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Dismounting and mounting the rear wheel *

Special stands are required to dismount the wheels to make sure the motorcycle is securely

fixed. The stands shown in the illustration can be found in the KTM Power Parts catalog.

Mount the rear stand. Make sure the stand rests on solid ground and is correctly mounted.

The rear wheel should not touch the ground

Unscrew the collar nut

[1]

, remove the chain tensioner

[2]

, hold the rear wheel while you

pull out the wheel spindle

[3]

. Push the rear wheel forward as far as possible and remove

the chain from the rear sprocket. Carefully take the rear wheel off the swing arm.

– DO NOT OPERATE THE REAR BRAKE WHEN THE REAR WHEEL HAS BEEN DISMOUNTED.

– ALWAYS PLACE THE WHEEL ON THE GROUND WITH THE BRAKE DISC POINTING UPWARDS.

OTHERWISE THE BRAKE DISC MAY BE DAMAGED.

– IF THE AXLE IS DISMOUNTED, CLEAN THE THREAD OF THE WHEEL SPINDLE AND COLLAR

NUT THOROUGHLY AND APPLY A NEW COAT OF GREASE (MOTOREX LONG THERM 2000) TO

PREVENT THE THREAD FROM JAMMING.

MAINTENANCE WORK ON CHASSIS AND ENGINE

Содержание 950 SUPERMOTO R

Страница 1: ...950 SUPERMOTO ART NR 3 211 82EN OWNER S MANUAL 2006 ...

Страница 2: ...s without previous notice KTM shall not be held liable for any deviations of availability and or ability to deliver illustrations descriptions printing and or other errors The illustrated models partly contain extra equip ment which is not applied to standard models 2005 by KTM SPORTMOTORCYCLE AG Mattighofen AUSTRIA All rights reserved Reprint also in extracts with written allowance of KTM SPORTMO...

Страница 3: ... an asterisk in the chapter Maintenance work on the chassis and engine must be performed If maintenance work should become necessary during a competition it should be performed by a trained mechanic KTM strongly recommends that all service work to your KTM should be performed by a qualified KTM dealer For your own safety use KTM approved parts and accessories only KTM is not liable for damage that...

Страница 4: ...ork described in the Lubrication and maintenance chart must be carried out by an authorized KTM workshop and confirmed in the service manual otherwise your warranty will become void The fuels and lubricants specified in the owner s manual or those of an equal quality must be used in accordance with the main tenance schedule The warranty or guarantee shall become void for damage and consequential d...

Страница 5: ...load of the fork 18 Damping action during compression of shock absorber 19 Rebound damping of shock absorber 19 GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE 20 Instructions for initial operation 20 Running in the LC8 engine 20 Accessories and payload 21 DRIVING INSTRUCTIONS 22 Check the following before each start 22 Starting when the engine is cold 24 Starting when the engine is warm or ...

Страница 6: ...sting the headlight range 56 Replacing the flasher bulbs 56 Replacing the brake light and taillight bulbs 57 Cooling system 58 Checking the cooling liquid level in the compensating tank 59 Checking the cooling liquid level in the radiator 60 Bleeding the cooling system 60 Changing the original position of the clutch lever 62 Checking the oil level of the hydraulic clutch 62 Checking and adjusting ...

Страница 7: ...ad tube Enter this num ber in the field on page no 1 The type label is located next to the chassis number Engine number engine type The engine number and the engine type are stamped into the left side of the engine below the engine sprocket Enter this number on page 1 SERIAL NUMBER LOCATIONS 6 ...

Страница 8: ...dditional fuel This produces a rich fuel air mixture necessary for cold start The fuel quantity and thus the engine speed are determined by the choke lever position At temperatures over 5 C 41 F it will suffice to pull the choke lever half way out At tem peratures below 5 C 41 F the choke lever should be pulled all the way out The hole is closed again by pushing the choke lever all the way back in...

Страница 9: ... the MODE button The indicator lamps 3 provide additional information on the motorcycle s running condition Display TEST When you switch on the ignition all of the display elements will light up for 1 second for the function test WS wheel size The display will change and show the diameter of the front wheel in inches for 1 second WS wheel size Then the CLOCK mode will be displayed or the mode that...

Страница 10: ...P 1 The TRIP 1 mode shows the speed the temperature of the cooling liquid and the trip odometer 1 To switch to the next display mode press the MODE button TRIP 2 The TRIP 2 mode shows the speed the temperature of the cooling liquid and the trip odometer 2 To switch to the next display mode press the MODE button TRIP F The TRIP F mode fuel displays the speed the temperature of the cooling liquid an...

Страница 11: ... to the CLOCK mode Simultaneously press MODE 1 and SET 2 The numbers on the clock will start to blink Use the MODE button to set the hours and the SET button to set the minutes The press the MODE and SET buttons simultaneously NOTE 0 00 will be displayed if the clock is not supplied with electricity This can be caused by a defective fuse or a fault in the board electric system see Troubleshooting ...

Страница 12: ...vel reaches the reserve mark the display will automatically switch to TRIP F and begin to count no matter which display mode was active before At the same time the fuel warning lamp will light up You will still have enough reserve fuel for at least 30 kilometers After refueling it will take approx 8 minutes for the fuel warning lamp to switch off and for TRIP F to automatically reset to 0 and retu...

Страница 13: ...een indicator lamp will blink in the blinker rhythm when the blinker is switched on NOTE The indicator lamp will blink slower when a blinker is broken The green indicator lamp will light up when the gearbox is in an idling position The blue indicator lamp will light up when the high beams are switched on The red warning light will light up when the cooling liquid has reached a tempera ture of appr...

Страница 14: ... handlebar to the left then turn the ignition key to the left The ignition key can be withdrawn in position and Combination switch The rocker switch LIGHTS 1 actuates the high beam or low beam High beam light Low beam light The light signal high beam is actuated with button 2 The indicator switch 3 returns to central position after actuation Press flasher switch towards switch housing to switch of...

Страница 15: ...ystem To open the cap insert the ignition key turn it 90 counterclockwise then lift off the filler cap To close the tank insert the filler cap turn the ignition key 90 clockwise and take out the key OPERATION INSTRUMENTS 14 Fuel taps 2 fuel taps 4 are mounted on the fuel tank that must be open when the motorcycle is run ning The level in the fuel tanks is equalized by means of a connecting hose Th...

Страница 16: ...on to the grips 2 during the ride To mount the seat attach the seat to the oval head screw 4 lower the seat in the back while sliding it towards the front Both noses 5 should fit into the frame Insert the catch bolts 6 in the lock housing and push the seat down in the back until you hear the catch bolts snap into place Check whether the seat is correctly mounted IF NOT CORRECTLY MOUNTED THE SEAT C...

Страница 17: ...ount the seat THE HELMET LOCK IS PROVIDED TO SECURE THE HELMET TO THE MOTORCYCLE WHEN PARKED DO NOT ATTACH THE HELMET OR OTHER OBJECTS TO THE STEEL ROPE WHILE DRIVING YOU CAN EASILY LOSE CONTROL OF THE MOTORCYCLE Shift lever The shift lever is mounted on the left side of the engine The position of the gears is shown in the illustration Neutral or the idle speed is located between first and second ...

Страница 18: ...securely on a firm surface The side stand is linked to the safety start system follow the driving instructions Foot brake pedal The foot brake pedal 2 is located in front of the right footrest Its basic position can be adjusted to your seat position see maintenance work Footrests The passenger footrests 3 fold up OPERATION INSTRUMENTS 17 3 2 1 ...

Страница 19: ...ound damping of fork The fork s damping action during rebound travel rebound damping can also be adjusted This allows you adjust the damping behavior to match your driving style and the payload The adjusting screws 2 are located on the upper end of the fork legs More information is provided in the chapter Adjusting the fork and shock absorber Spring preload of the fork The fork s preload can be ad...

Страница 20: ...ng speed The adjusting screw 1 for the low speed range can be adjusted with a screwdriver The adjusting screw 2 for the high speed range can be adjusted with a 17 mm socket wrench More information is provided in the chapter Adjusting the fork and shock absorber Rebound damping of shock absorber The shock absorber s damping action during rebound travel rebound damping can also be adjusted This allo...

Страница 21: ...first 200 kilometers 125 miles with new tires tilting the vehicle at different angles so that all sections are properly roughened Tires will not display their full grip characteristics until they are prop erly run in Motorcycles are sensitive to changes in the weight distribution Read the section on Accessories and payload when car rying luggage Pay attention to running in procedure Running in the...

Страница 22: ... WILL BE BLINDED NEVER LEAVE YOUR MOTORCYCLE WITHOUT SUPERVISION IF THE ENGINE IS RUNNING Accessories and payload Accessory parts and baggage can signifi cantly decrease a motorcycle s driving stability Please observe the following warnings NEVER DRIVE FASTER THAN 130 KPH 80 MPH IF YOU HAVE MOUNTED ACCESSORY PARTS ON YOUR MOTORCYCLE ACCESSORY PARTS CAN SIGNIFICANTLY IMPAIR THE MOTORCYCLE S HANDLIN...

Страница 23: ...ires showing cuts or dents must be replaced The tread depth must comply with the legal regulations Also check the air pressure Insufficient tread and incorrect air pressure deteriorate the driving performance 4 BRAKES Check correct functioning of the braking system Check for sufficient brake fluid in the reservoir The reservoirs have been designed in such a way that brake fluid does not need to be...

Страница 24: ...damage 9 BAGGAGE PAYLOAD Never exceed the maximum total weight 400 kg 883 lbs and the motorcycle s wheel loads The maximum total weight is comprised of the motorcycle in a running condition and refueled 205 kg 452 lbs the baggage and accessories the driver and passenger with protective gear and helmet Adjust the tire inflation pressure as well as the preload and damping properties of the fork and ...

Страница 25: ...EATH ALWAYS PROVIDE ADEQUATE VENTILATION WHILE THE ENGINE IS RUNNING NEVER OPERATE THE MOTORCYCLE WITH A RUN DOWN BATTERY OR WITHOUT THE BATTERY THIS CAN DAMAGE THE ELECTRONIC COMPONENTS OR SAFETY EQUIPMENT IN EITHER CASE AND THE MOTORCYCLE WILL NO LONGER BE ROADWORTHY IF THE OIL PRESSURE WARNING LAMP DOES NOT GO OUT AS SOON AS THE ENGINE IS RUN NING IMMEDIATELY SWITCH OFF THE ENGINE IF THE ENGINE...

Страница 26: ...the motorcycle off of the side stand Starting off Pull the clutch lever and engage 1st gear Slowly release the clutch lever while you open the throttle DO NOT ATTACH A HELMET OR OTHER OBJECTS TO THE HELMET LOCK ROPE WHILE DRIVING YOU CAN EASILY LOSE CONTROL OF THE MOTORCYCLE Shifting Riding You are now in first gear refered to as the drive or uphill gear Depending on the con ditions traffic road g...

Страница 27: ...AND CAUSE INCREASED WEAR STOP IMMEDIATELY IF A PERCEPTIBLE POWER LOSS OCCURS WHILE DRIVING DUE TO A DEFECTIVE IGNITION CAUSED BY A CYLINDER MISFIRING OR BREAKING DOWN IF THE UNBURNED FUEL AIR MIXTURE REACHES THE CATALYTIC CONVERTER IT WILL IGNITE AND THE RESULTING HEAT WILL DESTROY THE CATALYTIC CONVERTER AND THE ADJOINING COMPONENTS THE RED COOLANT WARNING LAMP LIGHTS UP WHEN THE COOLANT TEMPERAT...

Страница 28: ... the ignition Fold the side stand forward to the stop with your foot put the weight of the motor cycle on the stand and park the bike on a firm surface Lock the motorcycle ALWAYS PARK YOUR MOTORBIKE ON A SOLID AND HORIZONTAL SURFACE NEVER LEAVE YOUR MOTORCYCLE WITHOUT SUPERVISION AS LONG AS THE ENGINE IS RUNNING MOTORCYCLE ENGINES PRODUCE A GREAT AMOUNT OF HEAT WHILE RUNNING THE ENGINE RADIATORS E...

Страница 29: ... minutes for the fuel warning lamp 1 to switch off and for TRIP F to automatically reset to 0 and return to the previous display mode Press the SET key 2 for 2 seconds to immediately turn off the fuel warning lamp GASOLINE IS HIGHLY FLAMMABLE AND POISONOUS EXTREME CAUTION SHOULD BE USED WHEN HANDLING GASOLINE DO NOT REFUEL THE MOTORCYCLE NEAR OPEN FLAMES OR BURN ING CIGARETTES ALWAYS SWITCH OFF TH...

Страница 30: ...plugs z Check and adjust valve clearance z z Check engine fastening bolts for tight fit z z z Check all engine bolts accessible from the outside for tight fit z z z Check clutch linings z Check clutch pressure booster system z Clean the oil jet for the clutch lubrication z z CARBURETOR Check carburetor connection boots for cracks and leaks z z Check synchronisation of carburators using special too...

Страница 31: ...t z z z Check headlamp adjustment z z z 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 z z z Make sure all bolts and nuts are tight z z z BRAKES Check brake fluid level lining thickness and brake discs z z z Change brake fluid z Check brake lines for d...

Страница 32: ... inflation pressure z z z Check chain sprockets and chain guides for wear force fit and tension z z z Check bolts on pinion and chain sprocket for locking devices and a tight fit z z z Lubricate chain z z z Check wheel bearings and jerk damper for play z z z 950 SUPERMOTO 2006 IMPORTANT RECOMENDED MAINTENANCE PROCEDURES TO BE PERFORMED BASED ON A SEPARATE SUPPLEMENT ORDER at least once a year Serv...

Страница 33: ...n z Lubricate and adjust actuating cables and nipples z Bleed fork legs in regular intervals z Clean chain z Lubricate chain z z Check the chain tension grease the chain if necessary z Check tire pressure and wear z Check coolant level z Check fuel lines for leaks z Check all control elements for smooth running z Check brake performance z z Treat exposed metal components except for the braking and...

Страница 34: ...CTURE THE TANK AND CAUSE FUEL TO LEAK OUT IF YOU DISCONNECT SOCKET CONNECTORS WITH SELF LOCKING NUTS REPLACE THEM BEFORE REMOUNTING IF NO NEW SELF LOCKING NUTS ARE AVAILABLE APPLY LOCTITE 243 TO THE THREAD OF THE OLD NUTS IF THE THREAD IS DAMAGED REPLACE THE SCREWS AND NUTS DO NOT USE TOOTHED DISKS OR SPLIT WASHERS FOR THE ENGINE FASTENING BOLTS SINCE THEY WILL WORK THEIR WAY INTO THE FRAME COMPON...

Страница 35: ...gs are equally adjusted Adjusting compression damping of fork Hydraulic compression damping determines the reaction when the fork is compressed Turn the adjusting screws clockwise to increase damping turn it counterclockwise to reduce damping during compression Make the same damping rate adjustment to both fork legs STANDARD ADJUSTMENT Turn adjusting screw clockwise as far as it will go Turn 15 cl...

Страница 36: ...d on the fork The fork spring preload can be adjusted by turning the adjusting screws 2 wrench size 24 mm 5 mm 0 2 in Turning in a clockwise direction will increase the preload turning in a counterclockwise direc tion will decrease the preload 1 turn will change the preload by 1 mm Changing the preload will not affect the rebound damping adjustment although adjusting screw 1 will turn at the same ...

Страница 37: ... Turning in a clockwise direction will increase the damping turning counterclockwise will decrease the damping STANDARD ADJUSTMENT LOW SPEED Turn adjusting screw 1 clockwise as far as it will go Turn 15 clicks in a counterclockwise direction STANDARD ADJUSTMENT HIGH SPEED Turn adjusting screw 2 wrench size 17 mm clockwise as far as it will go Turn 2 turns in a counterclockwise direction THE DAMPIN...

Страница 38: ...ORBER IS FILLED WITH HIGH COMPRESSION NITROGEN NEVER TRY TO TAKE THE SHOCK ABSORBER APART OR TO DO ANY MAINTENANCE WORK YOUR SELF SEVERE INJURIES COULD BE THE RESULT MAINTENANCE WORK ON CHASSIS AND ENGINE 37 Breathing the fork legs Breath the fork legs regularly see Maintenance Schedule To breath place the motorcycle on the side stand and briefly remove the bleeder screws 2 to allow any overpressu...

Страница 39: ...CLE S HANDLING PERFORMANCE TO BECOME INSTABLE AND CAUSE IT TO CRASH MAINTENANCE WORK ON CHASSIS AND ENGINE 38 7 mm Checking the chain tension Place the motorcycle on the side stand Switch the transmission to neutral and push the chain up The distance between the chain and the swing arm should be 7 mm 0 3 in when the upper part of the chain A is tensioned see drawing Correct the chain tension if ne...

Страница 40: ...ON CHASSIS AND ENGINE 39 Chain maintenance For long chain life good maintenance is very important X ring chains require only modest maintenance The best way is to use lots of water but never use brushes or solvents After drying use a special chain spray designed for X ring chains Motorex Chainlube 622 NO LUBRICATION IS ALLOWED TO REACH THE REAR TIRE OR THE BRAKE DISK EITHERWISE THE ROAD ADHERENCE ...

Страница 41: ...ONS ALWAYS HAVE MAINTENANCE WORK AND REPAIRS TO THE BRAKE SYS TEM PERFORMED BY AN AUTHORIZED KTM WORKSHOP BRAKE PADS Your motorcycle is equipped with sintered brake pads in the front and rear and homologated accordingly They guarantee maximum braking performance Front brake pads Toshiba TT 2172 HH Rear brake pads Toshiba TT 2701 HH BRAKE PADS AVAILABLE IN THE ACCESSORY TRADE ARE OFTEN NOT AUTHORIZ...

Страница 42: ...not have any DOT 5 1 for refilling you may use DOT 4 brake fluid However you should replace it as soon as pos sible by DOT 5 1 Never use DOT 5 braking fluid It is based on silicone oil and has a purple color Gaskets and brake hoses are not compatible with it Brake fluid is exposed to a high thermal load and absorbs moisture from the air which lowers the boiling point The brake fluid should therefo...

Страница 43: ...R THE BRAKE PADS ARE COMPLETELY WORN DOWN IN THIS CASE CONSULT AN AUTHORIZED KTM DEALER IMMEDIATELY HAVE THE BRAKE FLUID CHANGED AT AN AUTHORIZED KTM WORKSHOP EVERY 2 YEARS Refilling front brake fluid It is not necessary to refill brake fluid under normal conditions see General information on KTM disk brakes However brake fluid must be refilled as soon as the brake fluid level reaches the MIN mark...

Страница 44: ...NT REMOVER USE ONLY CLEAN BRAKE FLUID TAKEN FROM A TIGHTLY SEALED CONTAINER Checking the front brake pads The brake pads can be seen from the rear The linings must be at least 1 mm 0 04 in thick AT THEIR MOST WORN POINT BRAKE PAD LININGS SHOULD NOT BE THINNER THAN 1 MM OTHERWISE THEY COULD LEAD TO BRAKE FAILURE FOR YOUR OWN SAFETY DON T PUT OFF HAVING YOUR BRAKE PADS CHANGED IF THE BRAKE PADS ARE ...

Страница 45: ...T AN AUTHORIZED KTM WORKSHOP EVERY 2 YEARS MAINTENANCE WORK ON CHASSIS AND ENGINE 44 Changing the basic position of the foot brake lever Loosen the counter nut 1 and turn the push rod 2 until the foot brake lever reaches the right position Tighten the counter nut Refilling the rear brake fluid reservoir It is not necessary to refill brake fluid under normal conditions see General information on KT...

Страница 46: ...H SKIN AND EYES IF YOU GET BRAKE FLUID IN YOUR EYES RINSE WITH PLENTY OF WATER AND CONSULT A DOCTOR DON T LET BRAKE FLUID GET IN CONTACT WITH PAINT IT IS AN EFFECTIVE PAINT REMOVER USE ONLY CLEAN BRAKE FLUID TAKEN FROM A TIGHTLY SEALED CONTAINER 12 mm min 1 mm Checking the rear brake pads The brake pads can be inspected from the rear The thickness of the linings may not be less than 1 mm 0 04 in A...

Страница 47: ...e correctly mounted The front wheel should not touch the ground MAINTENANCE WORK ON CHASSIS AND ENGINE 46 3 3 2 Remove the screws 1 from the left and right brake calipers and carefully pull the brake calipers off the brake disks towards the back Loosen the collar screw 2 and the clamping screws 3 on both fork leg axle passages Unscrew the collar screw approx 8 turns press on the collar screw with ...

Страница 48: ... mount the screws and tighten to 45 Nm Take the motorcycle off the front stand actuate the front wheel brake and vigorously com press the fork several times to align the fork legs Before you tighten the clamp screws 3 check whether the right brake disk C runs in the center of the brake caliper Move the right fork leg to the side if necessary then tighten the clamp screws on both fork leg axle pass...

Страница 49: ...ld the rear wheel while you pull out the wheel spindle 3 Push the rear wheel forward as far as possible and remove the chain from the rear sprocket Carefully take the rear wheel off the swing arm DO NOT OPERATE THE REAR BRAKE WHEN THE REAR WHEEL HAS BEEN DISMOUNTED ALWAYS PLACE THE WHEEL ON THE GROUND WITH THE BRAKE DISC POINTING UPWARDS OTHERWISE THE BRAKE DISC MAY BE DAMAGED IF THE AXLE IS DISMO...

Страница 50: ...ss the rear wheel towards the front to allow the chain tensioner to rest against the clamping screws IF YOU DON T HAPPEN TO HAVE A TORQUE WRENCH AT HAND MAKE SURE YOU HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POSSIBLE A LOOSE WHEEL SPINDLE CAN CAUSE THE MOTORCYCLE S HANDLING PERFORMANCE TO BECOME INSTABLE AND CAUSE IT TO CRASH AFTER MOUNTING THE REAR WHEEL KEEP OPERATING THE ...

Страница 51: ...air pressure to the motorcycle s total weight Proper pressure ensures optimum driving comfort and extends the life of your tires DO NOT MOUNT TIRES WHICH HAVE NOT BEEN APPROVED BY KTM OTHER TIRES COULD HAVE ADVERSE EFFECTS ON THE WAY YOUR MOTORCYCLE RIDES USE TIRES OF THE SAME BRAND AND TYPE FOR THE FRONT AND REAR WHEELS FOR YOUR OWN SAFETY REPLACE DAMAGED TIRES IMMEDIATELY WORN TIRES CAN HAVE A N...

Страница 52: ... front see illustration Connect the minus pole to the battery last IF ELECTROLYTE SULPHURIC ACID LEAKS FROM THE BATTERY PROCEED WITH GREAT CARE THE ELECTROLYTE CAN CAUSE SEVERE BURNS IN THE CASE OF SKIN CONTACT RINSE THOROUGHLY WITH WATER IN THE CASE OF CONTACT WITH THE EYES THOROUGHLY RINSE EYES WITH WATER FOR AT LEAST 15 MINUTES IMMEDIATELY CONSULT A DOCTOR THE BATTERY IS A CLOSED MODEL BUT CAN ...

Страница 53: ...of time the battery will run down and sulfa tize destroying the battery Recharge the battery every 3 months if it is being stored for a longer period of time NEVER REMOVE THE CLOSURE SINCE IT WILL BE DAMAGED TO AVOID DAMAGE TO THE ON BOARD ELECTRONIC SYSTEM ALWAYS DISCONNECT THE MINUS POLE BEFORE YOU CHARGE THE BATTERY TO CHARGE CONNECT THE BATTERY TO THE BATTERY CHARGER BEFORE YOU SWITCH ON THE B...

Страница 54: ... spare fuse is always at hand Replace a blown fuse only with an equivalent one If a new fuse that has just been set in gets blown again you are strongly advised to have it inspected by a KTM dealer The fuse capacity is 30 Ampere UNDER NO CIRCUMSTANCES IS A STRONGER FUSE ALLOWED TO BE SET IN OR A FUSE ALLOWED TO BE REPAIRED AN INEXPERT TREATMENT COULD DAMAGE THE WHOLE ELECTRICAL INSTALLATION CONTAC...

Страница 55: ...ach Fuse ACC 2 also protects the carburetor heaters from short circuits Sockets to connect the accessories are located under the headlight mask For more infor mation contact an authorized KTM workshop 54 Fuses for individual power consumers A fuse box is mounted under the seat containing additional fuses that protect the individ ual electric power consumers The power consumers and the correspondin...

Страница 56: ...s B in the headlight Mount the bulb socket rubber cap and connector Attach the headlight mask at the bottom mount the screw and tighten to 10 Nm MAINTENANCE WORK ON CHASSIS AND ENGINE 55 Replacing the headlight lamp Remove the screws 1 tilt the headlight mask up towards the front and detach at the bottom NEVER TOUCH THE GLASS OF THE BULB WITH YOUR FINGERS THE GLASS OF THE BULB MUST REMAIN ABSOLUTE...

Страница 57: ...er of the headlight Position your motorcycle loaded ready for the trip 5 meters 16 4 ft away from the wall and switch on the low beam The light dark cut off line should be 5 cm 2 in under the mark see drawing Replacing the flasher bulbs Remove the screw on the back of the turn signal carefully fold the lens 2 towards the motorcycle and remove Turn the cap 3 approx 15 in a counterclockwise directio...

Страница 58: ...rox 30 in a counterclockwise direc tion and remove it from the socket Proceed in the reverse order to mount a new bulb BULBS FOR THE TAILLIGHT Remove the bulb socket 4 from the housing and pull the bulb out of the socket Insert a new bulb and press the bulb socket all the way into the taillight housing Mount the upper rear and insert the screws Mount the baggage carrier and tighten the screws to 2...

Страница 59: ...OSSIBLE CAUSES SLOW RIDING WITH LARGE LOADS AT A HIGHER AIR TEMPERATURE IF POSSIBLE INCREASE YOUR RUNNING SPEED SO THAT MORE AIR CAN BLOW THROUGH THE RADIATORS SHOULD THE WARNING LIGHT STILL BE ON OFF AFTER 1500 METERS 1 MILE STOP IMMEDIATELY SWITCH OFF THE ENGINE AND LOOK FOR OTHER POSSIBLE CAUSES THE COOLING FAN ON THE RADIATOR IS NOT WORKING THE COOLING FAN MUST BE RUNNING WHEN THE COOLING LIQU...

Страница 60: ...lve in the radiator cap 4 a water temperature rising up to 125 C 257 F is admissi ble without fear of problems Any excess cooling liquid caused by thermal expansion is conducted to the compensating tank 5 It will be sucked back in as soon as the temperature in the cooling system drops MAINTENANCE WORK ON CHASSIS AND ENGINE 59 Checking the cooling liquid level in the compensating tank Check the lev...

Страница 61: ...IF YOU NEED TO REMOVE THE RADIATOR CAP WHEN THE ENGINE IS HOT HOLD THE CAP WITH A CLOTH AND OPEN SLOWLY ALLOWING ANY EXCESS PRESSURE TO ESCAPE DANGER OF SCALDING IF MORE THAN 1 LITER OF COOLING LIQUID NEEDS TO BE ADDED YOU WILL NEED TO BLEED THE COOLING SYSTEM ONLY CONTINUE TO DRIVE IF THERE IS ENOUGH COOLING LIQUID IN THE SYSTEM CONTACT AN AUTHORIZED KTM WORKSHOP TO HAVE THE ERROR ELIMINATED YOU ...

Страница 62: ...nt Add cooling liquid until it runs out of the vent holes without bubbles and immediately mount the screw to prevent air from entering the radiator Completely fill the radiator with cooling liq uid Mount the radiator cap and move the motorcycle into a horizontal position again Fill the compensating tank with cooling liq uid until it reaches a level between the MIN and MAX mark Close the compensati...

Страница 63: ...R APPLY EXCESSIVE FORCE 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 pur pose remove screws and cover 2 together with the rubber boot 3 The oil level in the hor izontal standing master cylinder should be 4 mm below the upper edge If necessary add SAE 10 biodegradable hydraulic oil Motorex clutch fluid 75 availa...

Страница 64: ...0 12 in at all times To check the play push back the protection cover 4 It should be possible to lift the cable approx 3 mm away from the adjusting screw 5 If necessary loosen the counter nut 6 turn the adjusting screw as needed tighten the counter nut again and slide on the protection cover IF THERE IS NO PLAY IN THE CHOKE CABLE THE BORE OF THE COLD STARTER SYSTEM CANNOT BE COMPLETELY CLOSED THIS...

Страница 65: ...on on the can KTM recommends Motorex Power Synt 4T in the 10W 50 viscosity for temperatures over 0 C 32 F or 5W 40 for temperatures under 0 C 32 F Checking the engine oil level Check the engine oil level when the engine is warm at least 4 bars on the temperature indi cator light up Allow the warm engine to run idle for approx 1 minute and place the motor cycle on a level surface not on the side st...

Страница 66: ...an oil change Since many parts must be demounted for an oil change we recommend having the engine oil changed by an authorized KTM workshop During the guaranty period the oil change must be performed by an authorized KTM mechanic Otherwise the guarantee will become void The engine oil change is to be carried out when the engine is still warm AN ENGINE HAVING BEEN RUN WARM AND THE ENGINE OIL IN IT ...

Страница 67: ... plugs the cover and both oil screens Clean all rubber seal rings and check for damage Replace if necessary Mount the oil drain plug on the engine with a new seal ring and tighten to 20 Nm Slide the oil screen 9 into the guides in the oil pump housing with the TOP mark facing up Make sure the form ring is in place and mount the cap 3 Tighten the screws to 10 Nm MAINTENANCE WORK ON CHASSIS AND ENGI...

Страница 68: ...fully slide the oil screen in the oil tank Position the con nector 2 mount the screws and tighten to 10 Nm Unscrew the plug 3 Add 2 5 liters 0 7 USgal of fully synthetic engine oil according to the JASO MA Norm e g Motorex Power Synt 4T and remount the plug Start the engine and allow to run warm in neutral until 4 bars on the temperature indicator light up Switch off the engine and check the engin...

Страница 69: ...switch Defect safe starting system Turn on the ignition switch the gear to neutral and switch the emergency OFF switch on Recharge the battery and investigate the causes for discharg ing contact an authorized KTM workshop Replace fuse IGNITION Remove the seat and replace the main fuse in the starter relay Check ignition lock and emergency OFF switch contact an authorized KTM workshop Contact an au...

Страница 70: ...un the fuel lines without kinks Check vacuum hoses and venting hoses of carburetors for correct position no kinks Have the air filter replaced at an authorized KTM workshop Engine overheats Insufficient cooling liquid Radiator fins are extremely dirty Foam forms in cooling system Radiator hose is kinked or damaged Thermostat defective Blown fan fuse Defect fan or thermoswitch for fan Refill coolin...

Страница 71: ...e chapter Engine oil Headlight and position light fail Blown fuse Replace fuse H L BEAM POSITION Flasher lights brake light horn and multi functional digital speedometer fail Blown fuse Replace fuse HORN BRAKELIGHT SPEEDO Time is not displayed or not cor rectly displayed Blown fuse thus no continuous power supply Replace fuse CLOCK and set the clock The battery is discharged The ignition power con...

Страница 72: ...ional digital speedometer display Blown fuse Replace fuse HORN BRAKELIGHT SPEEDO No speed display Defective sensor cable or oxidized socket connector Check the pickup cable for damage remove the headlight mask and check the cable connectors Contact an authorized KTM workshop 71 ...

Страница 73: ...re and a cloth Then take a short drive until the engine has reached the working temperature and also use the brakes Due to the heat the water also evaporates at the unapproach able parts of the engine and the brakes Slide back the protective covers on the handlebar mounted instruments so that any water that may have seeped into this part of the motorcycle is allowed to evaporate After the motorcyc...

Страница 74: ... road salt clean motorcycle thoroughly and let it dry treat engine carburetor swing arm and all other bare parts except for brake discs with a wax based anti corrosion agent KEEP ANTI CORROSION AGENT FROM GETTING INTO CONTACT WITH THE BRAKE DISCS FOR OTHERWISE THIS WILL SIGNIFICANTLY REDUCE THE BRAKING POWER AFTER RIDES ON SALTED ROADS CLEAN MOTORCYCLE THOROUGHLY WITH COLD WATER AND LET IT DRY WEL...

Страница 75: ...meated tarpaulin or blanket Do not use non air permeable materials as a possible humidity might not be able to escape and could cause corrosion IT WOULD BE VERY BAD TO LET THE ENGINE RUN FOR A SHORT TIME DURING THE STORAGE PERIOD THE ENGINE WOULD NOT GET WARMED UP ENOUGH AND THE THUS DEVELOPED STEAM WOULD CONDENSE DURING THE COMBUSTION PROCESS AND CAUSE THE VALVES AND EXHAUST TO RUST RE INITIATION...

Страница 76: ... 58W Air pressure front road driver only 2 4 bar 34 psi road with passenger maximum payload 2 4 bar 34 psi Tires rear 180 55 ZR17 M C 73W Air pressure rear road driver only 2 4 bar 34 psi road with passenger maximum payload 2 6 bar 37 psi Approved tires PIRELLI Scorpion Sync PIRELLI Dragon Supercorsa Pro DUNLOP Sport Max D 208 RR Fuel tank capacity 17 liters 4 5 USgal 4 liters 1 USgal reserve Gear...

Страница 77: ...total weight 400 kg 883 lbs FORK 950 SUPERMOTO Type 14187B20 WP Suspension Spring 5 6 450 Spring preload 5 mm 0 2 in Air chamber lenght 110 mm 4 3 in Fork oil SAE 5 WP 4860 0401 SHOCK ABSORBER 950 SUPERMOTO Type 15187B03 WP Suspension Spring 130 215 Spring preload 9 mm 0 35 in 950 SUPERMOTO 2006 FORK SHOCK SETTING Compression Rebound Spring preload turns Compression Low Speed Compression High Spee...

Страница 78: ...p bolts on fork leg axle passages M8 15 Nm Collar bolts for handlebar clamps M8 20 Nm AH bolt for handlebar mount M10 20 Nm HH clamp bolts for steering stem M8 20 Nm Collar bolt front rear brake disk M8x1 25 Loctite 243 30 Nm HH bolts on front brake caliper M10x1 25 Loctite 243 45 Nm HH bolts on handbrake cylinder M6 10 Nm HH bolts on footbrake cylinder M6 Loctite 243 10 Nm AH bearing bolt for foo...

Страница 79: ...st clamp M8 8 Nm Exhaust clamp for ball joint M8 35 Nm HH bolts on exhaust suspension M6 Loctite 243 12 Nm HH bolt on fuel level indicator M5 3 Nm HH bolts fuel taps M6 6 Nm AH bolts tank trim M6 6 Nm Jerk damper bolt rear wheel M10x1 25 Loctite 243 50 Nm Chainguard M5 5 Nm Chain sliding guard M5 5 Nm Taillight M6 8 Nm Other bolts on chassis M6 M8 M10 10 Nm 25 Nm 45 Nm Other collar nuts on chassis...

Страница 80: ...iction bearings 2 main bearings 1 supporting bearing Conrod bearing friction bearing Piston pin bearing dual fuel bearing Piston light alloy forged Piston rings 1 compression ring 1 taper face ring 1 single piece oil scraper ring with spiral type expander Engine lubrication dry sump with 2 trochoidal pumps pressure pump and suction pump Engine oil SAE 5W 40 10W 50 Motorex Power Synt 4T Quantity of...

Страница 81: ...A TEMPERATURE 0 C 32 F Engine oil Only use fully synthetic engine oils that meet the JASO MA quality requirements see infor mation on the can KTM recommends Motorex Power Synt 4T in the 10W 50 viscosity for temperatures over 0 C 32 F or 5W 40 for temperatures under 0 C 32 F BASIC CARBURETOR SETTING Type of carburetor CVRD 43 Main jet 155 front 160 rear Main air jet 40 Idling jet 42 Idle air jet 50...

Страница 82: ...he chain tension 38 Checking the cooling liquid level in the compensating tank 59 Checking the cooling liquid level in the radiator 60 Checking the engine oil level 64 Checking the front brake fluid level 42 Checking the front brake pads 43 Checking the oil level of the hydraulic clutch 62 Checking the rear brake pads 45 Choke lever 7 Cleaning 72 Clutch lever 7 Combination switch 13 Compression da...

Страница 83: ...ck absorber 19 Refilling engine oil 65 Refilling front brake fluid 42 Refilling the rear brake fluid reservoir 44 Replacing the brake light and taillight bulbs 57 Replacing the flasher bulbs 56 Replacing the headlight lamp 55 Running in the LC8 engine 20 Seat lock removing the seat 15 Serial number locations 6 Setting options in the display 10 Shift lever 16 Shifting Riding 25 Side stand 17 Spring...

Страница 84: ...ims should be directed to KTM Sportmotorcycle USA Inc 1119 Milan Avenue Amherst Ohio 44001 Telephone 440 9853553 TAMPERING WARNING TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED FEDERAL LAW PROHIBITS THE FOLLOWING ACTS OR CAUSING THEREOF 1 The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated ...

Страница 85: ...R USA ONLY 84 on steering head tube L S 1 2 3 4 5 6 7 8 9 on fuel tank on fuel tank under seat on fuel tank under seat on fuel tank under seat on frame tube R S on frame tube L S on frame tube R S under seat Sticker positions ...

Страница 86: ...NSUMER INFORMATION FOR USA ONLY 1 Type label USA 2 Before you go for the first ride 3 Suspension setting 4 Chain tension 5 Technical information 6 Green sticker 8 Type label CAN 7 Noise emission 9 EAVP 85 ...

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Страница 90: ...KTM Sportmotorcycle AG A 5230 Mattighofen www ktm at 11 2005 FOTO MITTERBAUER KTM Group Partner ...

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