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.

WORK 3
9
Warning
Environmental hazard Batteries contain environmentally-hazardous materials.
–Do not dispose of batteries as household waste.
–Dispose of batteries at a collection point for used batteries.
Warning
Environmental hazard Hazardous substances cause environmental damage.
–Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.
Info
Even when there is no load on the battery, it discharges steadily.
The charging level and the method of charging are very important for the service life of the battery.
Rapid recharging with a high charging current shortens the service life of the battery.
If the charging current, charging voltage, and charging time are exceeded, the battery will be destroyed.
If the battery is depleted from starting the vehicle repeatedly, the battery must be charged immediately.
If the battery is left in a discharged state for an extended period, it will become over-discharged and sul-
fated, destroying the battery.
The battery is maintenance-free, i.e., the acid level does not have to be checked.
Preparatory work
–Switch off the ignition by turning the black ignition key to the
position OFF .
–Remove the seat. ( p. 8)
–Remove the battery. ( p. 10)
311910-10
Main work
–Connect the battery charger to the battery. Adjust the battery
charger.
EU battery charger XCharge-professional (00029095050)
Alternative 1
US battery charger XCharge-professional
(00029095051)
Alternative 2
UK battery charger XCharge-professional
(00029095052)
Alternative 3
CH battery charger XCharge-professional
(00029095053)
Info
Follow the instructions of the charger and the manual.
–Disconnect the battery charger after charging the battery.
Guideline
The charging current, charging voltage, and charging time
must not be exceeded.
Charge the battery regularly
when the motorcycle is not
in use
3 months

3 WORK
10
Finishing work
–Install the battery. ( p. 11)
–Mount the seat. ( p. 8)
–Set the time and date.
3.5 Removing 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.
Caution
Danger of accidents Electronic components and safety devices will be damaged if the battery is
discharged or missing.
–Never operate the vehicle with a discharged battery or without a battery.
Preparatory work
–Switch off the ignition by turning the black ignition key to the
position OFF .
–Remove the seat. ( p. 8)
S01811-10
Main work
–Pull locking mechanism 1in the direction of the arrow.
–Fold open cover 2.
S01812-10
–Disconnect both negative cables 3from the battery.
–Disconnect both positive cables 4from the battery.
–Take the battery and battery case 5out of the battery com-
partment.

WORK 3
11
3.6 Installing 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.
Caution
Danger of accidents Electronic components and safety devices will be damaged if the battery is
discharged or missing.
–Never operate the vehicle with a discharged battery or without a battery.
S01812-11
Main work
–Position the battery in battery case 1.
Guideline
The even side of the battery case must be opposite the
poles.
–Position the battery and battery case in the battery compart-
ment.
–Position the positive cable 2and mount and tighten the
screw.
Guideline
Screw, battery termi-
nal
M6 4.5 Nm
(3.32 lbf ft)
–Position the negative cable 3and mount and tighten the
screw.
Guideline
Screw, battery termi-
nal
M6 4.5 Nm
(3.32 lbf ft)
S01813-10
–Close the cover 4and push down slightly.
The cover engages with an audible click.
Finishing work
–Mount the seat. ( p. 8)
–Set the time and date.

3 WORK
12
3.7 Checking the headlight setting
400726-10
–Park the vehicle on a horizontal surface in front of a light-
colored wall and make a mark at the height of the center of
the low beam headlight.
–Make another mark at a distance Bunder the first marking.
Guideline
Distance B5 cm (2 in)
–Position the vehicle perpendicular to the wall at a distance A
from the wall and switch on the low beam.
Guideline
Distance A5 m (16 ft)
–The rider, with luggage and passenger if applicable, now
mounts the motorcycle.
–Check the headlight setting.
The light-dark boundary must lie exactly on the lower
mark when the motorcycle is ready to operate with the
rider mounted along with any luggage and a passenger if
applicable.
» If the boundary between light and dark does not meet
specifications:
–Adjust the headlight range. ( p. 12)
3.8 Adjusting the headlight range
Preparatory work
–Check the headlight setting. ( p. 12)
–Remove the bottom triple clamp cover. ( p. 13)
S01826-10
Main work
–Turn adjusting screw 1to adjust the headlight range.
Info
Turn clockwise to increase the headlight range; turn
counterclockwise to reduce the headlight range.
If you have a payload, you may have to correct the
headlight range.
400726-11
–Set the headlight to marking B.
Guideline
The light-dark boundary must lie exactly on the lower mark
Bwhen the motorcycle is ready to operate with the rider
mounted along with any luggage and a passenger if applica-
ble.
Finishing work
–Install the bottom triple clamp cover. ( p. 13)

WORK 3
13
3.9 Removing the bottom triple clamp cover
M00557-10
–Remove screws 1.
–Lower triple clamp cover 2slightly.
M00558-10
–Disconnect plugs 3of the horn.
–Detach temperature sensor 4.
–Remove the triple clamp cover.
3.10 Installing the bottom triple clamp cover
M00558-11
–Plug in connectors 1of the horn.
–Attach temperature sensor 2.
M00557-11
–Position the triple clamp cover 3.
–Mount and tighten screws 4.
Guideline
Remaining chassis
screws
M6 10 Nm (7.4 lbf ft)

3 WORK
14
3.11 Opening the filler cap
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
–Do not refuel the vehicle in the vicinity of open flames or lit cigarettes.
–Switch off the engine for refueling.
–Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
–If any fuel is spilled, wipe it off immediately.
–Observe the specifications for refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–Avoid skin, eye and clothing contact with fuel.
–Immediately consult a doctor if you swallow fuel.
–Do not inhale fuel vapors.
–In case of skin contact, rinse the affected area with plenty of water.
–Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
–Change your clothing in case of fuel spills on them.
–Keep fuels correctly in a suitable canister, and out of the reach of children.
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
–Do not allow fuel to enter the groundwater, the soil, or the sewage system.
S01752-10
–Lift cover 1of the filler cap and insert ignition key 2in the
fuel tank lock.
S01753-10
Note
Danger of damage The ignition key may break if overloaded.
Damaged ignition keys must be replaced.
–Push down on the filler cap to take pressure off the igni-
tion key.
–Turn ignition key 2clockwise.
–Fold open filler cap 3.

WORK 3
15
3.12 Closing the filler cap
S01754-10
–Fold down filler cap 1.
–Turn ignition key 2clockwise.
S01755-10
–Push down the filler cap and turn the ignition key 2counter-
clockwise until the tank lock closes.
Warning
Fire hazard Fuel is highly flammable, toxic and a
health hazard.
–Check the filler cap is locked correctly after clos-
ing.
–Change your clothing in case of fuel spills on them.
–Rinse the affected area immediately with plenty of
water in the event of contact with the skin.
–Remove ignition key 2and close cover 3.
3.13 Refueling
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
–Do not refuel the vehicle in the vicinity of open flames or lit cigarettes.
–Switch off the engine for refueling.
–Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
–If any fuel is spilled, wipe it off immediately.
–Observe the specifications for refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–Avoid skin, eye and clothing contact with fuel.
–Immediately consult a doctor if you swallow fuel.
–Do not inhale fuel vapors.
–In case of skin contact, rinse the affected area with plenty of water.
–Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
–Change your clothing in case of fuel spills on them.
Note
Material damage Inadequate fuel quality causes the fuel filter to quickly become clogged.

3 WORK
16
In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in
problems with the fuel system.
–Refuel only with clean fuel that meets the specified standards.
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
–Do not allow fuel to enter the groundwater, the soil, or the sewage system.
S01771-10
–Switch off the engine.
–Open the filler cap. ( p. 14)
–Fill the fuel tank with fuel up to the lower edge Aof the filler
neck.
Total fuel tank
capacity, approx.
23 l
(6.1 US gal)
Super unleaded
(ROZ 95/RON
95/PON 91)
( p. 20)
–Close the filler cap. ( p. 15)

TECHNICAL DATA 4
17
4.1 Chassis tightening torques
Nut, valve ISO 10V2 12 Nm (8.9 lbf ft)
Loctite®2701™
Screw, combination switch, left M4 2 Nm (1.5 lbf ft)
Screw, side stand switch M4 2 Nm (1.5 lbf ft)
Rear fairing screw M5x12 3.5 Nm (2.58 lbf ft)
Rear fairing screw M5x17 3.5 Nm (2.58 lbf ft)
Remaining nuts, chassis M5 5 Nm (3.7 lbf ft)
Remaining screws, chassis M5 5 Nm (3.7 lbf ft)
Screw brake line holder on frame M5 2 Nm (1.5 lbf ft)
Screw, brake line holder on
swingarm
M5 5 Nm (3.7 lbf ft)
Screw, cable channel M5 5 Nm (3.7 lbf ft)
Screw, cable guide, wheel speed
sensor, rear
M5 3 Nm (2.2 lbf ft)
Screw, chain sliding guard M5 5 Nm (3.7 lbf ft)
Screw, combination switch, right M5 3.5 Nm (2.58 lbf ft)
Screw, cover part M5 3.5 Nm (2.58 lbf ft)
Screw, filler cap M5 3 Nm (2.2 lbf ft)
Screw, foot brake lever stub M5 6 Nm (4.4 lbf ft)
Loctite®243™
Screw, fuel level sensor M5 3 Nm (2.2 lbf ft)
Screw, heat guard on main silencer M5 4 Nm (3 lbf ft)
Screw, wind shield M5 3.5 Nm (2.58 lbf ft)
Spoke nipple M5 5 Nm (3.7 lbf ft)
Ground fitting on frame M6 6 Nm (4.4 lbf ft)
Nut, ABS module fastening M6 8 Nm (5.9 lbf ft)
Remaining chassis nuts M6 10 Nm (7.4 lbf ft)
Remaining chassis screws M6 10 Nm (7.4 lbf ft)
Screw, angle sensor M6 6 Nm (4.4 lbf ft)
Loctite®243™
Screw, ball joint of push rod on
foot brake cylinder
M6 10 Nm (7.4 lbf ft)
Loctite®243™
Screw, battery terminal M6 4.5 Nm (3.32 lbf ft)
Screw, cable channel M6 5 Nm (3.7 lbf ft)
Screw, chain guide M6 5 Nm (3.7 lbf ft)
Screw, clutch assembly M6 5 Nm (3.7 lbf ft)
Screw, cooler retaining bracket M6 7 Nm (5.2 lbf ft)
Screw, cover part M6 6 Nm (4.4 lbf ft)
Screw, engine guard M6 10 Nm (7.4 lbf ft)
Screw, exhaust clamp M6 8 Nm (5.9 lbf ft)
Screw, foot brake cylinder M6 10 Nm (7.4 lbf ft)
Loctite®243™
Screw, front brake disc M6 14 Nm (10.3 lbf ft)
Loctite®243™
Screw, front wheel speed sensor M6 10 Nm (7.4 lbf ft)

4 TECHNICAL DATA
18
Screw, fuel pump M6 6 Nm (4.4 lbf ft)
Screw, fuel tank M6 10 Nm (7.4 lbf ft)
Screw, fuel tap M6 6 Nm (4.4 lbf ft)
Screw, headlight M6 5 Nm (3.7 lbf ft)
Screw, lower rear part M6 6 Nm (4.4 lbf ft)
Screw, magnetic holder on side
stand
M6 6 Nm (4.4 lbf ft)
Loctite®243™
Screw, rear brake disc M6 14 Nm (10.3 lbf ft)
Loctite®243™
Screw, retaining bracket, angle
sensor
M6 10 Nm (7.4 lbf ft)
Loctite®243™
Screw, voltage regulator M6 6 Nm (4.4 lbf ft)
Screw, wheel speed sensor, rear M6 10 Nm (7.4 lbf ft)
Remaining chassis nuts M8 25 Nm (18.4 lbf ft)
Remaining chassis screws M8 25 Nm (18.4 lbf ft)
Screw, bottom triple clamp M8 12 Nm (8.9 lbf ft)
Screw, exhaust clamp M8 25 Nm (18.4 lbf ft)
Screw, foot brake lever M8 25 Nm (18.4 lbf ft)
Loctite®243™
Screw, fork stub M8 15 Nm (11.1 lbf ft)
Screw, front footrest bracket M8 25 Nm (18.4 lbf ft)
Loctite®243™
Screw, handle bar end hand guard M8 25 Nm (18.4 lbf ft)
Screw, handlebar clamp M8 20 Nm (14.8 lbf ft)
Screw, ignition lock (tamper-proof
screw)
M8 25 Nm (18.4 lbf ft)
Loctite®243™
Screw, rear footrest bracket M8 25 Nm (18.4 lbf ft)
Loctite®243™
Screw, steering damper M8 25 Nm (18.4 lbf ft)
Loctite®243™
Screw, steering damper clamp M8 12 Nm (8.9 lbf ft)
Screw, steering stem M8 20 Nm (14.8 lbf ft)
Screw, suitcase hook M8 20 Nm (14.8 lbf ft)
Loctite®243™
Screw, top triple clamp M8 20 Nm (14.8 lbf ft)
Remaining chassis nuts M10 45 Nm (33.2 lbf ft)
Remaining chassis screws M10 45 Nm (33.2 lbf ft)
Screw, front brake caliper M10 45 Nm (33.2 lbf ft)
Loctite®243™
Screw, handlebar support M10 40 Nm (29.5 lbf ft)
Loctite®243™
Screw, side stand M10 35 Nm (25.8 lbf ft)
Loctite®243™
Screw, side stand bracket M10 45 Nm (33.2 lbf ft)
Loctite®243™
Banjo bolt, brake line M10x1 25 Nm (18.4 lbf ft)
Nut, rear sprocket screw M10x1.25 50 Nm (36.9 lbf ft)
Loctite®243™
Lambda sensor M12x1.25 25 Nm (18.4 lbf ft)