OWNER’S MANUAL 2006 950 SUPER ENDURO R ART. NR. 3.211.172 EN 04/2006 KTM Group Partner KTM Sportmotorcycle AG A–5230 Mattighofen www.ktm.
INTRODUCTION » 1 We would like to congratulate you on your purchase of a KTM motorcycle. You are now the owner of a state-of-the-art sport motorcycle that guarantees to bring you lots of fun and enjoyment, provided that you clean and maintain it appropriately. Please insert the serial numbers of your motorcycle in the boxes below: Frame number Stamp of dealer Engine number Key number All information contained is without obligation.
IMPORTANT INFORMATION » 2 INTENDED PURPOSE The KTM 950 Super Enduro R is designed to resist the usual wear and tear of onor off-road service, providing maximum performance in competitive racing or private use. OWNER'S MANUAL Carefully read the entire Owner's Manual before you start riding your motorcycle, even if this will take a little time. It contains useful tips and information on the best way to handle the motorcycle and how to protect yourself from injuries.
IMPORTANT INFORMATION » WARRANTY The service work specified in the „Lubrication and Maintenance Schedule“ must be performed by an authorized KTM workshop. This is the only place that has the qualified technicians and the special tools required for the 950 Super Enduro R. Be sure to have the workshop verify all service work carried out in the service manual to avoid losing your right to claim under the warranty.
INDEX » INTRODUCTION . . . . . . . . . . . . . . . . IMPORTANT INFORMATION . . . . . . . . SERIAL NUMBER LOCATIONS . . . . . . Chassis number, Type label . . . . . . . Engine number, engine type . . . . . . OPERATION INSTRUMENTS . . . . . . . Clutch lever . . . . . . . . . . . . . . . . . Choke lever . . . . . . . . . . . . . . . . . . Hand brake lever . . . . . . . . . . . . . . OPERATION INSTRUMENTS . . . . . . . Multi-functional digital speedometer Display . . . . . . . . . . . . . . . . . . . . .
INDEX » Checking of brake fluid level - front brake . . . . . . . . . . . Checking the front brake pads . . . . . . . . . . . . . . . . . . . Checking rear brake fluid level . . . . . . . . . . . . . . . . . . . Checking the rear brake pads . . . . . . . . . . . . . . . . . . . . Dismounting and mounting the front wheel . . . . . . . . . . Dismounting and mounting the rear wheel . . . . . . . . . . . Tires, air pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking spoke tension . . . . .
SERIAL NUMBER LOCATIONS » 6 Chassis number, Type label The chassis number is stamped on the right side of the steering head tube. Enter this number 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.
OPERATION INSTRUMENTS » 7 Clutch lever 1 The clutch lever [1] is fitted on the left hand side of the handle bar. The adjusting screw [A] is used to change the original position of the clutch lever (see maintenance work on chassis and engine). The clutch is hydraulically actuated and adjusts itself automatically. A Choke lever If the choke lever [2] is pulled backwards, a bore in the carburetors will be opened in the carburetor through which the engine may draw in additional fuel.
OPERATION INSTRUMENTS » 1 2 3 8 Multi-functional digital speedometer The universal instrument is divided into 3 parts. Use the MODE and SET [1] button to change the display and the basic settings in the display. Display [2] shows all of the information that may be of interest to you. 5 display modes can be selected with the MODE button. The indicator lamps [3] provide additional information on the motorcycle's running condition.
OPERATION INSTRUMENTS » CLOCK ODO TRIP 1 TRIP 2 TRIP F 9 CLOCK You will recognize the CLOCK display by the blinking dots between the hours and minutes. It displays the speed, temperature of the cooling liquid and the clock. To switch to the next display mode, press the MODE button. ODO The speed, temperature of the cooling liquid and the total kilometers or miles traveled are shown in the ODO mode. To switch to the next display mode, press the MODE button.
OPERATION INSTRUMENTS » 1 1 2 10 sec 10 Setting options in the display KILOMETERS OR MILES. You can have the speed and distance shown in kilometers or miles in the display. The display can be adapted to the respective country on long-distance trips. To switch from kilometers to miles, switch on the ignition and press the MODE [1] button for approx. 10 seconds. The km/h display will switch to mph. The speed and the stored distances will be converted and displayed in miles.
OPERATION INSTRUMENTS » 2 11 RESETTING TRIP 2 The trip meter 2 runs continuously and counts up to 999.9. It can be used similarly to TRIP 1 or together with a switch available as an accessory (see below) for trips according to a roadbook. To return the trip meter 2 to zero, switch on the ignition, change to the TRIP 2 mode and press the SET button [2].
OPERATION INSTRUMENTS » 12 Cooling liquid temperature display 1 120°C (248°F) 110°C (230°F) 100°C (212°F) 70°C (158°F) 60°C (140°F) 50°C (122°F) 40°C (104°F) 2 The temperature display [1] is shown in 7 bars. The more bars that light up, the hotter the cooling liquid. When the lowest bar lights up, the cooling liquid has reached a temperature of approx. 40°C (104°F). When the upper bar lights up 120°C (248°F), all of the bars will start to blink and the red warning lamp [2] will light up.
OPERATION INSTRUMENTS » 13 Ignition lock 1 The ignition lock [1] has 3 switching positions. Ignition off, (engine can't be started) Ignition on, light on, (engine can be started) Ignition off, handlebar blocked To switch the ignition to position turn the ignition key to position and firmly press it into the lock. Turn the handlebar to the left, then turn the ignition key to the left. The ignition key can be withdrawn in position and . 2 3 Combination switch The light switch has 2 switch positions.
OPERATION INSTRUMENTS » 14 Starter tip switch Use the starter tip switch [2] to operate the electric starter. 2 Filler cap 3 The filler cap [3] can be locked and is provided with a fuel evaporation control system. 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 » 15 Grips 1 The grips [1] are used to maneuver the motorcycle. If carrying a passenger, the passenger can hold on to the grip during the ride. 1 Removal of seat Actuate the lever [2] while lifting the back of the seat [3]. 2 3 4 6 5 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.
OPERATION INSTRUMENTS » 16 Tool set The tool set [1] is located in the storage compartment under the seat. 1 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 gear. 2,3,4,5,6 N 1 Side stand Fold the side stand [2] forward to the stop with your foot and put the weight of the motorcycle on the stand. Make sure it is standing securely on a firm surface.
OPERATION INSTRUMENTS » 18 Compression damping of fork The fork's damping action during compression travel (compression damping) can be adjusted. This allows you adjust the damping behavior to match your driving style and the payload. The adjusting screws [2] are located under the cap [1] on the lower end of the fork legs. More information is provided in the chapter "Adjusting the fork and shock absorber.
OPERATION INSTRUMENTS » 19 Damping action during compression of shock absorber The shock absorber's damping action during compression travel (compression damping) can be adjusted. This allows you adjust the shock absorber's damping behavior to match your driving style and the payload. The damping rate can be adjusted in the low and high-speed range (Dual Compression Control). The designation low and high-speed refers to the movement of the shock absorber and not to the motorcycle's driving speed.
GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE » Instructions for initial operation – Make sure the work for the „pre-delivery inspection“ was performed by your authorized KTM workshop. The DELIVERY CERTIFICATE and SERVICE MANUAL will be handed over when you pick up your vehicle. – Read these operating instructions carefully before your first ride. – Enter the chassis, engine and key numbers on page 1. – Familiarize yourself with the operating elements.
GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE » – New tires have a smooth surface, which means that they must be run in to achieve full grip. For this purpose, ride the motorcycle carefully at moderate speed during the first 200 kilometers 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 properly run in.
DRIVING INSTRUCTIONS » 22 Check the following before each start When you start, the motorcycle must be in perfect mechanical condition. For safety reasons, you should make a habit of performing an overall check of your motorcycle before each start. The following checks should be performed: 1 FUEL Check the fuel quantity in the tanks. 2 CHAIN Check the tension and condition of the chain. A loose chain can fall off the sprockets and a worn-out chain can tear.
DRIVING INSTRUCTIONS » 23 5 CABLES Check the throttle cable for correct adjustment and smooth operation. 6 COOLING FLUID Check the level of cooling fluid when the engine is cold. 7 ELECTRICAL SYSTEM Start the engine and check the headlight, tail lamp, brake light, turn signals, indicator lamps, horn and emergency-off switch for proper functioning. 8 CHECK OIL LEVEL Insufficient oil results in premature wear and consequently to engine damage.
DRIVING INSTRUCTIONS » 24 Starting when the engine is cold 4 2 5 1 3 1 Switch on ignition (turn ignition key [1] into position ). NOTE: Usually the operating noise of the fuel pump can briefly be heard after the ignition is switched on. 2 Switch transmission to idle (green indicator lamp N [2] lights up). 3 Operate cold starting device (choke) [3]. Only pull the choke lever half way out at outer temperatures over 5°C (41°F). Pull the choke lever all the way out at outer temperatures below 5°C.
DRIVING INSTRUCTIONS » IF THE ENGINE IS DOES NOT CRANK WHEN YOU ACTUATE THE STARTER TIP SWITCH: – If the transmission is switched to idle – Check if the ignition is on – The headlight is on (the light is switched off when actuating the starter button) – If this is not the case, the battery is discharged – If the lights are on, proceed as described in the „Trouble-shooting“ section or contact a KTM dealer.
DRIVING INSTRUCTIONS » – The passenger must hold on to the driver or the grab handle during the ride and keep his feet on the passenger footrests. – Regularly make sure that the baggage and cases are tightly fastened. – After falling with the motorcycle, check all functions thoroughly before starting up operations again. – A bent handlebar must always be replaced. Never try to straighten the handlebar because this will cause it to lose its stability.
DRIVING INSTRUCTIONS » 27 – In the rain, or after the motorcycle has been washed, braking action may be delayed due to wet brake discs. First, the brakes must be braked dry. – On salt-sprayed or dirty roads brake action may be delayed as well. First, the brakes must be braked clean. – Remember that the stopping distance will be longer if you are carrying a passenger or baggage. – When you brake, the brake discs, brake pads, brake caliper and brake fluid heat up.
DRIVING INSTRUCTIONS » 28 Fuel, refueling 50 mm The LC8 engine requires unleaded fuel with at least RON 95 (USA = Premium PON 91, see technical specifications engine). If using lower octane fuel, it is easy to change over to the pre-programmed ignition curve for 80 - 94 octane (RON) (see activating the ignition curve for low-octane fuel). After refueling, it will take approx.
PERIODIC MAINTENANCE SCHEDULE » 1st Service after 1000 km Service every 7500 km or once a year Service every 15000 km or every 2 years Change engine oil and oil filter z z z Clean oil screens of engine and oil tank z z z Clean magnetic drain plugs of engine and oil tank z z z Check oil lines for damage and kink-less arrangement z z z ENGINE 950 SUPER ENDURO R 2006 A CLEAN MOTORCYCLE CAN BE CHECKED MORE QUICKLY WHICH SAVES MONEY! IF MOTORCYCLE IS USED FOR COMPETITION 7500 KM SERVICE SHOUL
PERIODIC MAINTENANCE SCHEDULE » BRAKES Service every 15000 km or every 2 years 1st Service after 1000 km Service every 7500 km or once a year ADD ON PARTS 950 SUPER ENDURO R 2006 A CLEAN MOTORCYCLE CAN BE CHECKED MORE QUICKLY WHICH SAVES MONEY! IF MOTORCYCLE IS USED FOR COMPETITION 7500 KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE! Service intervalls should never be exceeded by more than 500 km (300 miles).
PERIODIC MAINTENANCE SCHEDULE » 1st Service after 1000 km Service every 7500 km or once a year Service every 15000 km or every 2 years Check spoke tension and rim joint z z z Check tire condition and 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 at least once a year Ser
PERIODIC MAINTENANCE SCHEDULE » every 1000 km after off road use Check oil level Check brake fluid level Check brake pads for wear Check lighting system for proper operation Check horn for proper operation Lubricate and adjust actuating cables and nipples Bleed fork legs in regular intervals Clean chain Lubricate chain Check the chain tension; grease the chain if necessary Check tire pressure and wear Check coolant level Check fuel lines for leaks Check all control elements for smooth running Check brake
MAINTENANCE WORK ON CHASSIS AND ENGINE » 33 – If using a power washer, do not point the water jet at the electric components, plugs, cables, bearings, carburetor, etc. The high pressure will cause water to penetrate into the components and can cause them to malfunction or lead to premature wear. – Use special KTM screws with the correct thread length to fasten the spoiler to the tank. Mounting other screws or longer screws could puncture the tank and cause fuel to leak out.
MAINTENANCE WORK ON CHASSIS AND ENGINE » 950 SUPER ENDURO R 2006 Adjusting the fork and shock absorber Compression Rebound Spring preload (turns) Compression Low Speed Compression High Speed Rebound Spring preload (mm) SHOCK SETTING FORK 34 Comfort 25 25 1 25 2 22 8 Basic Setting 20 20 5 20 1.5 18 8 Sport (MX) 15 15 8 15 1 15 8 Max.
MAINTENANCE WORK ON CHASSIS AND ENGINE » 35 Adjusting rebound damping of fork 1 1 Hydraulic rebound damping determines the reaction when the fork is rebound. By turning the adjusting screw [1] (REB), the degree of damping of the rebound can be adjusted. Turn the knob clockwise to increase damping, turn it counterclockwise to reduce damping during rebounding. Make the same damping rate adjustment to both fork legs. STANDARD ADJUSTMENT – Turn adjusting screw clockwise as far as it will go.
MAINTENANCE WORK ON CHASSIS AND ENGINE » 36 Compression damping of shock absorber 1 2 The shock absorber can synchronize the compression damping in the low and high-speed range separately (Dual Compression Control). Low and high speed refers to the movement of the shock absorber during compression and not to the speed of the motorcycle. The low and high-speed technology overlaps. The low-speed setting is primarily for slow to normal shock absorber compression rates.
MAINTENANCE WORK ON CHASSIS AND ENGINE » 37 Rebound damping of shock absorber By using the adjusting screw [1], the degree of damping of the rebound can be adjusted. Turn the knob in a clockwise direction to increase damping, turn it in a counterclockwise direction to reduce damping during rebounding. STANDARD ADJUSTMENT: – Turn adjusting screw clockwise as far as it will go. – Turn 18 clicks in a counterclockwise direction.
MAINTENANCE WORK ON CHASSIS AND ENGINE » 38 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 15 - 17 mm (0.6 0.7 in) when the upper part of the chain [A] is tensioned (see drawing). Correct the chain tension if necessary.
MAINTENANCE WORK 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).
MAINTENANCE WORK ON CHASSIS AND ENGINE » 40 General informations about KTM disc brakes BRAKE CALIPERS: The brake calipers of this series “float“. This means that the brake calipers are not solidly attached to the caliper support. Thus, the brake pads are always in optimum contact with the brake disc. Secure the screws of the caliper support with Loctite 243 and tighten to 25 Nm. For safety reasons, always have maintenance work and repairs to the brake system performed by an authorized KTM workshop.
MAINTENANCE WORK ON CHASSIS AND ENGINE » 41 BRAKE FLUID RESERVOIRS: The brake fluid reservoirs on the front and rear wheel brakes have been designed in such a way that even if the brake pads are worn it is not necessary to top up the brake fluid. There is no reason to remove the reservoir cap under normal conditions. If the brake fluid level drops below the minimum either the brake system has a leak or the brake pads are completely worn down. In this case, consult an authorized KTM dealer immediately.
MAINTENANCE WORK ON CHASSIS AND ENGINE » 42 Adjusting of free travel at the hand brake lever min. 3 mm 1 Free travel at the hand brake lever may be readjusted by using adjusting screw [1]. In this way, the position of the point of pressure (i.e., the resistance you feel on the hand brake lever when the brake pads are pressed against the brake disc) can be adjusted for any hand size. At the hand brake lever, free travel must at least be 3 mm (0.12 in).
MAINTENANCE WORK ON CHASSIS AND ENGINE » 43 Checking rear brake fluid level The brake fluid reservoir for the rear disk brake is combined with the foot brake cylinder and has an inspection window. The brake fluid level should not drop below the "MIN" mark when the motorcycle is in a vertical position. – If the brake fluid level drops below the minimum either the brake system has a leak or the brake pads are completely worn down. In this case, consult an authorized KTM dealer immediately.
MAINTENANCE WORK ON CHASSIS AND ENGINE » 44 Dismounting and mounting the front wheel Jack the motorcycle up at the underride protection until the front wheel no longer touches the ground. Loosen the 2 clamping screws [2] on the left side of the fork fists. Loosen and remove the collar nut [1]., loosen the clamping screews [2] on the right side of the fork fist. Hold the front wheel, pull out the wheel spindle [3]. Carefully remove the front wheel from the fork.
MAINTENANCE WORK ON CHASSIS AND ENGINE » 2 3 45 To install the front wheel, lift it into the fork, position and mount the axle shaft [3]. Mount the collar nut [1], tighten the clamping screws [2] on the right fork leg axle passage to prevent the axle shaft from turning and tighten the collar nut to 40 Nm (30ft.lb). Loosen the clamp screws on the right fork leg. Take the motorcycle down from its stand.
MAINTENANCE WORK ON CHASSIS AND ENGINE » 46 Dismounting and mounting the rear wheel Jack the motorcycle up at the underride protection until the rear wheel no longer touches the ground. Unscrew the collar nut [1], remove the chain tensioner [2], hold on to the rear wheel while you pull out the axle passage [3]. Push the rear wheel as far to the front as possible, take the chain off of the rear sprocket and lay it on the rear sprocket guard. Carefully lift the rear wheel out of the swing arm.
MAINTENANCE WORK ON CHASSIS AND ENGINE » 4 5 47 Before remounting the rear wheel, clean and grease the bearing surface of the bushings [4] and the shaft seal ring [5]. The rear wheel is remounted in reverse order. Pay attention to the same mounting position of the axle passage and the chain tensioner. Before tightening the collar nut to 90 Nm, push the rear wheel forwards so that the chain tensioners lie on the tension screws.
MAINTENANCE WORK ON CHASSIS AND ENGINE » 48 Tires, air pressure Tire type, tire condition, and how much air pressure the tires have in them affect the way your motorcycle rides, and they must therefore be checked whenever you’re getting ready to go anywhere on your motorcycle. The factory mounted tires are approved for a maximum speed of 160 kph (100 mph). Under no circumstances should this speed be exceeded. Other tires can have a negative effect on the motorcycle's handling (e.g.
MAINTENANCE WORK ON CHASSIS AND ENGINE » 49 Checking spoke tension The correct spoke tension is very important for the stability of the wheels and thus for riding safety. A loose spoke causes the wheel to become unbalanced and before long other spokes will have come loose. Check spoke tension, especially on a new motorcycle, in regular intervals. For checking, tap on each spoke with the blade of a screw driver (see illustration). A clear tone must be the result. Dull tones indicate loose spokes.
MAINTENANCE WORK ON CHASSIS AND ENGINE » 50 Battery The battery is located under the seat and is maintenance-free. Maintenance-free means you will not need to check the acid level. Clean the battery terminals regularly and grease with acid-free grease if necessary. The charge condition and type of charge are very important for the battery's service life. 1 Never operate the motorcycle with a run-down battery or without the battery.
MAINTENANCE WORK ON CHASSIS AND ENGINE » 51 Charging the battery The battery discharges every day, even if it is not used. Always disconnect the battery when charging. Charge the battery as described in the instructions [1] on the battery housing. Do not exceed the amperage and charging time. Quick charging at a high amperage has an adverse effect on the service life. 1 Always use special charging devices to charge maintenance-free batteries, e.g. the KTM charging device (item no. 58429074000).
MAINTENANCE WORK ON CHASSIS AND ENGINE » 52 Main fuse 2 The main fuse [1] protects all power-consuming units on the motorcycle. It is located below the seat at the starter relay. For access to the fuse, remove the cover [2]. The capacity of the fuse is 30 A. A spare fuse [3] can be found under the other cover. When using the spare fuse, remember to replace it as soon as possible so that a spare fuse is always at hand. Replace a blown fuse only with an equivalent one.
MAINTENANCE WORK ON CHASSIS AND ENGINE » 53 Fuses for individual power consumers 2 1 A fuse box is mounted under the seat containing additional fuses that protect the individual electric power consumers. The power consumers and the corresponding capacities are listed on the cover of the fuse box [1]. The ACC 2 fuse protects the carburetor heaters from short circuits. Spare fuses 10 and 15 ampere [2] are located in the storage compartment. Replace a blown fuse only with an equivalent one.
MAINTENANCE WORK ON CHASSIS AND ENGINE » 54 Replacing the headlight lamp 1 Remove the screws [1], tilt the headlight mask up towards the front and detach at the bottom. 1 Never touch the glass of the bulb with your fingers. The glass of the bulb must remain absolutely free from grease. Heat will otherwise cause the grease to evaporate and settle down on the reflector. PARKING LIGHT BULB: Pull the bulb socket [2] out of the reflector and pull the bulb out of the bulb socket.
MAINTENANCE WORK ON CHASSIS AND ENGINE » 55 Adjusting the headlight range The payload can make it necessary to correct the headlight range. The headlight range can be adjusted with the adjusting screw [1]. Turning in a clockwise direction will reduce the headlight range, turning in a counterclockwise direction will increase the headlight range.
MAINTENANCE WORK ON CHASSIS AND ENGINE » 56 Replacing the brake light and taillight bulbs Remove the seat. Remove the screws on the grips [1] and the upper rear [2] and take off the parts. 2 1 BULB FOR BRAKE LIGHT: Turn the bulb socket [3] approx. 30° in a counterclockwise direction and pull it out of the taillight housing. Slightly press in the bulb, turn approx. 30° in a counterclockwise direction and remove it from the socket. Proceed in the reverse order to mount a new bulb.
MAINTENANCE WORK ON CHASSIS AND ENGINE » 57 Activating the ignition curve for low-octane fuel 1 If you are traveling to a country where fuel having at least 95 octane (RON) is not available, you can easily activate the corresponding ignition curve. A socket connector [1] is located on a brown-black cable under the fuse box. If the two connectors are connected to each other, the ignition curve for fuel having at least 95 octane (RON) is activated.
MAINTENANCE WORK ON CHASSIS AND ENGINE » 58 Cooling system The water pump in the engine ensures a forced circulation of the cooling liquid. When the engine is cold, the cooling liquid only circulates in the cylinders and cylinder heads. The thermostat will open when the engine reaches approx. 75°C (167°F) and the cooling liquid will also be pumped through the aluminum radiator [1]. Cooling is by means of the air stream. The lower the speed, the lower the cooling effect.
MAINTENANCE WORK ON CHASSIS AND ENGINE » 4 59 A mixture of 50% antifreeze and 50% distilled water is used as the cooling liquid. However, the anti-freeze protection must be at least -25° C (-13° F). Aside from antifreezing protection, this mixture also provides great corrosion protection which is why it must not be replaced by pure water. – For the cooling system, use only high-grade antifreezer (Motorex Anti-Freeze). Using lowergrade antifreeze agents, can cause corrosion and coolant foaming.
MAINTENANCE WORK ON CHASSIS AND ENGINE » 60 Checking the cooling liquid level in the radiator Hold the radiator cap [1] with a cloth, carefully turn in a counterclockwise direction and remove. The radiator should be completely filled with cooling liquid; no air should be in the radiator. If any cooling liquid is missing, the cooling system is probably leaking. Have the cooling system checked at an authorized KTM workshop. 1 If possible, check the cooling liquid level when the engine is cold.
MAINTENANCE WORK ON CHASSIS AND ENGINE » 61 Bleeding the cooling system To completely bleed the cooling system, the motorcycle must be raised approx. 50 cm (20 in) in the front. 1 Remove the radiator cap [1] and bleeder screw [2]. 2 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 liquid.
MAINTENANCE WORK ON CHASSIS AND ENGINE » 62 Changing the original position of the clutch lever The adjusting screw [1] can be used for individual adjustment of the original position of the clutch lever, thus allowing adjustment to an optimal position for every hand size. Turning the adjusting screw in a clockwise direction will move the clutch lever away from the handlebar. Turning the adjusting screw in a counterclockwise direction will move the clutch lever closer to the handlebar.
MAINTENANCE WORK ON CHASSIS AND ENGINE » 3 2 63 Checking and adjusting the throttle cable play You should feel 3-5 mm free travel on the throttle grip when you start to turn it. To adjust, loosen the counternut [2], turn the adjusting screw [3] as required and tighten the counternut again. Make sure that the throttle grip will return to the idle position automatically once you let go of it.
MAINTENANCE WORK ON CHASSIS AND ENGINE » 64 Engine oil JASO T903 MA TEMPERATUR 0°C 32°F 5W/40 10W/50 Automobile engine oil used to be used for four-stroke motorcycles before there were separate motorcycle specifications. Different technical developments made it necessary to have a separate specification for four-stroke motorcycles - the JASO T903 MA standard. Whereas car engines require long changing intervals, motorcycle engines require a higher power output at higher speeds.
MAINTENANCE WORK ON CHASSIS AND ENGINE » 65 Changing the engine oil and the oil filter, cleaning the oil screen You may only change the engine oil yourself after the warranty period has expired. The warranty will become void if you change the oil yourself during the warranty period. 1 2 2 NOTE: The LC8 engine has a dry-sump lubrication system. The engine oil is pumped from the oil sump in the engine case to the oil tank. The engine oil must also be drained from the oil tank during an oil change.
MAINTENANCE WORK ON CHASSIS AND ENGINE » 66 Remove the drain plug [1] from the oil tank and allow the oil to drain into a vessel. Remove the screws [2] and tilt the connector [3] to the side. 2 3 1 2 Carefully pull the oil screen [4] out of the oil tank. Thoroughly clean the drain plugs, the cover and both oil screens. Clean all rubber seal rings and check for damage. Replace if necessary. 4 Mount the oil drain plug on the engine with a new seal ring and tighten to 20 Nm.
MAINTENANCE WORK ON CHASSIS AND ENGINE » 67 Insert a new oil filter in the engine case, grease the O-ring and mount the oil filter cover together with the O-ring. Tighten the screws to 6 Nm. Only use original ktm oil filters. The engine can be damaged if other filters are used. Mount the oil drain plug on the oil tank with a new seal ring and tighten to 20 Nm. Grease the seal ring [1] and carefully slide the oil screen in the oil tank. Position the connector [2], mount the screws and tighten to 10 Nm.
TROUBLESHOOTING » 68 If you let the specified maintenance work on your motorcycle be carried out, disturbances can hardly be expected. Should an error occur nevertheless, we advise you to use the trouble shooting chart in order to find the cause of error. We would like to point out that many operations cannot be performed by oneself. In case of uncertainty, please contact a KTM-dealer.
TROUBLESHOOTING » 69 TROUBLE CAUSE REMEDY Engine cranks but doesn’t start. Operating error Open fuel taps, tank fuel, you did not use choke. Pay attention to starting off information (see driving instructions).
TROUBLESHOOTING » 70 TROUBLE CAUSE REMEDY Engine overheats Defect fan or thermoswitch for fan Contact an authorized KTM workshop.
TROUBLESHOOTING » 71 TROUBLE CAUSE REMEDY The battery is discharged The ignition (power consumer) hasn’t been switched off Recharge the battery according to the relevant instructions. The battery isn’t charged by the generator because Voltage regulator and generator should be checked by an authorized KTM workshop. No values are visible in the multifunctional digital speedometer display. Blown fuse Replace fuse HORN BRAKELIGHT SPEEDO. No speed display.
CLEANING » 72 Clean your motorcycle regularly in order to maintain the beauty of its plastic surfaces. The best manner would be to use warm water that has been mixed with a normal brand-name washing detergent and a sponge. The hard dirt can be removed before washing with the help of a soft water jet. If using a power washer, do not point the water jet at the electric components, plugs, cables, bearings, carburetor, etc.
CONSERVATION FOR WINTER OPERATION » 73 In the event that the motorcycle is also used in winter and on roads where one has to expect salt spraying, you will have to take precautions against the aggressive 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.
STORAGE » 74 Should you desire to make a pause over a longer space of time, please observe the following instructions: – Drive the tank empty to be able to fill up with fresh fuel when starting the motorcycle up again. – Clean motorcycle thoroughly (see chapter: CLEANING) – Change engine oil and oil filter (old engine oil contains aggressive contaminations). – Check antifreezer and amount of cooling liquid. – Allow the engine to warm up again, close the fuel taps and wait until the engine stalls.
TECHNICAL SPECIFICATIONS – CHASSIS » 75 CHASSIS 950 SUPER ENDURO R Frame tubular chrome-molybdenum-steel space frame Fork Wheel travel front WP Suspension – Up Side Down 4860 MXMA PA Rear suspension Wheel travel rear WP Suspension - Progressive Damping System shock absorber 4618 BAVP Front brake Disk brake, perforated brake disk Ø 300 mm (11.8 in), floating brake caliper and brake disk Rear brake Disk brake, perforated brake disk Ø 240 mm (9.
TECHNICAL SPECIFICATIONS – CHASSIS » CHASSIS 950 SUPER ENDURO R Battery 12V 11.2 Ah maintenance-free Steering head angle 64.4° Wheel base 1577 ± 10 mm (62 in) Seat height, unloaded 965 mm (38 in) Ground clearance, unloaded 330 mm (13 in) Dry weight 190 kg (419.4 lbs) Max. axle load, front 190 kg (419.4 lbs) Max. axle load, rear 250 kg (552 lbs) Max.
TECHNICAL SPECIFICATIONS – CHASSIS » 77 TIGHTENING TORQUES – CHASSIS 950 SUPER ENDURO R 2006 Collar bolt on front wheel spindle M24x1.5 40 Nm Collar nut wheel spindle rear M25x1.5 90 Nm AH bolt shock absorber top/bottom M14x1.5 80 Nm Collar nut for swing arm bolt M19x1.5 130 Nm AH bolts on subframe M10x1.
TECHNICAL SPECIFICATIONS – CHASSIS » 78 TIGHTENING TORQUES – CHASSIS 950 SUPER ENDURO R 2006 Bolt for side stand switch M4 2 Nm Drain plug on oil tank M12x1,5 Exhaust nuts on manifold M8 evenly, do not bend sheet metal Exhaust clamp M8 12 Nm Senkschraube Hitzeschutzblech M6 8 Nm HH bolt on fuel level indicator M5 3 Nm HH bolts fuel taps M6 6 Nm Collar screw for underride protection M8 25 Nm Spoke nipple M5 5 Nm ± 1 Nm Jerk damper bolt rear wheel M10x1,25 Chainguard M5 5 Nm C
TECHNICAL SPECIFICATIONS – ENGINE » 79 ENGINE 950 LC8 Design liquid-cooled, 2-cylinder 4-stroke engine with 75° V arrangement with balancer shaft and electric starter Displacement 942 cc Bore / Stroke 100/60 mm Compression ratio 11.5:1 Fuel unleaded fuel with at least RON 95 (USA: Premium PON 91*) Valve timing 4 valves controlled over bucket tappet and 2 camshafts, camshaft drive with gears/chain Valve diameter intake: 38 mm exhaust: 33 mm Valve clearance, cold intake: 0.10 - 0.
TECHNICAL SPECIFICATIONS – ENGINE » 80 ENGINE 950 LC8 Ignition system breakerless transistorized electronic ignition system with digital ignition advance Ignition timing 5° BTDC at 1200 rpm Generator 12V 450W at 6000 rpm Spark plug NGK CR 8 EK Electrode distance 0.7 mm Cooling system liquid cooled, permanent circulation of cooling liquid through water pump Cooling liquid 2.1 liters (0.55 USgal), 50% antifreeze, 50% distilled water, at least –25° C Starting aid 0.
HEAD WORD INDEX » Accessories and payload . . . . . . . . . . . . . . . . . . . . . . . . . Activating the ignition curve for low-octane fuel . . . . . . . . Adjusting compression damping of fork . . . . . . . . . . . . . . Adjusting of free travel at the hand brake lever . . . . . . . . . Adjusting rebound damping of fork . . . . . . . . . . . . . . . . . Adjusting the engine idle speed . . . . . . . . . . . . . . . . . . . Adjusting the fork and shock absorber . . . . . . . . . . . . . .
HEAD WORD INDEX » Ignition lock . . . . . . . . . . . . . . . . . . . . . . Important information . . . . . . . . . . . . . . . Index . . . . . . . . . . . . . . . . . . . . . . . . . . . Indicator lamps . . . . . . . . . . . . . . . . . . . . Instructions for initial operation . . . . . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . Jump start . . . . . . . . . . . . . . . . . . . . . . . Main fuse . . . . . . . . . . . . . . . . . . . . . . . . Maintenance work on chassis and engine . .
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BEDIENUNGSANLEITUNG 2006 950 SUPER ENDURO R ART. NR. 3.211.172 DE 04/2006 KTM Group Partner KTM Sportmotorcycle AG A–5230 Mattighofen www.ktm.
