Instruction/ maintenance manual of the product 950 SUPER ENDURO R 950 KTM
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950 SUPER ENDURO R KTM Sportmotorcycle AG A–5230 Mattighofen www.ktm.at 04/2006 FOTO: MITTERBAUER KTM Group Partner ART. NR. 3.211.172 EN OWNER’S MANUAL 2006.
INTRODUCTION » 1 All information contained is without obligation. KTM-Sportmotorcycle AG particularly reserves the right to modify any equipment, technical specifications, prices, colors, shapes, mat.
IMPORTANT INFORMATION » INTENDED PURPOSE The KTM 950 Super Enduro R is designed to resist the usual wear and tear of onor off-road service, providing maximum perform- ance in competitive racing or private use.
W ARRANTY 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.
INDEX » 4 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 IMPOR T ANT INFORMA TION . . . . . . . . . . . . . . . . . . . . . . . . . .2 SERIAL NUMBER LOCA TIONS . . . . . . . . . . . . . . . . . . . . . . . .6 Chassis number , T ype label .
INDEX » 5 Checking of brake fluid level - front brake . . . . . . . . . . . . .42 Checking the front brake pads . . . . . . . . . . . . . . . . . . . . .42 Checking rear brake fluid level . . . . . . . . . . . . . . . . . . . . .43 Checking the rear brake pads .
Chassis number, Type label The chassis number is stamped on the right side of the steering head 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.
Clutch lever 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 .
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 dis- play . Display [2] shows all of the information that may be of interest to you.
CLOCK Y ou 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. T o 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.
Setting options in the display KILOMETERS OR MILES. Y ou can have the speed and distance shown in kilometers or miles in the display . The dis- play can be adapted to the respective country on long-distance trips. T o switch from kilometers to miles, switch on the ignition and press the MODE [1] button for approx.
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. T o return the trip meter 2 to zero, switch on the ignition, change to the TRIP 2 mode and press the SET button [2] .
Cooling liquid temperature display 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.
Ignition lock 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 T o switch the ignition to position turn the ignition key to position and firmly press it into the lock.
Starter tip switch Use the starter tip switch [2] to operate the electric starter . Filler cap The filler cap [3] can be locked and is provided with a fuel evaporation control system. T o open the cap insert the ignition key , turn it 90° counterclockwise, then lift off the filler cap.
Removal of seat Actuate the lever [2] while lifting the back of the seat [3] . Grips The grips [1] are used to maneuver the motorcycle. If carrying a passenger , the passenger can hold on to the grip during the ride. T o mount the seat, attach the seat to the oval head screw [4] , lower the seat in the back while sliding it towards the front.
Side stand Fold the side stand [2] forward to the stop with your foot and put the weight of the motor- cycle on the stand. Make sure it is standing securely on a firm surface. The side stand is linked to the safety start system; follow the driving instructions.
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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.
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.
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 author- ized KTM workshop. The DELIVERY CER- TIFICA TE and SERVICE MANUAL will be handed over when you pick up your vehicle.
GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE » 21 – New tires have a smooth surface, which means that they must be run in to achieve full grip.
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.
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.
Starting when the engine is cold 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).
IF THE ENGINE IS DOES NOT CRANK WHEN YOU ACTUA TE THE ST ARTER TIP SWITCH: – If the transmission is switched to idle – Check if the ignition is on – The headlight is on (the light is switched of.
DRIVING INSTRUCTIONS » 26 – 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.
– 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.
Fuel, refueling 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).
PERIODIC MAINTENANCE SCHEDULE » 950 SUPER ENDURO R 2006 A CLEAN MOTORCYCLE CAN BE CHECKED MORE QUICKL Y WHICH SA VES MONEY! IF MOTORCYCLE IS USED FOR COMPETITION 7500 KM SERVICE SHOULD BE CARRIED OUT AFTER EVER Y RACE! Service intervalls should never be exceeded by more than 500 km (300 miles).
PERIODIC MAINTENANCE SCHEDULE » 950 SUPER ENDURO R 2006 A CLEAN MOTORCYCLE CAN BE CHECKED MORE QUICKL Y WHICH SA VES MONEY! IF MOTORCYCLE IS USED FOR COMPETITION 7500 KM SERVICE SHOULD BE CARRIED OUT AFTER EVER Y RACE! Service intervalls should never be exceeded by more than 500 km (300 miles).
PERIODIC MAINTENANCE SCHEDULE » 950 SUPER ENDURO R 2006 A CLEAN MOTORCYCLE CAN BE CHECKED MORE QUICKL Y WHICH SA VES MONEY! IF MOTORCYCLE IS USED FOR COMPETITION 7500 KM SERVICE SHOULD BE CARRIED OUT AFTER EVER Y RACE! Service intervalls should never be exceeded by more than 500 km (300 miles).
PERIODIC MAINTENANCE SCHEDULE » 950 SUPER ENDURO R 2006 VITAL CHECKS AND CARE PROCEDURES TO CONDUCTED BY THE OWNER OR THE MECHANIC before each start after every cleaning every 1000 km after off road .
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 pres- sure will cause water to penetrate into the components and can cause them to malfunction or lead to premature wear .
Adjusting the fork and shock absorber There are a number of ways to adjust the fork and shock absorber to match the chassis to your driving style and the payload.
Adjusting rebound damping of fork 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. T urn the knob clockwise to increase damping, turn it counterclockwise to reduce damping dur- ing rebounding.
Compression damping of shock absorber 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.
Rebound damping of shock absorber By using the adjusting screw [1] , the degree of damping of the rebound can be adjusted. T urn the knob in a clockwise direction to increase damping, turn it in a counterclockwise direction to reduce damping during rebounding.
Correcting the chain tension Loosen the collar nut [1] , loosen the counternuts [2] and turn the left and right adjustment screws [3] the same distance. T ighten the counternuts [2] . T o make sure the rear wheel is aligned, the marks on the chain tensioners must be in the same position on the left and right in relation to the reference marks [B] .
Checking the chain for wear T o check the chain for wear proceed as follows: Switch the transmission to idle and put a load of approx. 15 kilograms (33 lbs) on the lower part of the chain (see illustration). Now measure the distance between 18 chain rollers on the upper part of the chain.
BRAKE P ADS: Y our motorcycle is equipped with sintered brake pads in the front and rear and homologated accordingly . They guarantee maximum braking performance.
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.
Checking the front brake pads The brake pads can be inspected from below . 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.
43 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). At their most worn point brake pad linings should not be thinner than 1 mm, otherwise they could lead to brake failure.
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.
MAINTENANCE WORK ON CHASSIS AND ENGINE » 45 T o 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.
MAINTENANCE WORK ON CHASSIS AND ENGINE » 46 1 3 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] .
MAINTENANCE WORK ON CHASSIS AND ENGINE » 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 .
Tires, air pressure T ire 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).
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 rid- ing safety . A loose spoke causes the wheel to become unbalanced and before long other spokes will have come loose.
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 termi- nals 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.
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 instruc- tions [1] on the battery housing. Do not exceed the amperage and charging time.
Main fuse 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 .
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 . Under no circumstances is a stronger fuse allowed to be set in or a fuse allowed to be “repaired”.
P ARKING LIGHT BULB: Pull the bulb socket [2] out of the reflector and pull the bulb out of the bulb socket. HEADLIGHT BULB: Unplug the connector [3] and remove the rubber cap [4] . T urn the bulb socket [5] approx. 30° in a counterclockwise direction and remove.
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] . T urning in a clockwise direction will reduce the headlight range, turning in a counterclockwise direction will increase the headlight range.
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. BULB FOR BRAKE LIGHT : T urn the bulb socket [3] approx. 30° in a counterclockwise direction and pull it out of the taillight housing.
57 Activating the ignition curve for low-octane fuel 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.
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] .
A mixture of 50% antifreeze and 50% distilled water is used as the cooling liquid. How- ever , the anti-freeze protection must be at least -25° C (-13° F). Aside from antifreezing pro- tection, this mixture also provides great corrosion protection which is why it must not be replaced by pure water .
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.
Bleeding the cooling system T o completely bleed the cooling system, the motorcycle must be raised approx. 50 cm (20 in) in the front. Remove the radiator cap [1] and bleeder screw [2] . Completely fill the radiator with cooling liquid. Mount the radiator cap and move the motor- cycle into a horizontal position again.
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. T urning the adjusting screw in a clockwise direction will move the clutch lever away from the handlebar .
Checking and adjusting the throttle cable play Y ou should feel 3-5 mm free travel on the throttle grip when you start to turn it. T o 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.
Refilling engine oil Unscrew the plug [1] and refill engine oil. The quantity of oil between the MIN and MAX marks is 0.6 liter . Mount the plug and check the engine for leaks. – Insufficient amounts of or low-grade engine oil lead to premature wear in the engine.
Changing the engine oil and the oil filter, cleaning the oil screen Y ou may only change the engine oil yourself after the warranty period has expired. The war- ranty will become void if you change the oil yourself during the warranty period. NOTE: The LC8 engine has a dry-sump lubrication system.
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. Carefully pull the oil screen [4] out of the oil tank. Thoroughly clean the drain plugs, the cover and both oil screens.
Insert a new oil filter in the engine case, grease the O-ring and mount the oil filter cover together with the O-ring. T ighten 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.
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 .
TROUBLESHOOTING » TROUBLE CAUSE REMEDY Engine cranks but doesn’t start. Operating error Blown fuse for the fuel pump The plug and socket connector on the wiring harness is oxidized Open fuel taps, tank fuel, you did not use choke. Pay atten- tion to starting off information (see driving instructions).
TROUBLESHOOTING » TROUBLE CAUSE REMEDY Engine overheats Defect fan or thermoswitch for fan Contact an authorized KTM workshop. Engine stalls while driving No fuel Operating error Fuse for fuel pump h.
TROUBLESHOOTING » TROUBLE CAUSE REMEDY The battery is discharged The ignition (power consumer) hasn’t been switched off The battery isn’t charged by the generator because Recharge the battery according to the relevant instructions. V oltage regulator and generator should be checked by an authorized KTM workshop.
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.
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 ta ke precautions against the aggressive road salt.
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.
TECHNICAL SPECIFICATIONS – CHASSIS » CHASSIS 950 SUPER ENDURO R Frame tubular chrome-molybdenum-steel space frame Fork WP Suspension – U p S ide D own 4860 MXMA P A Wheel travel front 250 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.
TECHNICAL SPECIFICATIONS – CHASSIS » 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.
TECHNICAL SPECIFICATIONS – CHASSIS » TIGHTENING TORQUES – CHASSIS 950 SUPER ENDURO R 2006 Bolt for side stand switch M4 2 Nm Drain plug on oil tank M12x1,5 25 Nm Exhaust nuts on manifold M8 evenl.
TECHNICAL SPECIFICATIONS – ENGINE » 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.
TECHNICAL SPECIFICATIONS – ENGINE » 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.
HEAD WORD INDEX » 81 Accessories and payload . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 Activating the ignition curve for low-octane fuel . . . . . . . . . . .57 Adjusting compression damping of fork . . . . . . . . . . . . . . . . .34 Adjusting of free travel at the hand brake lever .
HEAD WORD INDEX » 82 Ignition lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Important information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Index . . . . . . . . . . . . . . . . . . . . . . . . . . .
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950 SUPER ENDURO R KTM Sportmotorcycle AG A–5230 Mattighofen www.ktm.at 04/2006 FOTO: MITTERBAUER KTM Group Partner ART. NR. 3.211.172 DE BEDIENUNGSANLEITUNG 2006.
An important point after buying a device KTM 950 SUPER ENDURO R 950 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought KTM 950 SUPER ENDURO R 950 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data KTM 950 SUPER ENDURO R 950 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, KTM 950 SUPER ENDURO R 950 you will learn all the available features of the product, as well as information on its operation. The information that you get KTM 950 SUPER ENDURO R 950 will certainly help you make a decision on the purchase.
If you already are a holder of KTM 950 SUPER ENDURO R 950, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime KTM 950 SUPER ENDURO R 950.
However, one of the most important roles played by the user manual is to help in solving problems with KTM 950 SUPER ENDURO R 950. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device KTM 950 SUPER ENDURO R 950 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
