Complete factory shop manual including electrical wiring diagrams for 2003-2007 KTM 950 Adventure, 950 Adventure S, 950 Super Enduro, 950 Supermoto, 990 Adventure, 990 Adventure S, 990 Super Duke Motorcycle. It's the same service manual used by dealers that guaranteed to be fully functional and intact without any missing page to save your precious time.

This repair manual (including maintenance, overhaul, disassembling & assembling, adjustment, tune-up, operation, inspecting, diagnostic & troubleshooting…) is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices.

"'03-'07 950-990.pdf"
394 pages; 2003-2007 Repair manual for
950/990 ADVENTURE
990 SUPER DUKE
950 SUPERMOTO
950 SUPER ENDURO

"'03-'06 950-990.pdf"
394 pages; 2003-2006 Repair manual for
950/990 ADVENTURE
990 SUPER DUKE
950 SUPERMOTO
950 SUPER ENDURO

"'03-'05 950-990"
203 MB PDF; 2003-2005 Service manual for 950 Adventure, 990 Super Duke
LANGUAGE: EN/DE/FR/IT/ES

"'03 950 Adventure (S) (EN).pdf"
185 pages; 2003 Service manual for 950 Adventure, Adventure S

"'03 950 Adventure (S) (DE).pdf"
386 pages, German; 2003 Service manual for 950 Adventure, Adventure S

"'03 950 Adventure Owners Manual.pdf"
55 pages; 2003 Owners manual for 950 Adventure

EXCERPT:
Disassembling the cylinder head and checking parts for wear
NOTE: the illustration shows the font cylinder. The procedure for the rear cylinder is identical.
– Pull all of the bucket tappets 1 out of the cylinder head.
NOTE:
– Note down the mounting position to ensure that the same bucket tappet is inserted in the same bore during installation.
– The compensating washers 2 for the valve clearance (shims) usually adhere to the bottom of the bucket tappets and should be set aside together with the bucket tappets.
– Invert the cylinder and cylinder head and remove the three Allen bolts 3 and nuts.
– Remove the cylinder and pistons from the cylinder head and discard the cylinder head gasket.
– Unscrew the chain guide.
– Press the valve springs together using the valve assembling tool (590.29.019.000 with the attachment 600.29.041.000 4) and remove the valve spring key from the valve shaft. Relieve the springs and remove from the cylinder head.
NOTE: note down the mounting position of the valves to ensure that the valves are mounted in the same position during installation.
– Pull the valve shaft seal off the valve 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 for the other valves.
– Clean all parts.
Sealing area
Check the spark plug thread and valve seats for damage or cracks. Use a straight edge A and a feeler gauge B to check the sealing area to the cylinder for distortion. Max. distortion: 0.05 mm.
Valve seats
The valve seats may not be impacted. Width of sealing seat: intake max. 1.8 mm; outlet max. 2.0 mm. Reseat the valves if necessary.
Valves
Check the valve disk for wear and runout. The valve disk runout should not exceed 0.03 mm. The valve seat may not be impacted. The sealing area should be in the middle of the valve seat. The valve shaft is hardchrome-plated. Wear usually occurs at the valve guide.
Valve guides
The valve guides are checked with the limit plug gauge C590.29.026.006 (Ø 6.05 mm). If the limit plug gauge can easily be
pushed into the valve guide, the valve guide needs to be replaced at a special workshop.
Valve springs
Check the valve springs for fractures or other wear. Measure the spring length with a sliding caliper in an unloaded condition:
Minimum length of inner spring: 38.0 mm (950) or 37.0 (990)
Maximum length of outer spring: 41.3 mm (950) or 41.2 (990)