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maintenance work on chassis and engine

1. Setting options in the display KILOMETERS OR MILES You 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 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 dis tances will be converted and displayed in miles To return to kilometers proceed as described above SET CLOCK Switch on the ignition and change 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 TRIP 1 The trip meter 1 runs continuously and counts up to 999 9 It can be used to measure the length of a certain route on a trip or the distance between two refueling stops To return the trip meter 1 to zero switch on the ignition change to the TRIP 1 mode and press the SET button 2 OPERATION INSTRUMENTS 11 RESETTING TRIP 2 The trip meter 2 runs continuously and counts up to 999 9 It can be used similarly to TRIP
2. 13 PERIODIC MAINTENANCE SCHEDULE 29 c ae ae ad A 13 MAINTENANCE WORK ON CHASSIS AND ENGINE 33 Starter tip switch i scele e EM dl are nd 14 Adjusting the fork and shock absorber 34 2 erat Er eH SEA 14 Adjusting compression damping of fork 34 Fuel taps xc es US EAM EMINUS 14 Adjusting rebound damping of fork 35 eia PM 15 Adjusting the spring preload the fork 35 Removal 15 Compression damping of shock absorber 36 TOOLSET videns ess nonce ders ees referet e mte de a ee 16 Rebound damping of shock absorber 37 Shift leVer s oL ames ot bes Gok IAS TAE boas 16 Breathing the fork legs 37 Side stand a du cde ER eod eG 16 Checking the chain tension 38 Foot brake pedal 17 Correcting the chain tension 38 Compression damping of fork 18 Chain maintenance 39 Rebound damping of fork 18 Checking the chain for wear 39 Spring preload of the fork 18 General informations about KTM disc brakes 40
3. 54 Adjusting the headlight range 55 Replacing the flasher bulbs 55 Replacing the brake light and taillight bulbs 56 Activating the ignition curve for low octane fuel 57 Coolifig SVSEGITE Ao dae eon 58 Checking the cooling liquid level in the compensating tank 59 Checking the cooling liquid level in the radiator 60 Bleeding the cooling system 61 Changing the original position of the clutch lever 62 Checking the oil level of the hydraulic clutch 62 Checking and adjusting the throttle cable play 63 Checking and adjusting the choke cable play 63 Adjusting the engine idle speed 63 Engine gll s aset ind e tess e ud s dd 64 Checking the engine oil level 64 SERIAL NUMBER LOCATIONS 6 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 Enter this number on page 1 OPERATION INSTRUMENTS 1 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
4. CAUTION If the brake pads are replaced too late when the lining is partly or completely worn off the steel parts on the brake pads will grind against the brake disks This significantly decreases the braking effect and destroys the brake disks 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 WARNING OOO 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 Have the brake fluid changed at an authorized KTM workshop every 2 years 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 WARNING OOS 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 CAUTION If the brake pads are replaced too late so that the lining is partly or entirely worn away the steel components of the brake pad will rub against the brake disc imparing the braking effect and destroying the brake disc MAINTENANCE WORK ON CH
5. Engine stalls while driving No fuel Operating error Fuse for fuel pump has blown Fuse for the carburetor heater has blown causing the carburetor to ice Refuel Open fuel taps Replace fuse FUEL PUMP Replace fuse ACC2 High oil consumption Engine oil level too high Engine oil too thin viscosity Check engine oil level when the engine is warm correct if necessary Use thicker engine oil see 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 TROUBLESHOOTING 71 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 Voltage regulator and generator should be checked by an authorized KTM workshop No values are visible in the multi functional 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 che
6. Am If you do not have a torque wrench to mount the wheel have the torques corrected by an authorized KTM workshop 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 front wheel keep operating the hand brake until the pressure point returns Always keep the brake disks free from oil and grease otherwise the braking effect will be significantly reduced 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 CAUTION 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 Term 2000 to prevent the thread from jamming MAINTENANCE WORK ON CHASSIS AND ENGINE 4 Before remounting the rear wheel clean and grease
7. ts aget cece Sais ee a 74 Instructions for initial operation 20 Technical specifications chassis 75 Introduction 3st tra Ei Sud Rer cpu eo 1 Technical specifications engine 79 JUMP Stat i2 dh dom ne eb eaa AL dons oad hei bl lt Mres alr pressure eie merde t wade 48 Main fuse itt cc dios alius en Bau noe ad Bes 52 TOOLSET ecb SATIRE RU TID MA ave 16 Maintenance work on chassis and engine 33 Troubleshootlng xs RET UM wad 68 Multi functional digital speedometer 8 Operation instruments 7 Periodic maintenance 29 Rebound damping of fork 18 Rebound damping of shock absorber 37 Rebound damping of shock absorber 19 Refilling engine 64 Re initiation after time of storage 74 Removal ot Seat iiec do oak Swe a eS 15 Replacing the brake light and taillight bulbs 56 Replacing the flasher bulbs 55 Replacing the headlight lamp 54 Running in the LC8 20 Serial number locations 6 Setting options in the display 10 Shift lever
8. INDEX 5 Adjusting of free travel at the hand brake lever 42 Refilling engine 64 Checking of brake fluid level front brake 42 Changing the engine oil and the oil filter Checking the front brake pads 42 cleaning the oil screen 65 Checking rear brake fluid level 43 68 Checking the rear brake pads AS CLEANING iut es coach ee a Sexe a Eten a 72 Dismounting and mounting the front wheel 44 CONSERVATION FOR WINTER OPERATION 73 Dismounting and mounting the rear wheel 460 5 STORAGE aae ai EE RU o Re E SED WE gie 74 Tires air pressure 48 RE INITIATION AFTER TIME OF STORAGE 74 Checking spoke tension 49 TECHNICAL SPECIFICATIONS CHASSIS 75 RAV rece UE A que al COE 50 TECHNICAL SPECIFICATIONS ENGINE 79 Charging the battery 51 Engines arent ar thnk Ro E es PERSE ND on ed 80 JUMP Start 2 pee duerme pu ae Yes vhi Rea 51 HEAD WORD INDEX 2 42 xc e oe f e AXE wines 81 Main fuse steam ia Ee ng E AEn UR USER 52 Fuses for individual power consumers 53 Replacing the headlight lamp
9. 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 ZA WARNING d Never operate the motorcycle with a run down battery or without the battery This can dam age the electronic components or safety equipment in either caseand the motorcycle will no longer be roadworthy DISMOUNTING AND MOUNTING THE BATTERY Detach the rubber band 1 First disconnect the negative pole then the positive pole from the battery Install the battery with the terminals facing the front see illustration Connect the minus pole to the battery last WARNING d If electrolyte sulphuric acid leaks from the battery proceed with great care The elec trolyte can cause severe burns n the case of skin contact rinse thoroughly with water Inthe case of contact with the eyes thoroughly rinse eyes with water for at least 15 min utes Immediately consult a doctor The battery is a closed model but can nevertheless emit explosive gases Avoid sparks and open fire near the battery Defective batteries must be stored out of the reach of children Ensure proper disposal of discarded batteries CAUTION Never remove the closing cover 2 otherwise the battery will be damaged STORAGE If the
10. The radiator fan switches on when the cooling liquid reaches a temperature of 102 C 216 F Additional air is blown through the radiator to prevent the cooling system from overheating CAUTION The temperature indicator 2 will begin to blink and the red cooling liquid temperature warn ing lamp 3 will light up when the cooling liquid reaches approx 120 C 248 F having exceeded the normal operating temperature Possible 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 liquid temperature is 120 C 248 F and the ignition is on If the fan is not working and there appears to be sufficient cool ing liquid the only thing you can do is to drive on to your nearest authorized KTM work shop at the least possible engine load Too little cooling liquid in the system Check whether any cooling liquid is leaking out also on the bottom of the motorcycle Let the engine cool down and check the cooling liquid level in the radiator see chapter Checking the cooling liquid level in the radiator Only continue to drive if there is enough cooling liquid in the system Contact an authorized KTM w
11. a The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorpo rated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use and b the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person In accordance with the international quality management ISO 9001 standard KTM uses quality assurance processes that lead to the highest possible product quality REG NO 12 100 6061 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 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 use ful tips and information on the best way to handle the motorcycle and how to protect yourself from injuries The Manual also con tains important information on service and maintenance your own interest pay particular attention to the information marked as follows WARNING ee CAUTION Ignoring these instructions can endanger your body and Ignoring these instructions could cause damage to parts your life of your motorcycle or that the motor cycle is not road safe anymo
12. evenly do not bend sheet met Exhaust clamp 12N Senkschraube Hitzeschutzblech 8N HH bolt on fuel level indicator 3N HH bolts fuel taps 6N Collar screw for underride protection 25N Spoke nipple 5Nm 1N Jerk damper bolt rear wheel Loctite 243 50 N Chainguard 5N Chain sliding guard 6N Taillight 8N Other bolts on chassis 10 N 25 N 45N Other collar nuts on chassis 15 N 30 N 50 N 333 il ee el eo 3 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 15 mm exhaust 0 25 0 30 mm Crankcase bearing friction 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 lubricatio
13. kas aad are RE qus RR COSAS TR wads 16 Shifting RIdIng ONCE 25 Sid starid icum s 16 Spring preload of the fork 18 Starter tip Switch etc eiie td wha 14 USE THIS SPACE FOR NOTES USE THIS SPACE FOR NOTES 84 3211240en E2777 09 2007 FOTO MITTERBAUER
14. 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 This drains the carburetor float chambers Correct tire pressure Disassemble and charge battery see chapter BATTERY Jack up the motorcycle if possible so the wheels do not touch the ground The storage place should be dry and not subject to excessive temperature fluctuations Cover the motorcycle with an air permeated tarpaulin or blanket Do not use non air permeable materials as a possible humidity might not be able to escape and could cause corrosion CAUTION 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 AFTER TIME OF STORAGE Mount the charged battery pay attention to polarity and set the clock Fill up tank with fresh fuel Check motorcycle as before each start see driving instructions Take a short careful test ride first NOTE Before you put your motorcycle away for the winter you have to check all parts for their function and wear Should any service jobs repairs or any refitting be necessary you should have them carried out during the off season lower workload a mechanics s
15. t rev engine when cold Because the piston is warming up faster than the water cooled cylinder it can cause engine damage Always let the engine warm up before and refrain from driving with full load until the engine is warm Release the choke lever after a maximum of 1 kilometer 0 6 mile otherwise the cat alytic converters will be destroyed DRIVING INSTRUCTIONS 25 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 f 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 IF THE ENGINE CRANKS BUT DOES NOT START WHEN YOU ACTUATE THE STARTER TIP SWITCH Check if the fuel taps are open Check if the choke lever has been operated Check if sufficient fuel is in the tank f this is not the case refill the tank f sufficient fuel is in the tank proceed as described in the Trouble shooting section or contact a KTM dealer NOTE This motorcycle is equipped with a safety start ing system The engine can only be started if the transmission is in neutral or the clutch lever is pulled If the side stand is folded down the engine can only be started if the trans mission is in neutral or the clutch lever is pulled The engine will stall if a gear is engaged and the clut
16. 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 TRIP F When the fuel level 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 O and return to the previous display mode NOTE Press the SET key for 2 seconds to immediately turn off the fuel warning lamp OPERATION INSTRUMENTS 12 120 C 248 F 110 C 230 F 91 100 C 212 F UE EN 70 C 158 F 60 C 140 F 50 C 122 F 40 C 104 F 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 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 CAUTION Possible causes for an increase in temperature causing the red warning light for th
17. 5 Add cooling liquid see above for mixture ratio if the cooling liquid level drops below the MIN mark If you need to add cooling liquid quite often the cooling system may leak If the compen sating tank is empty also check the cooling liquid level in the radiator Have the cooling system checked by an authorized KTM workshop MAINTENANCE WORK ON CHASSIS AND ENGINE 60 A 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 WARNING OSS If possible check the cooling liquid level when the engine is cold If you need to remove the radiator cap when the engine is hot hold the cap with a cloth and open slowly allow ing any excess pressure to escape danger of scalding CAUTION If more than 1 liter of cooling liquid needs to be added you will need to bleed the cool ing system Only continue to drive if there is enough cooling liquid in the system Contact an author ized KTM workshop to have the error eliminated You will damage the engine if you con tinue to drive when the cooling liquid temperature warning lamp is on MAINTENANCE WORK ON CHASSIS AND ENGINE 61 Bleedi
18. If the brake fluid level drops below the minimum either the brake system has a leak or the brake pads are com pletely worn down In this case consult an authorized KTM dealer immediately BRAKE FLUID We recommend that you use Motorex DOT 5 1 brake fluid when you refill or change the brake fluid DOT 5 1 brake fluid has a wet boiling point of 180 C 356 F 25 C 45 F higher than DOT 4 and is safer for high performance applications Brake fluid DOT 5 1 is a polyethyl ene glycol based fluid amber colored and can be mixed with DOT 4 brake fluid Do not in any event use DOT 5 brake fluid It is based on silicone oil and is dyed purple KTM motor cycle gaskets and brake hoses are not designed for DOT 5 brake fluid Have the brake fluid for the front and rear brake changed at authorized KTM workshop every 2 years BRAKE DISCS Wear reduces the thickness of the brake disc in the area of contact 4 with the brake pads The brake disk should not be thinner than 4 5 mm 0 18 in at the weakest point A Check the wear at several points WARNING OOO Brake disks that are less than 4 5 mm 0 18 in thick are a safety hazard Have worn brake disks replaced immediately MAINTENANCE WORK ON CHASSIS AND ENGINE 42 Adjusting of free travel at the hand brake lever Free travel at the hand brake lever may be readjusted by using adjusting scre
19. Turn 5 turns in a clockwise direction MAINTENANCE WORK ON CHASSIS AND ENGINE 36 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 The low and high speed technology overlaps The low speed setting is primarily for slow to normal shock absorber compression rates The high speed setting is effective at fast compression rates 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 20 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 1 5 turns in a counterclockwise direction UN WARNING OOS The damping unit of the shock absorber is filled with high compression nitrogen Never try to take the shock absorber apart or to do anymaintenance work yourself Severe injuries could be the result Never unscrew the black screw connection 24mm 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 clo
20. as the 4th bar on the temperature indicator lights up If the red oil pressure warning lamp lights up while driving the oil pressure is too low to adequately lubricate the engine Stop immediately and switch off the engine if you continue to drive engine damage will occur within a short period of time Check the engine oil level or con tact an authorized KTM workshop Never have the throttle wide open when changing down to a lower gear The engine will overspeed damaging the valves In addition the rear wheel blocks so that the motorcycle can easily get out of control Never use your motorcycle without an air filter Otherwise dust and dirt may enter the engine and cause increased wear Stop immediately if a perceptible power loss occurs while driving due to a defec tive ignition caused by a cylinder misfir ing or breaking down If the unburned fuel air mixture reaches the catalytic con verter 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 temperature has reached 120 c 248 F Possible causes for the increase in tem perature low driving velocity and high load situation in high air temperatures level of coolant in the system is insufficient fan at radiator is not running improper use of the clutch while driving at low velocities Let the engine cool down Meanwhile check whether any cooling
21. 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 WARNING For safety reasons always have maintenance work and repairs to the brake system 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 Ferit 1 0 450 FF WARNING OCS Brake pads available in the accessory trade are often not authorized for operation of your KTM motorcycle in road traffic The brake pads design and friction factor and therefore the braking power can deviate significantly from original KTM brake pads If you use different brake pads than those provided with the original equipment it cannot be warranted that they are authorized for use in road traffic Your motorcycle will not longer comply with the regulations authorizing the use of vehicles for road traffic and the warranty will be void 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
22. motorcycle is being immobilized for longer periods of time remove and charge the battery Storage temperature O 35 C 32 95 F avoid direct sunlight Charge the battery every 3 months 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 instruc tions 1 on the battery housing Do not exceed the amperage and charging time Quick charg ing at a high amperage has an adverse effect on the service life Always use special charging devices to charge maintenance free batteries e g the KTM charg ing device item no 58429074000 You can also use this charging device to test the off load voltage and startability of the battery and generator It is impossible to overcharge the battery with this device Charge the battery immediately if it is empty when you start the motorcycle If left to stand in an uncharged condition for a longer period 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 CAUTION 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
23. resulting in premature wear and even chain breakage Too much slack in the chain on the other hand can result in the chain jumping off the chain wheels If this happens the chain could also block the rear wheel or damage the engine n either case the operator is likely to lose control of the motorcycle 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 Tighten the counternuts 2 To 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 Before tightening the wheel spindle make sure the chain tensioner 4 rests against the adjustment screws and the rear wheel is aligned with the front wheel Tighten the collar nut 1 to 90 Nm Am 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 MAINTENANCE WORK ON CHASSIS AND ENGINE 39 CDCA 123 max 272 mm na DOO 16 17 18 Chain maintenance Maintenance of the X ring chain is reduced to a minimum Rinse off any heavy dirt with plenty of water Residual used grease must be removed prior to lubrication Motorex Chain Clean
24. speed during the 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 character istics until they are properly run in For reasons of safety it is recommended to exchange the valve insert whenever a new tire is mounted Immediately increase the tire inflation pres sure when driving on the road again 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 Check spoke tension especially on a new motorcycle in reg ular intervals For checking tap on each spoke with the blade of a screw driver see illus tration A clear tone must be the result Dull tones indicate loose spokes If necessary have the spokes retightened and the wheel centered by a KTM dealer If you continue to drive with loose spokes the spokes can tear and lead to instable handling performance Torn spokes can damage the air hose The loss of air can easily cause the motorcycle to go out of control Excessively tensioned spokes may rupture due to local overloading The spokes must be tensioned to 5 Nm 1 Nm MAINTENANCE WORK ON CHASSIS AND ENGINE 50 Battery
25. 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 WARNING CSCS If you don t happen to have a torque wrench at hand make sure you have the tighten ing 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 footbrake until the pressure point returns It is very important to keep the brake disk free from oil and grease otherwise the brak ing effect would be strongly reduced 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 can cause it to wobble at higher speeds Tire type and size can be found in the technic
26. to allow the tires to reach the necessary operating temper ature Maximum road grip is assured when the tires are warm The front and rear wheel are allowed to be fitted only with tires that have the same profile type GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE 21 ART NNI New tires have a smooth surface which means that they must be run in to achieve full grip For this purpose ride the motor cycle 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 char acteristics until they are properly run in The factory mounted tires are approved for a maximum speed of 160 kph 100 mph Under no circumstances should this speed be exceeded Wheels with a different rim diameter or other rim width may not be mounted oth erwise the vehicle handling will no longer be safe Observe the traffic regulations drive defensively and trying to look ahead as far as possible so that any hazards can be recognized as early as possible The faster you drive the more sensitive your motorcycle will be to crosswind and changing road conditions Your motorcy cle can easily go out of control at high speeds Choose your driving speed according to the conditions and your driving skills Drive carefully on unknown roads or on unfamiliar trials Renew the vizor on your helmet on time so as
27. to position 9 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 99 Combination switch The light switch has 2 switch positions A Low beam light B High beam light The red short circuit button 2 serves to switch off the engine Leave the switch pressed until the engine stops With the button 3 the horn will sound Flasher switch The flasher switch 4 is mounted on the left side of the handlebar Flasher left gt Flasher right OPERATION INSTRUMENTS 14 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 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 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 The fuel pump stops running when the engine is switched off and fuel cannot flow to the carburetors so the fuel taps do not need to be closed when the motorcycle is switched off Opening the fuel tap Turn the knob all the
28. way to the left Closing the fuel tap Turn the knob all the way to the right OPERATION INSTRUMENTS 15 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 Removal of seat Actuate the lever 2 while lifting the back of the seat 3 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 A If not correctly mounted the seat can slip while you are driving and cause you to lose con trol of your motorcycle OPERATION INSTRUMENTS 16 Tool set The tool set 1 is located in the storage compartment under the seat 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 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
29. will be handed over when you pick up your vehicle Read these operating instructions care fully before your first ride Enter the chassis engine and key num bers on page 1 Familiarize yourself with the operating elements Adjust the hand brake lever and foot brake lever to your most comfortable position This motorcycle is equipped with 2 cat alytic converters Leaded fuel will destroy the catalytic converters Please use unleaded fuel only Get used to handling the motorcycle on an empty parking lot before starting on a longer drive Also try to drive as slowly as possible and in standing position to improve your feeling for the vehicle Do not drive along off road tracks which go beyond your abitily and experience Hold the handlebars with both hands and leave your feet on the foot rests while driving Remove your foot from the foot brake lever when you are not braking If the foot brake lever is not released the brake pads rub continuously and the braking system is overheated Do not make any alterations to the motor cycle and always use ORIGINAL KTM SPARE PARTS Spare parts from other manufacturers can impair the safety of the motorcycle New wheels a smooth surface which means that they must be run in to achieve full grip For this purpose ride the motor cycle carefully at moderate speed during the first 200 kilometers 125 miles with new tires tilting the vehicle at different angles so that a
30. 60 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 N AH bolts on subframe M10x1 25 Loctite 243 45 N AH bolts on back of footrest support M8 Loctite 243 25 Engine carrier bolts M10 45 HH clamp bolts on top triple clamp M8 20N HH clamp bolts on bottom triple clamp M8 15N HH screw for steering head M20x1 5 12N HH clamp bolts on fork leg axle passages M8 15N Collar bolts for handlebar clamps M8 20N AH bolt for handlebar mount 20N HH clamp bolts for steering stem M8 20N Collar bolt front rear brake disk M6 Loctite 243 14 N HH bolts on front brake caliper M8 Loctite 243 25 HH bolts on handbrake cylinder M6 10 N HH bolts on footbrake cylinder M6 Loctite 243 10 Nm AH bearing bolt for foot brake pedal M8 Loctite 243 25 Nm HH bolts on foot brake pedal surface M5 Loctite 243 6 Nm AH bolts for side stand bracket engine Loctite 243 40 Nm HH bolts for side stand fixture side stand bracket Loctite 243 25 Nm HH bolts for side stand mounting Loctite 243 35 Nm HH bolt for spring rest on side stand Loctite 243 25 Nm 3 3 3 3 3 3 3 3 3 3 3 3 3 3 TECHNICAL SPECIFICATIONS CHASSIS 78 TIGHTENING TORQUES CHASSIS 950 SUPER ENDURO R 2008 Bolt for side stand switch 2N Drain plug on oil tank 25N Exhaust nuts on manifold
31. 611 After drying use a chain spray specially designed for X ring chains Motorex Chainlube 622 WARNING CSCS No lubrication is allowed to reach the rear tire or the brake disk eitherwise the road adherence and the rear wheel braking effects would be strongly reduced and the motor cycle could easily get out of control The chain does not a chain joint for safety reasons Always have the chain replaced in an authorized KTM workshop where the service technicans have the required riveting tool Never mount a normal chain joint Also check sprockets and chain guides for wear and replace if necessary Checking the chain for wear To check the chain for wear proceed as follows Switch the transmission to idle and put a load of approx 15 kilograms 33 Ibs on the lower part of the chain see illustration Now measure the distance between 18 chain rollers on the upper part of the chain The chain needs to be replaced when the distance is 272 mm 10 70 in Since chains do not always wear evenly repeat the measurement at different parts of the chain Replace the chain if any X rings are missing NOTE If you mount a new chain the sprockets should also be replaced New chains wear faster if used on old used sprockets 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
32. ASSIS 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 CAUTION Do not operate the hand brake when the front wheel has been dismounted Make sure the brake disc is always on top when you lay down the wheel otherwise the brake disc can be damaged Before remounting the front wheel clean and grease the shaft seal rings 4 and the bear ing surface A of the distance bushings and mount the distance bushings Slightly push back the brake pads with a screwdriver Set up the front wheel facing in the running direc tion MAINTENANCE WORK ON CHASSIS AND ENGINE 45 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 Ib Loosen the clamp screws on the right fork leg Take the motorcycle down from its stand Press the front wheel brakes and push down on the fork a few times vigorously so that the fork legs come into alignment Only after this has been accomplished tighten the clamp screws on both fork legs with 15 Nm
33. OPERATION INSTRUMENTS 17 For off road riding you can use the rubber band 1 to additionally secure the center stand in its folded up position NOTE A center stand is available from your authorized KTM workshop as an accessory 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 NOTE A passenger footrest system is available from your authorized KTM workshop as an acces sory The motorcycle is already approved for two seats 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 Rebound 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 3 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 adjusted by means of the adjusting screws 4 More information is provided in
34. OWNER S MANUAL 2008 950 SUPER ENDURO R ART NR 3 211 240 EN INTRODUCTION 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 KTM Sportmotorcycle AG particularly reserves the right to modify any equipment technical specifications prices colors shapes materials services service work constructions equipment and the like so as to adapt them to local conditions or to cancel any of the above items all without previous announcement and without giving reasons KTM may stop manufacturing certain models 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 2008 by KTM SPORTMOTORCYCLE AG Mattighofen AUSTRIA All rights reserved Reprint also in extracts with written allowance of KTM SPORTMOTORCYCLE AG Mattighofen only COMSUMER INFORMATION FOR AUSTRALIA ONLY Tampering with noise control system prohibited Owners are warned that the law may prohibit
35. al specifications and in the homologation certificate Tire condition has to be checked every time you want to ride your motorcycle Before TIRES AIR PRESSURE leaving check for punctures and nails or other sharp objects that might have become 950 SUPER ENDURO R embedded in the tire Refer to the specific regulations in your country for minimum tire tread requirements Offroad We recommend replacing tires at the latest when the tread is down to 2 mm 0 08 in Tire pressure should be checked regularly on a cold tire Adapt the air pressure to the Road rider only motorcycle s total weight Proper pressure ensures optimum driving comfort and extends the life of your tires Road with passenger WARNINGS am Oo NE Do mount tires which have not been approved by KTM Other tires could have adverse Maximum payload effects on the way your motorcycle rides Tire releases are available on the Internet at www ktm com 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 negative effect on how your motorcycle performs especially wet surfaces If air pressure is too low abnormal wear and overheating of the tire can result New wheels 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
36. and jerk damper for play 950 SUPER ENDURO R 2008 ADDITIONAL SERVICE WORK THAT MUST BE PERFORMED UNDER A SEPARATE ORDER 7500 km or once a year e 15000 km or every 2 years Perform complete fork maintenance Perform complete shock absorber maintenance 15000 km or Clean and lubricate steering head bearing and sealing elements Clean and adjust the carburetors Treat the electrical contacts and switches with contact spray Treat battery connections with contact grease Change coolant fluid PERIODIC MAINTENANCE SCHEDULE 950 SUPER ENDURO R 2008 VITAL CHECKS AND CARE PROCEDURES TO CONDUCTED BY THE OWNER OR THE MECHANIC each start every cleaning off road use after 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 performance Treat SR RR metal components except for the braking and exhaust systems with wax based anti corrosion agen
37. ch lever is released with the side stand folded down Starting when the engine is warm or hot 1 Switch on ignition turn ignition key into position O 2 Switch transmission to idle green indi cator lamp N lights up 3 Donotaccelerate operate starter button 4 Theoil pressure warning lamp should go out as soon as the engine is running 5 Takethe 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 Shifting Riding You are now in first gear refered to as the drive or uphill gear Depending on the con ditions traffic road gradient etc you can shift to a higher gear Close the throttle while pulling the clutch lever engage the next gear release the clutch lever and carefully open the throttle If you turned on the choke make sure you turn it off again as soon as engine is warm Only accelerate to the extent that road and weather conditions allow Be especially care ful when you accelerate in curves Abrupt opening of the throttle can cause the motor cycle to go out of control and also increases fuel consumption By shifting down use the brakes if neces sary and close throttle at the same time Pull clutch lever and shift down to the next gear Let clutch lever go slowely and open throt tle or shift down again If the engine is killed f ex at a crossing sim ply pull the clutch lever and start It is not n
38. ck the cable connectors Contact 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 CAUTION 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 Before you wash your motorcycle close the muffler openings Use warm water with a commercial detergent and sponge Coarse dirt can be removed with a soft water jet Areas that are heavily soiled can be sprayed with a motorcycle cleaner e g Motorex 900 and cleaned with a brush After the motorcycle has been rinsed with a soft water jet it should be dried by air pressure 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 motorcycle has cooled down oil or lubricate all
39. ckwise 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 WARNING OOS The damping unit of the shock absorber is filled with high compression nitrogen Never try to take the shock absorber apart or to do any maintenance work yourself Severe injuries could be the result 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 overpressure to escape from the fork CAUTION Excessive pressure in the interior of the fork can cause leaks in the fork If your fork is leak ing it is recommended to open the breather plugs before having the seals replaced MAINTENANCE WORK ON CHASSIS AND ENGINE 38 ZANT Checking the chain tension 5 Place the motorcycle 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 WARNING OSC If chain tension is too great parts within the secondary power transmission chain chain sprockets transmission and rear wheel bearings will be subjected to unnecessary stress
40. d be used when han dling gasoline Do not refuel the motorcycle near open flames or burning cigarettes Always switch off the engine before refuelling Be careful not to spill gasoline on the engine or exhaust pipe while the engine is hot Wipe up spills promptly If gasoline is swallowed or splashed in the eyes seek a doctor s advice immediately PERIODIC MAINTENANCE SCHEDULE 950 SUPER ENDURO R 2008 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 Maintenance work performed by an authorized KTM workshop is not a substitute for care and maintenance by the driver Service every once a year Service every every 2 years Change engine oil and oil filter Clean oil screens of engine and oil tank Clean magnetic drain plugs of engine and oil tank Check oil lines for damage and kink less arrangement 7500 km or Renew spark plugs Check and adjust valve clearance Check engine fastening bolts for tight fit Check all engine bolts accessible from the outside for tight fit Check clutch linings Check clutch pressure booster system Clean the oil jet for the clutch lubrication Check carburetor connection boots for cracks and leaks Check synchronisation of carburators using special to
41. de stand switch clutch switch emergency off switch Make sure all bolts and nuts are tight Check brake fluid level lining thickness and brake discs Change brake fluid Check brake lines for damage and leaks Check adjust smooth operation free travel of handbrake footbrake levers Check bolts of brake system for tight fit Check shock absorber and fork for leaks and proper operation Clean fork dust sleeves Bleed fork legs Check swinging fork pivot Check adjust steering head bearing Check all chassis bolts for tight fit fork plates fork leg axle nuts bolts swinging fork pivot reversing lever shock absorber PERIODIC MAINTENANCE SCHEDULE 31 950 SUPER ENDURO R 2008 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 Maintenance work performed by an authorized KTM workshop is not a substitute for care and maintenance by the driver Service every once a year Service every every 2 years Check spoke tension and rim joint Check tire condition and inflation pressure Check chain sprockets and chain guides for wear force fit and tension Check bolts on pinion and chain sprocket for locking devices and a tight fit Lubricate chain Check wheel bearings
42. der the warranty The warranty or guarantee shall become void for damage and consequential damage caused by manipulations or conversions to the motorcycle AUTOMOTIVE FLUIDS The fuels lubricants and liquids specified in the Owner s Manual or automotive fluids with equivalent specifications must be used in accordance with the maintenance schedule SPARE PARTS ACCESSORIES For your own Safety only use spare parts and accessories approved by KTM KTM shall not assume any liability for other products or consequential damage resulting from the use of such products ENVIRONMENT Motorcycle driving is a wonderful sport and we hope that you will be able to enjoy it to the full It may however involve potential problems for the environment or lead to conflicts with others These problems or conflicts can be avoided if the motorcycle is used responsibly To safeguard the future of motorcycle sports make sure that you use the motorcycle in accordance with the law show that you are environmentally conscious and respect the rights of others Enjoy driving your motorcycle KTM SPORTMOTORCYCLE AG 5230 MATTIGHOFEN AUSTRIA INDEX 4 INTRODUCTION 3 3 5 2 ER DURS wee E 1 Damping action during compression of shock absorber 19 IMPORTANT 2 Rebound damping of shock absorber 19 SERIAL NUMBER LOCATIONS 6 GENERAL TIPS AND WARNINGS FOR STARTING Chassis
43. e avoided Also check the state of the brake hose and the thickness of the brake linings Check free travel at hand brake lever and foot brake lever DRIVING INSTRUCTIONS 23 m 5 CABLES gt Check the throttle cable for correct adjustment and smooth operation 2 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 9 BAGGAGE PAYLOAD Never exceed the maximum total weight 400 kg 883 Ibs and the motorcycle s wheel loads The maximum total weight is comprised of the motorcycle in a running condition and refueled 200 kg 442 Ibs 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 shock absorber to the total weight Make sure your luggage is correctly fastened before you drive off 10 REAR MIRROR Sit on the motorcycle and check the adjustment of the rear mirror 24 DRIVING INSTRUCTIONS Starting when the engine is cold 1 Switch on ignition turn ignition key 1 into position NOTE Usually the operating noise of the f
44. e cool ing liquid temperature to light up Driving too slowly and driving with a heavy load at high air temperatures Not enough cooling liquid in the system The ventilator on the left radiator is not running Improper use of the clutch when driving slowly Indicator lamps The green indicator lamp will blink in the blinker rhythm when the blinker is switched on lt gt NOTE The indicator lamp will blink faster 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 approx 120 C 248 F The orange warning light will light up when the fuel level reaches the reserve mark At the same time the display will automatically change to TRIP F see TRIP F The red warning lamp lights up when the ignition is switched on but the engine is not running When the engine is started the warning lamp will go out as soon as the oil pressure is high enough amp OS This indicator lamp has no function OPERATION INSTRUMENTS 13 Ignition lock i The ignition lock 1 has 3 switching positions e Ignition off engine can t be started C Ignition on light on engine can be started A Ignition off handlebar blocked To switch the ignition to position turn the ignition key
45. ecessary to switch the gear to NEUTRAL ART EMI Avoid abrupt load changes while riding around bends and on wet or slippery ground Otherwise you might easily lose control over your motorcycle While riding your motorcycle never switch the ignition lock to positions amp And amp Do not try to change the settings of the multi functional digital speedometer while driving Your attention will be distracted from the traffic and may cause you to lose control of your motorcycle When driving off road always have a friend on a second motorcycle to keep you company so that you can help each other should difficulties arise DRIVING INSTRUCTIONS 26 The passenger must hold 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 CAUTION High rpm rates when the engine is cold have an adverse effect on the life of your engine We recommend you run the engine in a moderate rpm range for a few miles giving it a chance to warm up After that no further precautions in this respect need be taken The engine has reached operating temperature as soon
46. ervation for winter operation 73 Bleeding the cooling system 61 Cooling liquid temperature display 12 suntan 5 ELE ie chri E 26 Cooling systemi vue vorat Hr d eter 58 Breathing the fork legs 37 Correcting the chain tension 38 Chain maintenarnee uu dec re ME ee Rt 39 Damping action during compression of shock absorber 19 Changing the engine oil and the oil filter Dismounting and mounting the front wheel 44 cleaning the screen 65 Dismounting and mounting the rear wheel 46 Changing the original position of the clutch lever 62 DISplay eso sake treat ahd dre dto toutes iru Meca opt 8 Charging the battery 51 Drivinginstructions 22 Chassis number Type 6 Engine number engine type 6 Check the following before each start 22 ENGINE Oll d e PHA 80 Checking and adjusting the choke cable play 63 NI HER aa 64 Checking and adjusting the throttle cable play 63 Eillepcapusx SET DOSE OO Aedes t 14 Checking of brake f
47. fective in your country Never pour used oil in the sewer or dispose of it outdoors 1 liter of used oil will pollute 1 000 000 liters of water MAINTENANCE WORK ON CHASSIS AND ENGINE 34 950 SUPER Adjusting the fork and shock absorber ENDURO R2008 There are a number of ways to adjust the fork and shock absorber to match the chassis to your driving style and the payload g 8 z 8 8 E Ha We have provided a table with pragmatical values to help you tune up your motorcycle These E 2 z5 3 5 tune up specifications are reference values only and should serve as a basis for your per 8 83 5 sonal chassis and suspension tuning Do not make arbitrary changes to the settings 4 mum 40 since this may impair the handling characteristics particularly the high speed range Comfort 25 25 1 25 2 22 8 Make sure both fork legs are equally adjusted Basic Setting 20 20 5 20 1 5 18 8 Sport MX 15 15 8 15 1 15 8 Max payload 20 20 5 15 1 15 8 Adjusting compression damping of fork Hydraulic compression damping determines the reaction when the fork is compressed The degree of compression can be adjusted with adjusting screws at the bottom of the fork legs Carefully pry out the protection cover 1 with a screwdriver and remove Turn the adjusting screws 2 clockwise to increase damping turn it counterclockwi
48. he JASO MA quality requirements see infor 5W 40 10W 50 mation on the can KTM recommends Motorex Power Synt 4T 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 stand The oil level should be between the MIN and MAX marks add engine oil if necessary CAUTION Always check the oil level when the engine is warm A cold engine can distort the measur ing results Engine oil expands when heated increasing the oil level Refilling engine oil Unscrew the plug 1 and refill engine oil The quantity of oil between the MIN and MAX marks is O 6 liter Mount the plug and check the engine for leaks CAUTION Insufficient amounts of or low grade engine oil lead to premature wear in the engine Do not overfill the engine case Do not underfill the engine case MAINTENANCE WORK ON CHASSIS AND ENGINE 65 Changing the engine oil and the oil filter cleaning the oil screen CAUTION You 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 syste
49. hops This way you can avoid the long waiting times at your mechanic at the beginning of the next biking season TECHNICAL SPECIFICATIONS CHASSIS 75 CHASSIS 950 SUPER ENDURO R Frame tubular chrome molybdenum steel space frame Fork WP Suspension Up Side Down 4860 MXMA PA Wheel travel front 250 mm 9 8 in Rear suspension WP Suspension Progressive Damping System shock absorber 4618 BAVP Wheel travel rear 255 mm 10 in Front brake Disk brake perforated brake disk 300 mm 11 8 in floating brake caliper and brake disk Rear brake Disk brake perforated brake disk 240 mm 9 5 in floating brake caliper and brake disk Authorized front tires METZELER MCE KAROO FRONT 90 90 21 540 M S up to a max of 160 kph 100 mph Air pressure front Offroad 1 7 bar 24 psi only 2 4 bar 34 psi Road with passenger 2 4 bar 34 psi Authorized rear tires METZELER MCE KAROO 140 80 18 M C 700 M S up to a max of 160 kph 100 mph Air pressure rear Offroad sone oe tes 1 5 bar 21 psi Road driveronly 2 5 bar 35 psi Road with passenger 2 7 bar 38 psi Fuel tank capacity 14 liters 3 7 USgal 4 liters 1 USgal reserve Gear ratio rear wheel 17 45 Chain 5 8 x 5 16 X ring Lighting headlight H4 12V 60 55W socket P43t position l
50. ight front 12V 5W socket W2 1x9 5d indicator lamps position light rear 12V 5W socket W2 1x9 5d stoplight 12V 21W socket BA15s licens plate illumination 12V 5W socket W2 1x9 5d flasher 12V 10W socket BA15s further tire releases are available on the Internet at www ktm com TECHNICAL SPECIFICATIONS CHASSIS 76 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 Ibs Max axle load front 190 kg 419 4 Ibs Max axle load rear 250 kg 552 Ibs Max total weight 400 kg 883 Ibs 950 SUPER ENDURO R 2008 FORK SHOCK FORK 950 SUPER ENDURO R Type 14187D32 WP Suspension 2 E 5 FEIER 5 Spring 5 9 450 E 5 E 22 BE 3 gs Spring preload turns 5 8 2727 Air chamber lenght 100 mm 4 in Comfort 25 25 1 25 2 22 8 Fork oil SAE 5 WP 4860 0401 Basic Setting 20 20 5 20 1 5 18 8 SHOCK ABSORBER 950 SUPER ENDURO R Type 15187D06 WP Suspension Spring 140 215 Spring preload mm 8 mm 0 31 in Sport MX 15 15 8 15 1 15 8 Max payload 20 20 5 15 1 15 8 TECHNICAL SPECIFICATIONS CHASSIS 71 TIGHTENING TORQUES CHASSIS 950 SUPER ENDURO R 2008 Collar bolt on front wheel spindle M24x1 5
51. ing harness is oxidized Open fuel taps tank fuel you did not use choke Pay atten tion to starting off information see driving instructions Replace THE FUEL pump fuse Remove the panel and fuel tank clean the plug and socket connector and spray with contact spray Engine will not reach full power Fuel supply partically interrupted Carburetors leaking Air filter very dirty The ignition curve for 80 octane is activated Check the fuel taps run 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 Activate the ignition curve for 95 octane if fuel with at least RON 95 USA Premium PON 91 is being used 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 Refill cooling liquid see maintenace work check cooling system for leaks Clean radiator with water jet Replace cooling liquid use antifreezer with brand name Run the radiator hose correctly or replace Have the thermostat checked opening temperature 75 C 167 F or replaced contact an authorized KTM workshop Replace fuse FAN TROUBLESHOOTING 10 TROUBLE CAUSE REMEDY Engine overheats Defect fan or thermoswitch for fan Contact an authorized KTM workshop
52. ive clothing and helmet 22 DRIVING INSTRUCTIONS 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 In both cases this can damage other motorcycle components and cause the motorcycle to go out of control A chain that is too tight or not greased will cause unnecessary wear to the chain and sprockets 3 TIRES Check for damaged tires Tires 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 refilled even when the brake pads are worn If the level of brake fluid falls below the minimum value this indicates a leak in the braking system or completely worn out brake pads Arrange for the braking system to be checked by a KTM specialist as com plete failure of the braking system can b
53. k on your motorcycle be carried o nevertheless we advise you to use the trouble shooting chart in order to fi ut disturbances can hardly be expected Should an error occur nd 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 TROUBLE CAUSE REMEDY Engine does not start when the Operating errror starter button is actuated Discharged battery Blown fuse IGNITION Blown main fuse Defect ignition lock Defect safe starting system Turn on the ignition switch the gear to neutral 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 contact an authorized KTM workshop Contact an authorized KTM workshop The engine cranks only with pulled A gear is engaged clutch lever A gear is engaged and the side stand is still folded down Defect safe starting system Shift the transmission to neutral Shift the transmission to neutral Contact an authorized KTM workshop Engine cranks with gear engaged Defect safe starting system Contact an authorized KTM workshop 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 wir
54. le 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 aE 95 octane RON is activated If you disconnect the plug and socket connection the ignition curve for fuel having 80 94 octane RON is activated Although this causes the engine to lose some of its power out E d Buc put it prevents poor glow ignitions and engine damage If fuel having at least RON 95 USA Premium PON 91 is not available the ignition curve for 80 94 octane RON must be activated to prevent engine damage 1 Muse b ea MM 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 Soiled cooling fins also impair the cooling effect If for example slow urban traffic or waiting at a traffic light cause little or no air to stream through the radiator the temperature of the cooling liquid will rise
55. liquid is leak ing out of the motorcycle Check the cool ing liquid level in the radiator not only in the compensating tank CAUTION SCALDING HAZARD Do not drive on until there is sufficient liquid in the col ing system In the event that while riding on your motorcycle you notice any unusual oper ation related noise stop immediately turn the engine off and contact an author ized KTM dealer Braking Close throttle and apply the hand and foot brakes at the same time Carefully apply the brakes on sandy wet or slippery surfaces Always brake with feeling blocking wheels can cause you to skid or fall Also change down to lower gears depending on your speed Always finish braking before you enter a curve When driving downhill use the braking effect of the engine Change down one or two gears but do not overspeed the engine In this way you will not need to brake so much and the brakes will not overheat DRIVING INSTRUCTIONS 21 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 The hotter these parts get the weake
56. ll 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 LC8 engine Even finely machined surfaces of engine parts have rougher surfaces than parts that slide on each other for a long time Therefore every engine must be run in For this reason do not demand maximum performance from the engine for the first 1000 kilometers 620 miles The vehicle must be run in at low changing performance level for the first 1000 km 620 miles Do not exceed the maximum speeds listed in the table during this time GEAR MAXIMUM SPEED 154 50 km h 30 mph 2 70 km h 40 mph 3rd 95 km h 60 mph Ath 115 km h 70 mph 5th 135 km h 85 mph 6th 160 km h 100 mph ADT MEN Wear suitable clothing when driving a motorcycle Clever KTM drivers always wear a helmet boots gloves and a jacket regardless of whether driving all day or just for a short trip The protective cloth ing should be brightly colored so that other vehicle can see you as early as possible Your passenger will also need suitable protective clothing Do not drive after having consumed alcohol Drive at a moderate speed for the first few kilometers of each trip
57. luid level front brake 42 lasher switch d ouk o s b LV 13 Checking rear brake fluid level 43 Foot brake pedal 17 Checking spoke tension 49 Fuel refueling eio dirum niece ied ei 28 Checking the chain for wear 39 rE eltaps css oot beta o Int rt 14 Checking the chain 38 Fuses for individual power consumers 53 Checking the cooling liquid level in the compensating tank 59 General informations about KTM disc brakes 40 Checking the cooling liquid level in the radiator 60 General tips and warnings for starting the motorcycle 20 Checking the engine oil level 64 GIDS trek chee eek aes evene wire Mas 15 HEAD WORD INDEX 82 Hand brake levet 77 Starting Off oec eal a he dies chet ducta seas 25 lenition lock ee al US oles ees 13 Starting when the engine is 24 Important information 2 Starting when the engine is warm or hot 25 OS od der petal wold Beat ee 4 Stopping and 27 Indicator lamps BAe ms EG eS 12 7 Storag enea oos bets
58. m 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 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 WARNING CSCS An engine having been run warm and the engine oil in it is very hot do not burn yourself Remove the screws on the right side of the underride protection 1 and on the left and front 2 and remove the underride protection Park the motorcycle on an even surface in an upright position Place a vessel under the engine to catch the used oil and remove the oil drain plug 3 Take off the cover 4 and pull the oil sieve out of the engine case with a pair of pliers Remove the oil filter cover 5 and pull the oil filter out of the engine case with circlip pliers upside down 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 Carefully pull the oil screen 4 out of the oil tank Thoroughly clean the drain plugs the cover and both oil screens Clean all rubbe
59. move 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 available from your authorized KTM workshop CAUTION KTM uses biodegradable hydraulic mineral oil to actuate the hydraulic clutch Do not mix this oil with any other hydraulic oil Always use original KTM hydraulic oil available from your authorized KTM workshop to make sure your clutch operates smoothly Never refill with brake fluid MAINTENANCE WORK ON CHASSIS AND ENGINE 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 To check the correctness of this setting start the engine turn the handlebar left and right in both cases as far as it will go This must not cause any changes in idling speed Otherwise you have to increase the backlash of the throttle cable Checking and adjusting the choke cable play The choke cable must have a play of approx 3 mm 0 12 in at all times To check the play push back the protection cover 4 It should be possible to lift the cable ap
60. n dry sump with 2 trochoidal pumps pressure pump and suction pump Engine oil SAE 5W 40 10W 50 Motorex Power Synt AT Quantity of engine oil approx 3 0 liters 0 8 USgal during oil filter change Primary drive straight toothed spur wheels 35 67 Clutch multi disc clutch in oil bath hydraulically operated Transmission 6 speed claw shifted Gear ratio Ist gear 12 35 2nd gear 15 32 3rd gear 18 30 4th gear 20 27 bth gear 24 27 6th gear 27 26 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 Starting aid 0 9 kW electric starter BASIC CARBURETOR SETTING JASO T903 MA Type of carburetor CVRD 43 Main jet 155 front 160 rear TEMPERATUR Main air jet 40 pe Idling jet 42 Idle air jet 50 5W 40 10W 50 Idle air cutoff jet 80 Jet needle NDFB Engine oil Needle position 2nd from top Only use fully synthetic engine oils that meet Mixture control screw open 2 1 4 turns the JASO MA quality requi
61. n 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 direction and remove Slightly depress the bulb turn it approx 30 counterclockwise and pull it out of the socket To mount the lamp reverse the worksteps indicated above When you mount the screw first turn it in a counterclockwise direction until it engages in the thread and then tighten slightly MAINTENANCE Y WORK ON CHASSIS AND ENGINE 56 Remove the seat Remove the screws on the grips 1 and the upper rear 2 and take off the parts 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 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 grips and tighten the screws to 25 Nm Tighten the screws on the upper rear to 5 Nm Mount the seat MAINTENANCE WORK ON CHASSIS AND ENGINE 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 availab
62. ncrease the weight on the side stand The side stand or engine case can be damaged and the motorcycle can tip over DRIVING INSTRUCTIONS 28 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 After refueling it will take approx 8 minutes for the fuel warning lamp to switch off and for TRIP F to automatically reset to O and return to the previous display mode CAUTION Use unleaded fuel with at least RON 95 USA Premium RON 91 If using lower octane fuel the ignition curve must be changed otherwise engine damage will occur This motorcycle is equipped with a catalytic converter that will be destroyed if you use leaded fuel Always use unleaded fuel Fuel expands when its temperature rises Therefore do not fill the tank to the top see fig When you close the filler cap make sure it is correctly positioned NOTE After refueling it will take approx 8 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 ZN WARNING CSCS Gasoline is highly flammable and poisonous Extreme caution shoul
63. ng the cooling system To 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 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 Mount the radiator cap and move the motor cycle into a horizontal position again Fill the compensating tank with cooling liquid until it reaches a level between the MIN and MAX mark Close the compensating tank 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 CAUTION Adjustment of the clutch lever position is only possible within certain limits Only turn the adjusting screw manually and never 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 re
64. nning 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 was active when the ignition was switched off OPERATION INSTRUMENTS 9 mn a a a a oa Um 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 TRIP 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 and the distance traveled since reaching the low fuel mark the low fuel indicator lamp lights up To return to the CLOCK mode press the MODE button OPERATION INSTRUMENTS 10
65. number 6 THE MOTORGYGLE a 20 Engine number engine type 6 Instructions for initial operation 20 OPERATION INSTRUMENTS 7 Running the LC8 20 Clutch lever TD SET bee ee Se 7 Accessories and payload 21 Choke lever s seeded arid ERR MR HR UE eae oe 7 DRIVING INSTRUCTIONS 22 Hand brake lever 7 Check the following before each start 22 OPERATION INSTRUMENTS 8 Starting when the engine is cold 24 Multi functional digital speedometer 8 Starting when the engine is warm or hot 25 DISDIAY ace he Th cor spins sr er o cd es 8 Staring Ofta toner hana dss a tmb dtt 25 Setting options in the display 10 Shifting Ridinig 22222222 erm aed Y 25 Cooling liquid temperature display 12 gt 3 75 tales aceite 26 Indicator 12 Stopping and 27 Ignition lOCK rn Seen cies Roe Ie BE RR 13 Fuel ref eling e etm ee Vete es 28 Combination switch
66. of the friction bearings and bearing positions and treat the chain with chain spray Treat all bare areas except brake disks with a corrosion inhibitor e g Motorex Protect amp Shine The exhaust pipes and mufflers are made of stainless steel and should be treated with a suitable care product To prevent the electric system from malfunctioning treat the ignition lock emergency off switch combination switch and connectors with contact spray 13 CONSERVATION FOR WINTER OPERATION 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 WARNING oat a stash ri mU ae oe ae ere Keep anti corrosion agent from getting into contact with the brake discs for otherwise this will significantly reduce the braking power CAUTION After rides on salted roads clean motorcycle thoroughly with cold water and let it dry well STORAGE 14 Should you desire to make a pause over 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
67. ol if necessary adjust Check idle setting 1400 rpm Check breeder hoses and fuel lines for damage and kink free arrangement ADD ON PARTS CARBURETOR Check cooling system for leaks and antifreeze protection Check radiator fan for proper operation Check the exhaust system for leaks and correct suspension and the clamps for a tight fit Check actuating cables for damage smooth operation and kink less arrangement adjust and lubricate ojo 15000 km or PERIODIC MAINTENANCE SCHEDULE 30 950 SUPER ENDURO R 2008 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 Maintenance work performed by an authorized KTM workshop is not a substitute for care and maintenance by the driver Service every 7500 km or once a year 15000 km or every 2 years Check the oil level in the hydraulic clutch reservoir Check air filter renew if necessary clean air filter box Check cables for damage and kink less arrangement Check headlamp adjustment ADD ON PARTS Check electrical system for function low high beams stop light turn indicators headlamp flasher tell tale lamps speedometer illumination horn si
68. original position of the clutch lever see maintenance work on chassis and engine The clutch is hydraulically actuated and adjusts itself automatically 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 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 Hand brake lever The hand brake lever 3 is mounted on the right side of the handlebar The adjusting screw B can be used to change the basic position of the hand brake lever see Maintenance OPERATION INSTRUMENTS 8 TEST WS 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 5 display modes can be selected with the MODE button The indicator lamps 3 provide additional information on the motorcycle s ru
69. orkshop to have the error elim inated You will damage the engine if you continue to drive when the cooling liquid tem perature warning lamp is on Excessive use of the clutch at slow speed MAINTENANCE WORK ON CHASSIS AND ENGINE 59 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 CAUTION For the cooling system use only high grade antifreezer Motorex Anti Freeze Using low ergrade antifreeze agents can cause corrosion and coolant foaming More antifreeze must be added if you plan to travel to a region where temperatures are expected to drop below 25 C 13 F Pressure induced by heating of the cooling liquid in the cooling system is controlled by a valve 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 Checking the cooling liquid level in the compensating tank Check the level of the cooling liquid when the engine is cold It should fall between the MIN and MAX marks on the compensating tank
70. prox 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 CAUTION If there is no play in the choke cable the bore of the cold starter system cannot be com pletely closed This will result in high fuel consumption irregular engine operation extreme wear on the pistons and cylinders and will destroy the catalytic converters Adjusting the engine idle speed The idle speed should be 1400 rpm when the engine is warm The idle speed can be adjusted with the adjusting knurl 7 near the left frame tube Turning in a clockwise direction will increase the idle speed turning in a counterclockwise direction will reduce the idle speed MAINTENANCE WORK ON CHASSIS AND ENGINE 64 Engine oil JASO T903 MA Automobile engine oil used to be used for four stroke motorcycles before there were sepa rate motorcycle specifications Different technical developments made it necessary to have a separate specification for four stroke motorcycles the JASO T903 MA standard Whereas TEMPERATUR car engines require long changing intervals motorcycle engines require a higher power out orc put at higher speeds Most motorcycle engines also use the same oil to lubricate the trans 32 F mission and the clutch The JASO MA standard responds to these special requirements Only use fully synthetic engine oils that meet t
71. r 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 5 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 6 Tighten the screws to 10 Nm MAINTENANCE WORK ON CHASSIS AND ENGINE 67 Insert a new oil filter the engine case grease the O ring and mount the oil filter cover together with the O ring Tighten the screws to 6 Nm CAUTION 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 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 engine oil level see Checking the engine oil level Check the engine and the oil tank for oil leakage Mount the underride protection and tighten the screws to 25 Nm TROUBLESHOOTING 68 If you let the specified maintenance wor
72. r the brak ing effect In extreme cases the entire braking system can fail If the resistance in the hand brake lever or foot brake pedal feels spongy too much play this is an indication that something is wrong with the brake system Don t ride your motorcycle anymore without first having the brake system looked over by a KTM dealer Stopping and parking Apply the brakes fully and put the engine into neutral To stop the engine switch off 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 WARNING OOS 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 exhaust exhaust system brake discs and shock absorbers can become very hot Do not touch any of these parts after operating the motorcycle and take care to park it where pedestrians are not likely to touch it and get burned Never park your motorcycle in places where there exist fire hazards due to dry grass or other easily flammable materials CAUTION Always take out the ignition key when parking your motorcycle so that it cannot be used by unauthorized persons The side stand is dimensioned for the weight of the motorcycle only Sitting on the motor cycle will i
73. re The Owner s Manual corresponded to the latest information available for this model series at the time it was printed Minor devia tions resulting from enhancements to the motorcycle design cannot be entirely precluded The Owner s Manual is an integral part of the motorcycle and must be handed over to the new owner when the motorcycle is sold SERVICE Observance of the service maintenance and operating instructions for the engine and chassis specified in the Owner s Manual is a prerequisite for faultless operation and the avoidance of premature wear Please observe the prescribed breaking in periods inspec tion intervals and service intervals Strict observance will significantly prolong the service life of your motorcycle Use of the motorcycle under extreme conditions e g on extremely muddy and wet terrain can lead to higher than average wear on components such as the drive train or the brakes In this case it may become necessary to service or replace wear parts before the service limit specified in the maintenance schedule has been reached 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 un
74. rements see infor Starting jet 68 mation on the can KTM recommends Motorex Power Synt 4T in PON CLC RON ROZ S the 1OW 50 viscosity for temperatures over St M o o 87 91 RON Research Octane Number 0 C 32 F or 5W 40 for temperatures under ROZ Research Oktan Zahl 0 C 32 F 91 Premium 95 MON Motor Octane Number HEAD WORD INDEX 81 Accessories and payload 21 Checking the front brake 42 Activating the ignition curve for low octane fuel 57 Checking the oil level of the hydraulic clutch 62 Adjusting compression damping of fork 34 Checking the rear brake pads 43 Adjusting of free travel at the hand brake lever 42 Choke levers iue ee ve Dre e ee bre REO 7 Adjusting rebound damping of fork 35 JCleanifng Pt Mes edd Pre ete d be UY 72 Adjusting the engine idle speed 63 1 rGl tch leyer ut ut A eee 7 Adjusting the fork and shock absorber 34 Combination switch 13 Adjusting the headlight range 55 Compression damping of fork 18 Adjusting the spring preload on the fork 35 Compression damping of shock absorber 36 Battery bu Eee le ie adde 50 Cons
75. se to reduce damping during compression Make the same damping rate adjustments to both fork legs STANDARD ADJUSTMENT Turn adjusting screw clockwise as far as it will go Turn 20 clicks in a counterclockwise direction MAINTENANCE mone ON CHASSIS AND ENGINE 35 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 Turn the knob clockwise to increase damping turn it counterclockwise to reduce damping dur ing rebounding Make the same damping rate adjustment to both fork legs STANDARD ADJUSTMENT Turn adjusting screw clockwise as far as it will go Turn 20 clicks in a counterclockwise direction Adjusting the spring preload 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 time Make the same spring preload adjustments to both fork legs Generally if the preload is higher the rebound damping should also be set higher STANDARD ADJUSTMENT Turn adjusting screw counterclockwise as far as it will go
76. se 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 HEADLIGHT BULB Unplug the connector 3 and remove the rubber cap 4 Turn the bulb socket 5 approx 30 in a counterclockwise direction and remove Insert a new bulb making sure the tabs A on the lamp engage in the recess 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 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 TO CHECK Determine the distance from the ground to the center of the headlight when your motorcy cle is loaded and ready for the trip baggage driver passenger Make a mark on a light wall behind a level surface at a height corresponding to the center 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 o
77. switch on the battery charger When the battery is charged switch off the battery charger before you discon nect the battery Provide adequate ventilation when charging the battery a closed room the battery emits explosive gases when charging Electrolytes will escape through the safety valves if the battery is charged too long or at an excessive voltage or amperage This will reduce battery capacity Try to avoid quick charges Jump start Jump starts are not recommended since they can damage the motorcycle s electronic System MAINTENANCE WORK ON CHASSIS AND ENGINE 52 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 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 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 CAUTION 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 Contact a specialized KTM dealer should defects of the electric system occur more freq
78. 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 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 allows you adjust the damping behavior to match your driving style and the payload The adjusting screw 3 is located on the bottom of the shock absorber More information is provided in the chapter Adjusting the fork and shock absorber GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE 20 Instructions for initial operation Make sure the work for the pre delivery inspection was performed by your author ized KTM workshop The DELIVERY CER TIFICATE and SERVICE MANUAL
79. to ensure optimum vision in any sit uation When light shines directly on scratched visor the operator will be blinded A passenger may only ride on the motor cycle if passenger footrests are mounted A passenger footrest system is available from your authorized KTM workshop as an accessory The motorcycle is already approved for two seats Never leave your motorcycle without super vision if the engine is running Accessories and payload Accessory parts and baggage can signifi cantly decrease a motorcycle s driving stabil ity Please observe the following warnings ART Never drive faster than 130 kph 80 mph if you have mounted accessory parts on your motorcycle Accessory parts can sig nificantly impair the motorcycle s han dling especially in the maximum speed range Fasten the baggage close to the center of the motorcycle and distribute the weight evenly on the front and rear wheels and on the left and right Baggage must be securely and adequately fastenend loose baggage will significantly impair driving safety A high payload will change the motorcy cle s handling and considerably increase the braking distance adapt your driving speed accordingly Never exceed the maximum permissible laden weight and the axle weights The maximum permissible laden weight is made up of the following components Motorcycle ready for operation and tank full Luggage Driver and passenger with protect
80. ts Treat ignition steering lock and light switch with contact spray Check spoke tension sound test Check the rims for damage and deformation Check exhaust system for leaks and correct fit Check air filter renew if necessary clean air filter box Check shock absorber and fork for leaks and proper operation Clean fork dust sleeves MAINTENANCE WORK ON CHASSIS AND ENGINE 33 CAUTION 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 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 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 components and become loose Always use self locking nuts Let the motorcycle cool down before servicing to avoid being burned Properly dispose of oils grease filters fuel cleansers etc Observe the regulations ef
81. uel pump can briefly be heard after the ignition is switched on Switch transmission to idle green indicator lamp N 2 lights up 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 4 Do not accelerate operate starter button 4 5 The oil pressure warning lamp 5 should go out as soon as the engine is running 6 7 Ww N Take the motorcycle off of the side stand Push the choke lever back in after a short time max 1 km 0 6 mile WARNING OOS Do not start the engine and allow it to idle in a closed room Exhaust fumes poison ous and can cause loss of consciousness and death Always provide adequate ventila tion 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 caseand the motorcy cle will no longer be roadworthy CAUTION If the oil pressure warning lamp does not go out as soon as the engine is running imme diately switch off the engine If the engine is not switched off engine damage will occur within a short period of time Check the engine oil level or contact a ktm workshop Maximum period for continuous starting 5 seconds Wait at least 5 seconds before try ing again Don t ride your motorcycle with full load and don
82. uently MAINTENANCE WORK ON CHASSIS AND ENGINE 53 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 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 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 CAUTION 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 Fuses ACC 1 and ACC 2 3 are designed for accessories with a maximum power consump tion of 10 amperes each 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 MAINTENANCE WORK ON CHASSIS AND ENGINE 54 Replacing the headlight lamp Remove the screws 1 tilt the headlight mask up towards the front and detach at the bottom CAUTION 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 grea
83. w 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 CAUTION At the hand brake lever free travel must at least be 3 mm 0 12 in Only then may the pis ton in the hand brake cylinder be moved to be recognized by the greater resistance of the hand brake lever If this free travel is not provided pressure will build up in the braking system and the front wheel brake may fail due to overheating Checking of brake fluid level front brake The brake fluid reservoir is linked with the hand brake cylinder at the handlebar and the reservoir is provided with an inspection glass With the reservoir in a horizontal position the brake fluid level should not go below middle of the glass WARNING OCS 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 Have the brake fluid changed at an authorized KTM workshop every 2 years 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 WARNING OOO 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

maintenance work on chassis and engine

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