KTM 1090 Adventure R 2018 Manual

SETUP INSTRUCTIONS 2018
1090 Adventure R
Art. no. 3213803en

INTRODUCTION
*3213803en*
3213803en
11/2017
INTRODUCTION
Perform the work described in these setup instructions before the vehicle is delivered to the customer.
Read the setup instructions in their entirety before beginning work.
These setup instructions were written to correspond to the latest state of this series. We reserve the right to make
changes in the interest of technical advancement without at the same time updating this manual.
We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop
are not specified here. It is assumed that the work will be performed by a fully trained mechanic.
All specifications are non-binding. KTM Sportmotorcycle GmbH specifically reserves the right to modify or delete
technical specifications, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice
and without specifying reasons, to adapt these to local conditions, as well as to stop production of a particular
model without prior notice. KTM accepts no liability for delivery options, deviations from illustrations and descrip-
tions, misprints, and other errors. The models portrayed partly contain special equipment that does not belong to
the regular scope of supply.
© 2017 KTM Sportmotorcycle GmbH, Mattighofen Austria
All rights reserved
Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission
of the copyright owner.
ISO 9001(12 100 6061)
According to the international quality management standard ISO 9001, KTM uses quality assur-
ance processes that lead to the maximum possible quality of the products.
Issued by: TÜV Management Service
KTM Sportmotorcycle GmbH
Stallhofnerstraße 3
5230 Mattighofen, Austria
This document is valid for the following models:
1090 Adventure R EU (F9903RD)
1090 Adventure R US (F9975RD)
1090 Adventure R CN (F9987RD)

1 MEANS OF REPRESENTATION
2
1.1 Symbols used
The meaning of specific symbols is described below.
Indicates an expected reaction (e.g. of a work step or a function).
Indicates an unexpected reaction (e.g. of a work step or a function).
Indicates a page reference (more information is provided on the specified page).
Indicates information with more details or tips.
Indicates the result of a testing step.
Indicates a voltage measurement.
Indicates a current measurement.
Indicates a resistance measurement.
Indicates the end of an activity including potential rework.
1.2 Formats used
The typographical formats used in this document are explained below.
Proprietary name Indicates a proprietary name.
Name®Indicates a protected name.
Brand™ Indicates a brand available on the open market.
Underlined terms Refer to technical details of the vehicle or indicate technical terms, which
are explained in the glossary.

SETUP 2
3
2.1 Unpacking and setting up the vehicle
S01880-10
–Remove the straps and box.
A00227-10
–Remove the adhesive tape in the upper area of the motorcycle.
A00228-10
–Roll down the film at the sides.
Info
To avoid damaging the motorcycle during unpacking,
leave the other films on the vehicle until you have fin-
ished work on the vehicle.
–Remove the separate enclosure and unpack it. Check the sepa-
rate enclosure for completeness.
–Check the vehicle for transport damage.
A00229-10
–Remove the controls from the transport holder.
–Remove the screws and handlebar clamps.
–Remove the transport holder.
S01881-10
–Remove the right hand guard.
–Position the controls on the right half of the handlebar.
Tighten the screws.
Guideline
Screw, combination
switch, right
M5 3.5 Nm
(2.58 lbf ft)
Remaining chassis
screws
M6 10 Nm (7.4 lbf ft)
The catch on the combination switch engages in the
recess of the mirror clamp.
–Mount the right hand guard.

2 SETUP
4
Guideline
Hand guard screw M8 15 Nm (11.1 lbf ft)
Hand guard fitting M6 6 Nm (4.4 lbf ft)
S01878-10
Warning
Danger of accidents A repaired handlebar poses a
safety risk.
If the handlebar is bent or straightened, the mate-
rial becomes fatigued. The handlebar may break as a
result.
–Change the handlebar if the handlebar is damaged
or bent.
–Position the handlebar.
Info
Make sure the cables and wiring are positioned cor-
rectly.
–Position the handlebar clamps. Tighten the screws evenly.
Guideline
Screw, handlebar
clamp
M8 20 Nm (14.8 lbf ft)
Markings Aface backwards.
Handlebar scale markings Bare located centrally
between the handlebar clamps.
–Check the throttle grip for smooth operation.
A00226-10
–Mount and tighten the rear mirror on both sides.
–Install the wind shield. ( p. 8)
S01875-10
–Mount reflector 1with spring washers 2on holding
plate 3.
–Mount the retaining plate on the license plate holder.

SETUP 2
5
S01876-10
(1090 Adventure R EU, 1090 Adventure R CN)
–Mount the license plate holder.
S01877-10
(1090 Adventure R US)
–Bond the reflectors on the right and left side of the reflec-
tor holder.
–Mount the reflector holder on license plate bracket.
–Carefully loosen and remove the tension belt over the
swingarm.
Info
An assistant prevents the motorcycle from falling over.
–Carefully loosen and remove the tension belts around the lower
triple clamp.
The vehicle is released at the front.
–Take the vehicle off the palette together with an assistant.
S01870-01
–Remove radiator shield 4.
–Remove screws 5.
–Position radiator guard.
Info
Pay attention to the guides and the holding lugs.
–Mount and tighten screws 5and 6.
Guideline
Screw, cooler retain-
ing bracket
M6 7 Nm (5.2 lbf ft)

2 SETUP
6
S01871-10
–Mount the frame protector elements 7on both sides.
–Position the left crash bar with frame protector and attach the
clamp to the frame tube.
Info
Cover the components to protect them against damage.
–Mount screw 8but do not tighten yet.
Guideline
Remaining chassis
screws
M10 45 Nm (33.2 lbf ft)
–Position clamps and mount the new screws 9but do not
tighten them yet.
Guideline
Remaining chassis
screws
M6 10 Nm (7.4 lbf ft)
–Mount screw bk but do not tighten yet.
Guideline
Remaining chassis
screws
M6 10 Nm (7.4 lbf ft)
S01872-10
–Position the right crash bar with frame protector and attach
the clamp to the frame tube.
Info
Cover the components to protect them against damage.
–Mount screw bl but do not tighten yet.
Guideline
Remaining chassis
screws
M10 45 Nm (33.2 lbf ft)
–Position clamps and mount the new screws bmbut do not
tighten them yet.
Guideline
Remaining chassis
screws
M6 10 Nm (7.4 lbf ft)
–Mount screw bn but do not tighten yet.
Guideline
Remaining chassis
screws
M6 10 Nm (7.4 lbf ft)
S01873-10
–Mount and tighten screws bo with nuts.
The crash bars are equally aligned with each other.
–Tighten all the screws of the crash bar.
Guideline
Remaining chassis
screws
M6 10 Nm (7.4 lbf ft)
Remaining chassis
screws
M10 45 Nm (33.2 lbf ft)

SETUP 2
7
S01874-10
–Mount rubber dampers bp on the engine guard.
–Position the engine guard. Mount and tighten the screws with
the distance sleeves.
Guideline
Screw, engine guard M6 10 Nm (7.4 lbf ft)
S01882-10
–Position footrest rubber bq.
–Mount locking plate br and nut bs.
–Tighten nut bs.
–Repeat the operation on the opposite side.
–Remove the seat. ( p. 8)
–Remove spare key and KEYCODECARD under the seat and keep
in a safe place for the handover.
–Recharge the battery. ( p. 8)
–Remove the remaining films.
–Check the headlight setting. ( p. 12)
–Refuel. ( p. 15)
–Prepare the vehicle according to the specifications in the
KTM Dealer.net for handover to the customer.

3 WORK
8
3.1 Installing the wind shield
A00225-10
–Position wind shield 1.
–Mount and tighten screws 2.
Guideline
Screw, wind shield M5 3.5 Nm
(2.58 lbf ft)
3.2 Removing the seat
S01782-10
–Insert the ignition key in the seat lock 1and turn it clock-
wise by 45 °.
–Raise the rear of the seat, pull the seat back, and lift it off.
–Remove the ignition key.
3.3 Mounting the seat
0
0
220
0
11
401677-10
–Hook the catch 1of the seat onto the fuel tank, lower the
rear and push it forward.
–Insert the locking pin 2into the lock housing and push down
the rear of the seat until the locking pin engages with an audi-
ble click.
–Check that the seat is correctly mounted.
3.4 Recharging the battery
Warning
Risk of injury Battery acid and battery gases cause serious chemical burns.
–Keep batteries out of the reach of children.
–Wear suitable protective clothing and safety glasses.
–Avoid contact with battery acid and battery gases.
–Keep sparks or open flames away from the battery.
–Only charge batteries in well-ventilated rooms.
–Rinse the affected area immediately with plenty of water in the event of contact with the skin.
–Rinse eyes with water for at least 15 minutes and consult a doctor immediately if battery acid and
battery gases get into the eyes.