls short of the minimum diameter or if the crankshaft is worn Center the new bearing shells with the assembling sleeve 600 29 046 028 2 The assemb...

Page 42: ...the outside to the inside The inner lock ring 4 does not need to be removed Heat the case evenly in an oven at 150 C the old bearing will fall out of the bearing seat by itself and the new bearing ca...

Page 43: ...ck the clearance between the inner and outer rotor Setpoint value 0 1 mm Wear limit 0 2 mm Use a feeler gauge A to check the clearance between the outer rotor and the case Setpoint value 0 2 mm Wear l...

Page 44: ...shaft with pliers and remove the valve spring washer NOTE a washer 14x30x2 is located under the spring retainers for the exhaust valve springs to increase the spring preload Repeat the above procedure...

Page 45: ...der Measure the end gap with a feeler gauge A Piston ring end gap max 0 50 mm If the end gap is larger than indicated above check the cylinder for wear If the cylinder wear is within the tolerance lim...

Page 46: ...ricate the valve shafts and insert the valves in their original position in the valve guides NOTE a washer 14x30x2 is located under the spring retainers for the exhaust valve springs to increase the s...

Page 47: ...PPING LIGHTLY WITH THE HAMMER HANDLE APPLYING MORE FORCE WILL ONLY DAMAGE THE PISTON RINGS Invert the cylinder head mount a new cylinder head gasket and put the cylinder into position NOTE the cylinde...

Page 48: ...and disk and mount the lock ring 4 Use the special tool 600 29 043 050 to press in the new shaft sealing ring on the balancer shaft 3 open side first Position the stator press the cable duct in the g...

Page 49: ...s must be even 10 steel lamella 4 may not have any recesses 11 lining disks 5 wear limit 2 65 mm Inner clutch hub 6 check the outer and inner teeth for wear Needle bearing 7 check for wear Springs in...

Page 50: ...act Check the return surface B on the shift rail for wear replace if excessively grooved Guide bolts 6 Check for a tight fit and wear Guidance Check play play between guide bolts and slider max 0 7 mm...

Page 51: ...Check the needle bearings in the idler gears Assembling the main shaft Clamp the main shaft in the vise use protective jaws with the gear facing down Mount the needle bearing 1 and slide the 5th gear...

Page 52: ...ar facing down Oil the needle bearing 1 and mount Slide the 2nd gear idler 2 with the groove facing up over the needle bearing Mount the stop disk 3 30 2 x 39 x 1 5 mm and the lock ring 4 with the sha...

Page 53: ...wheel 4 together Check the segments in the freewheel for wear Check the freewheel hub 5 at the freewheel running surface for wear Apply Loctite 648 to the flange areas on the rotor and the freewheel h...

Page 54: ...PRIMARY PINION 6 9 OUTER CLUTCH HUB 6 9 CLUTCH DISKS 6 10 CLUTCH COVER 6 11 OIL SCREEN 6 12 WATER PUMP 6 12 CYLINDER HEAD REAR WITH TIMING CHAIN 6 13 CHAIN TENSIONER CYLINDER REAR 6 15 CAMSHAFTS CYLIN...

Page 55: ......

Page 56: ...pump into the engine case NOTE contrary to common practice the two marks for the outer and inner rotor of the pressure pump are not on the same side Mount the pressure pump case 6 and fix with the sh...

Page 57: ...n bolts to 10 Nm Slide on the disk insert the needle roller 1 and mount the oil pump gear 2 with the collar facing the rear Slide on the spacer washer 3 and mount the lock ring 4 on the oil pump shaft...

Page 58: ...grooves and tilt aside paying attention to the shift rollers 3 fix with grease if necessary Mount the shift drum 4 and allow the shift forks to engage in the shift drum NOTE since 3 different shift fo...

Page 59: ...ase gasket in place Case half Slide the protective sleeve 600 29 005 000 over the countershaft Slip on the generator end case half Tap lightly on the countershaft with a rubber hammer if necessary CAU...

Page 60: ...sh of the shift rail and the clearance of the shift bolt The backlash of the shift rail is the distance the rail travels until the shift shaft begins to move You should be able to feel the pressure of...

Page 61: ...n must be placed over the rear sprocket Attach a stop disk 22 x 29 5 x 2 4 mm to the balancer shaft Check the balancer shaft for smooth operation Freewheel Slip the freewheel 3 on the crankshaft and a...

Page 62: ...octite 243 to the bolt and tighten to 20 Nm CAUTION MAKE SURE NO LOCTITE THREAD ADHESIVE IS ON THE PIVOT AREA OF THE BOLT THIS COULD CAUSE THE TIMING CHAIN TENSIONING RAIL TO BLOCK AND BREAK Insert th...

Page 63: ...outer clutch hub The gear is secured by 3 needle rollers Outer clutch hub Slide the outer clutch hub onto the shaft leaving enough room for the ring gear 7 which is positioned by a pin CAUTION THE RIN...

Page 64: ...ted Mount the pressure springs with disks and bolts M6x16 Tighten the bolts crosswise to 10 Nm Clutch disks First mount the supporting plate 1 and then the spring washer 2 with the open side facing ou...

Page 65: ...r together with the outer clutch cover inserting the bolts as illustrated Tighten to 10 Nm Screw the locking bolt back in M6x30 M6x30 M6x30 M6x85 M6x30 M6x30 M6x30 M6x35 M6x30 M6x30 Clutch cover Mount...

Page 66: ...p Mount the oil screen cover tighten the two M6x35 M6x40 bolts to 10 Nm Water pump Mount the water pump wheel 3 and disk on the shaft Hold with the holding spanner 600 29 082 000 secure the bolt 4 M6x...

Page 67: ...ENT THE PISTON PIN RETAINER FROM FALLING OUT OF THE ENGINE CASE THE PISTON PIN RETAINER 2 MUST BE IN THE POSITION SHOWN IN THE ILLUSTRATION Push the cylinder head and cylinder down Mount the cylinder...

Page 68: ...e over the gear teeth 1 onto the chain teeth 2 of the double timing gear Hold the double timing gear towards the outside by inserting your finger through the hole in the bearing bolt Mount and grease...

Page 69: ...oner bolt and new sealing washer to the chain tensioner element without compressing the spring Measure the distance 2 between the sealing washer and the cylinder head The measured value has to be betw...

Page 70: ...inder head Place plastigauge measuring strips 5 600 29 012 000 on the camshaft bearing positions Carefully mount the camshaft bearing bridge and tighten the bolts in the camshaft bearing bridge to 10...

Page 71: ...chain Mount a new base gasket NOTE make sure the crankshaft is blocked in the cylinder front TDC position Fit the timing chain and chain tensioning rail in the cylinder Tilt the chain tensioning rail...

Page 72: ...er nuts 2 to 8 Nm 2nd stage Tighten the cylinder head nuts crosswise CAUTION THE TIGHTENING TORQUE FOR THE 2ND STAGE IS 43 NM SINCE THE SPECIAL WRENCH 600 29 081 000 IS USED FOR NUT 3 IT MUST BE TIGHT...

Page 73: ...the chain tensioner element without compressing the spring Measure the distance 2 between the sealing washer and the cylinder head The measured value should be between 6 mm and 11 mm If the value is l...

Page 74: ...d Place plastigauge measuring strips 5 600 29 012 000 on the camshaft bearing positions Carefully mount the camshaft bearing bridge and tighten the bolts in the camshaft bearing bridge to 10 Nm M8 and...

Page 75: ...inside the bucket tappets are not actuated If the camshafts are in a different position check the timing and reset Check valve clearance see page 12 7 Remove the crankshaft blocking tool 3 Insert the...

Page 76: ...sh the spark plug shaft inserts all the way in Mount the valve cover gaskets 2 and spark plug shaft gaskets 3 Valve cover Mount the valve cover Insert bolts 4 with the sealing washers and tighten to 1...

Page 77: ...XILIARY STARTER RELAY 7 4 CHECKING THE DIODES 7 4 CHECKING THE STARTER RELAY 7 5 CHECKING THE STARTER EINGINE 7 5 CHECKING THE CLUTCH SWITCH 7 5 CHECKING THE TIP SWITCH AND THE EMERGENCY OFF SWITCH 7...

Page 78: ...er 3 Charging the battery see Owner s Manual page 33 Jump start see Owner s Manual page 33 Checking the charging voltage rectifier regulator NOTE the following figures only apply to fully charged batt...

Page 79: ...osed current can flow through diode 7 and the neutral switch against the ground Clutch is pulled clutch switch 8 is closed the current can flow through the clutch switch against the ground NOTE if the...

Page 80: ...the clutch lever with the gear engaged The auxiliary starter relay should switch at half of the lever travel If not check the clutch switch Observe the idle indicator lamp it may not light up If it do...

Page 81: ...the cable tree Connect an ohmmeter to the bipolar connector AL 3 yellow and brown cable colors of the clutch switch and slowly pull the clutch lever The switch should close around 2 3 of the lever tra...

Page 82: ...ncy OFF switch 3 The pulse generator 5 reports the crankshaft position to the ECU 4 The ECU uses this signal to calculate the ignition point for each cylinder Battery voltage is supplied to both ignit...

Page 83: ...istance of the pulse generator 190 300 at 20 C NOTE if the resistance figure is correct but the signal voltage deviates check the distance between the pulse generator and the pulse generator wheel see...

Page 84: ...tuated If not try a new ignition coil or new spark plug If no spark is visible during the first test perform the following tests Is battery voltage being applied to the ECU orange cable color at conne...

Page 85: ...tery 1 is conducted to the ECU control unit 4 through the switched on ignition lock 2 and the switched on emergency OFF switch 3 The EPC valves 5 are supplied with battery voltage via the emergency OF...

Page 86: ...OPEN SLIGHTLY RESULTING IN A LACK OF POWER FOR THE ENTIRE SPEED RANGE Checking the gear sensor Use a digital multimeter to measure the voltage between the blue green cable neutral and the ground on co...

Page 87: ...THE CARBURETOR 8 4 ASSEMBLING THE CARBURETOR 8 7 CHECKING THE FLOAT LEVEL 8 10 ADJUSTING THE MIXTURE CONTROL SCREW 8 10 CHECKING THE THROTTLE SENSOR 8 11 ADJUSTING THE THOTTLE SENSOR 8 11 ADJUSTING TH...

Page 88: ...8 2 Repair manual KTM LC8 Art Nr 3 206 009 E CARBURATOR KEIHIN CVRD 43...

Page 89: ...et diameter 50 and the ACV jet 2 jet diameter 80 In an overrun condition or during upon sudden closure of the throttle valve the momentary high under pressure causes the diaphragm 3 of the ACV valve t...

Page 90: ...en the carburetor was dismounted Pull the fuel connection 4 out of the carburetor Remove the diaphragm cover 5 Remove the throttle slide spring 6 and pull the throttle slide 7 out of the carburetor to...

Page 91: ...valve for wear at the conical seat Unscrew the ACV cover 5 and remove the spring 6 together with the diaphragm 7 Remove the O ring 8 from the recess around the air jet 9 Check the diaphragm 7 for crac...

Page 92: ...THE ACV VALVE SIDE TO AVOID DAMAGING THE ACV VALVE Hold the throttle valve against the light in a closed condition No light should be visible on the side of the throttle valve NOTE if any light is vis...

Page 93: ...T THE THROTTLE SHAFT TO KEEP IT FROM BENDING Screw on the idle air jet 3 main jet 4 with main jet holder and starter jet 5 Screw the idle air mixture control screw 6 with the O ring shim and spring in...

Page 94: ...diaphragm and mount the ACV cover 4 Position the float 5 together with the needle valve and float hinge pin 6 in the carburetor housing Tighten the fixing screw 7 on the float hinge pin See pages 8 1...

Page 95: ...TE a small air jet 5 should be mounted in the tab of the throttle slide diaphragm Insert the throttle slide and diaphragm 6 in the carburetor pushing the jet needle in the needle jet see arrow Mount t...

Page 96: ...e page 8 11 to adjust the throttle cable Adjusting the float level NOTE it is not necessary to separate the two carburetors to adjust the float level Remove the float chamber Turn the carburetor aside...

Page 97: ...ough throttle cable play when the carburetors are dismounted Tighten the screw on the throttle sensor and remount the carburetors see Chapter 3 Check the readings with the carburetors mounted see abov...

Page 98: ...TROUBLE SHOOTING Repair manual KTM LC8 Art Nr 3 206 009 E TROUBLE SHOOTING 10 2 INDEX 9 1 9...

Page 99: ...nition switch the transmission to neutral switch on the emergency OFF switch Charge battery and look for cause of discharging replace defective parts Replace the IGNITION fuse in the fuse box Remove t...

Page 100: ...ower consumer was not switched off The battery is not being charged by the generator Fuse is blown Pickup cable is damaged or cable connector contacts are oxidizing REMEDY Check the position of the EP...

Page 101: ...10 2 REPLACING THE REAR WHEEL BEARING 10 3 REPLACING THE FORK LEGS 10 4 REPLACING THE SHOCK ABSORBER 10 5 REPLACING THE STEERING HEAD BEARING 10 6 REPLACING THE SWING ARM BEARING 10 7 REPLACING THE CH...

Page 102: ...DISKS ARE NOT APPLIED Take the bearing spacing tube out of the hub and knock out the second grooved ball bearing 6 Press a new grooved ball bearing 6 into the hub with a suitable tool CAUTION WHEN YOU...

Page 103: ...the hub and tap a new grooved ball bearing 4 in the hub with the back of special tool 584 29 091 000 A Mount the lock ring 3 in the groove and check for a good fit Mount the shaft seal ring 2 grease a...

Page 104: ...3 Remove the bolts 4 on both brake calipers Loosen the clamp bolts on both sides of the bottom 5 and top 6 triple clamps Pull both fork legs down out of the triple clamps The new fork legs are mounted...

Page 105: ...the frame Mount the new shock absorber in the same way it was dismounted and tighten the upper bolt to 100 Nm Secure the lower bolt on the shock absorber with Loctite 243 and tighten to 45 Nm NOTE if...

Page 106: ...LLS WILL BE DAMAGED Insert the special tool 584 29 092 000 with the collet 584 29 089 000 into the steering head from below and drive the outer ring bl on the upper steering head bearing out of the st...

Page 107: ...ol 584 29 086 000 B NOTE the procedure for the second swing arm bearing is identical except that the stop disks 9 also need to be removed Place the anvil dolly 600 29 056 000 A underneath and press th...

Page 108: ...h a lock washer and screw on the nut Dismount the rear wheel see Owner s Manual page 31 and pull the rear sprocket carrier out of the rear wheel hub Loosen the rear sprocket nuts and remove the rear s...

Page 109: ...X ring 6 to each bolt Place bracket 1 over the chain from behind The marks A B must face up Slide pressing pin 3 with the smaller diameter into the spindle of pressing tool 2 and turn spindle back Ins...

Page 110: ...r manual KTM LC8 Art Nr 3 206 009 E TECHNICAL SPECIFICATIONS LC8 ENGINE 11 2 TECHNICAL SPECIFICATIONS 950 ADVENTURE CHASSIS 11 3 TOLERANCES MOUNTING CLEARANCES ENGINE 11 5 TIGHTENING TORQUES ENGINE 11...

Page 111: ...ngine oil SAE 5W 40 10W 50 f ex Motorex Power Synt 4T Quantity of engine oil approx 3 0 liters during oil filter change or approx 3 3 liters for dry engine Primary drive Straight toothed spur wheels 6...

Page 112: ...re on road alone 2 4 bar passenger 2 4 bar Tires rear Pirelli MT90 150 70 18 M C 70V Metzeler MCE Karoo 150 70R18 M C 70H M S max 160 km h Air pressure on road alone 2 6 bar passenger 2 8 bar Fuel tan...

Page 113: ...ion damping high speed turns 1 5 1 5 1 1 1 5 1 5 1 1 Rebound clicks 18 18 15 18 17 12 10 10 18 18 15 18 20 17 13 13 Preload adjuster turns 5 5 8 5 6 6 8 18 5 5 8 5 6 6 12 12 STANDARD ADJUSTMENT FORK A...

Page 114: ...g L ring 0 85 mm 0 87 mm Thickness of 1st ring L ring 1 20 mm 1 22 mm Thickness of 2nd ring 1 22 mm 1 24 mm Thickness of oil scraper ring 2 47 mm 2 49 mm Piston pin piston Diameter of piston ring bore...

Page 115: ...prings unloaded 30 77 mm 29 0 mm Spring tension 19 0 at a load of at least 20 kg 24 kg Thermostat radiator Opening temperature of thermostat 73 C 77 C Opening stroke of thermostat over 7 mm at 100 C D...

Page 116: ...HH bolts on oil pump cover M6 Loctite 243 10 Nm Plug on oil filter housing M14x1 5 Loctite 243 15 Nm Oil jets M6x0 75 Loctite 243 10 Nm Oil pressure switch M10x1 10 Nm AH bolt on shift locating drum...

Page 117: ...HH bolts on footbrake cylinder M6 Loctite 243 10 Nm AH bearing bolt for foot brake pedal M8 Loctite 243 25 Nm AH bolt for top of brake hose guide M6 Loctite 243 8 Nm HH bolts on foot brake pedal surf...

Page 118: ...sary cleaning the air filter box 12 10 Checking the brake fluid level lining thickness brake disks 12 10 Changing the brake fluid 12 11 Checking the bolts on the brake system for force fit 12 12 Clean...

Page 119: ...Check electrical system for function low high beams stop light turn indicators headlamp flasher tell tale lamps speedometer illumination horn side stand switch clutch switch emergency off switch Make...

Page 120: ...KS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC Check oil level Check brake fluid level Check brake pads for wear Check lighting system for proper operation Check horn for proper o...

Page 121: ...ount a new seal ring on the drain plug screw back in and tighten to 20 Nm Unscrew the oil drain plug 2 on the oil tank and allow the oil to drain into a receptacle NOTE dispose of the used oil properl...

Page 122: ...viscosity for temperatures over 0 C or 5W 40 for temperatures under 0 C Fill approx 2 7 liters of engine oil into the oil tank The oil tank will be filled up to the top Start the engine and allow to...

Page 123: ...electrode distance The distance should be 0 6 mm Insert new spark plugs with the special tool 600 29 073 000 and tighten to 12 Nm CAUTION DO NOT EXCEED THE FIXED TORQUE SINCE SPARK PLUGS BREAK EASILY...

Page 124: ...ce is incorrect for one or more valves measure how large the deviation is Use thinner or thicker compensating washers depending on whether the valve clearance is too small or too large Dismount the ca...

Page 125: ...age all of the lining disks and steel disks together Wear limit 48 0 mm Check the clutch disks for damage breakage recesses Checking the clutch pressure booster system Check the outer and inner part f...

Page 126: ...PING FIRST THEN START THE ENGINE DO NOT DROP THE SPECIAL TOOL DO NOT RUN THE ENGINE WITH DEFECTIVE CARBURETORS RISK OF THE ENGINE MISFIRING Connect each dial gauge on the special tool to a cylinder Yo...

Page 127: ...n idle until the fan switches on CAUTION WATCH THE TEMPERATURE INDICATOR FOR THE COOLING LIQUID TO AVOID ENGINE DAMAGE IN CASE THE RADIATOR FAN IS DEFECTIVE Lubricating the cables NOTE only use lubric...

Page 128: ...ough fresh brake fluid in the brake fluid reservoir Tighten the bleeder screw again Move the hand brake cylinder into a horizontal position and add DOT 5 1 brake fluid Motorex Brake Fluid DOT 5 1 up t...

Page 129: ...AGED IF DOT 5 BRAKE FLUID IS USED BRAKE FLUID CAN CAUSE SKIN IRRITATIONS AVOID COMING INTO CONTACT WITH THE SKIN OR EYES IF BRAKE FLUID SPLASHES INTO YOUR EYES RINSE THOROUGHLY WITH WATER AND CONSULT...

Page 130: ...nut 1 until no clearance is left NOTE do not tighten the blind nut since you may damage the bearing Gently tap on the top triple clamp with a plastic hammer to relieve any distortion and tighten the 5...

Page 131: ...Checking the spoke tension and rim run out Spoke nipple 4 Nm 2 1 Nm maximum radial lateral run out of the rim without tires 1 2 mm maximum radial lateral run out of the rim with tires front 2 3 mm rea...

Page 132: ...mp upwards but do not pull the triple clamp all the way off of the steering stem 1 The weight of the front wheel and the fork will give you access to the lower steering head bearing Clean the gasket e...

Page 133: ...t into a receptacle Mount the compensating tank again Remove the drain plug 4 on the radiator and allow the cooling liquid to drain into a receptacle Mount the drain plug again and tighten Fill approx...

Page 134: ...ER HORN COOLING FAN 13 10 LIGHTS 13 12 LIGHTS USA 13 14 INSTRUMENTS 13 16 GROUND CONNECTION 13 18 POSITIVE CONNECTION 13 19 CONNECTOR LIST Connector AA AF 13 20 Connector AG AJ 13 21 Connector AK AM 1...

Page 135: ...2 2 2 C_BH 6 C_BE 3 2 2 2 2 rear 2 2 2 2 2 2 2 2 speedometer for multi func digital handle bar switch octane selector roadbook aditional instruments brake switch C_AL2 2 2 2 2 bl wh bl gn 1 1 1 1 pu...

Page 136: ...on C stands for connector connector The 2nd and 3rd positions AA stand for the connector type The 4th and 5th positions 20 specify the number of pins in the connector in this case 20 poles The 5th pos...

Page 137: ...I1 2 C_AR 2 diode C_BB 9 battery 2nd 3th N starter motor clutch switch start system C_AR 3 yellow 0 5 7 2 diode 1 31 page 7 9 A start relay C_AL 31 30 950 Adventure sidestand switch 2 9 brown 0 5 1 or...

Page 138: ...206 009 E RUN cable harness cable switch or or bu bl or re wh bl START start stop switch bl or STOP bl unpulled br ye clutch switch pulled position switch folded down pi br sidestand switch bl gn fold...

Page 139: ...blue 1 2 yellow red 1 yellow red 0 5 red black 0 5 red white 0 5 black yellow 1 2 12 13 fan brake horn flasher system light start system roadbook aditional instruments clock fuel pump 5 14 11 30 C_BI1...

Page 140: ...13 7 Repair manual KTM LC8 Art Nr 3 206 009 E ignition switch r y r o r w r w r w LOCKED OFF ON...

Page 141: ...itch N 2nd gear 3th gear ignition coil 1 C_AM2 3 3 1 black 0 5 yellow 0 5 blue 0 5 orange 1 orange 0 5 20 brown 0 5 brown 0 5 black blue 0 5 blue grey 0 5 ignition switch 2nd 3th N 2 2 19 battery 31 4...

Page 142: ...13 9 Repair manual KTM LC8 Art Nr 3 206 009 E ignition switch r y r o r w r w r w LOCKED OFF ON RUN cable harness cable switch or or bu bl or re wh bl START start stop switch bl or STOP bl...

Page 143: ...olet 0 5 5 9 turn indicator system C_BD 12 C_BG 4 1 C_AH4 2 C_AH3 2 ignition switch C_AK1 2 30 G yellow blue 0 5 yellow blue 0 5 10 A fuse brown 0 5 page7 9 D C_BI 2 2 2 horn switch 1 1 brown 1 brown...

Page 144: ...Nr 3 206 009 E ignition switch r y r o r w r w r w LOCKED OFF ON harness pi switch cable br pi bl bl flasher switch pu OFF TURN R br or cable br gn re bu bu gr TURN L OFF br horn switch switch cable...

Page 145: ...ow 1 0 1 2 3 brake switch yellow 1 light switch C_AB 9 1 3 1 red 1 white 0 5 15 A fuse C_AH2 2 rear yellow brown 1 brown 0 5 5 ignition switch licence plate lamp 2 ignition switch low high beam switch...

Page 146: ...shed pushed bu wh bl bl ye brake light switch LIGHT OFF LIGHT P LIGHT light switch switch cable harness cable ye wh br ye ye re ye wh wh gn wh gn re LO ye harness high low beam switch bu cable br swit...

Page 147: ...ed 1 ignition switch red 1 15 A fuse ignition switch 10 A fuse C_AD 12 low high beam switch C_AZ 4 licence plate lamp HI LO head light flasher C_AH2 2 rear brake switch brown 0 5 brown 0 5 brown 0 5 w...

Page 148: ...shed pushed bu wh bl bl ye brake light switch LIGHT OFF LIGHT P LIGHT light switch switch cable harness cable ye wh br ye ye re ye wh wh gn wh gn re LO ye harness high low beam switch bu cable br swit...

Page 149: ...13 7 14 C_AA 20 v C_AN 4 speedometer C_AT1 2 10 A fuse speed sensor handlebar switch for multi func digital 2 4 C_AX 2 19 31 11 ignition switch temperature sensor t 9 brown 0 5 brown 0 5 black brown 0...

Page 150: ...13 17 Repair manual KTM LC8 Art Nr 3 206 009 E cable harness gn switch cable unpushed pushed bu wh bl bl ye brake light switch...

Page 151: ...h clutch switch multi func digital speedometer ECU rear light brakelight 950 Adventure start relay rear flasher starter motor left front flasher regulator brown handle bar switch battery horn switch h...

Page 152: ...e orange flasher relay positve connection ignition switch 10 15 A fuse box red white 10 10 A A yellow red yellow red tachometer multi func digital speedometer yellow front brake switch high low beam s...

Page 153: ...ctor AC 6 pole 2 Front light On the connector support under the multifunctional digital speedometer Connector AD 12 pole 3 Light turn signal horn switch On the connector support under the multifunctio...

Page 154: ...ltifunctional digital speedometer Rear brake light switch 3 Under the right rear side cover Left front turn signal 4 Under the left front side cover Right front turn signal 5 Under the right front sid...

Page 155: ...rator cover Connector AL 2 pole Clutch switch 4 Behind the headlight under the connector support Pick up 5 Between the water pipe and the front cylinder head Fuel sender 6 Between the left tank and th...

Page 156: ...head Connector AP 6 pole Ignition lock Under the fuse box Connector AQ 1 pole Connector for auxiliary devices Kl 15 ignition Kl 30 battery Kl 31 ground Behind the headlight under the connector support...

Page 157: ...radiator next to the fan Regulator 7 On the right side of the battery case under the starter relay Connector AV 2 pole Temperature switch for the radiator fan On the right behind the radiator next to...

Page 158: ...nal digital speedometer On the left side of the engine between the cylinders Connector AY 1 pole 2 Oil pressure switch On the left side of the frame under the air filter box Connector AZ 4 pole Rear t...

Page 159: ...e multifunctional digital speedometer Connector BF 1 pole Octane selector Behind the air filter box Connector BB 9 pole 1 Start stop light switch On the connector support under the multifunctional dig...

Page 160: ...BJ 1 pole Oil pressure switch On the left frame under the air filter box Connector BI 2 pole Radiator fan motor 1 On the right behind the radiator next to the fan Regulator 2 On the right side of the...

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KTM 950 ADVENTURE 2003, Manual

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