KTM 1190 Adventure EU 2013 Manual

SETUP INSTRUCTIONS 2013
1190 Adventure EU
1190 Adventure FR
1190 Adventure AUS
1190 Adventure JP
Art. no. 3213057en

INTRODUCTION 1
INTRODUCTION
The work described in these setup instructions must be performed before the vehicle is delivered to the customer.
Read the setup instructions in their entirety before beginning work.
Print out the current PDI form found on the KTM DEALER.NET.
These setup instructions were written to correspond to the latest state of this series. We reserve the right to make changes in the inter-
est 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 AG specifically reserves the right to modify or delete technical specifica-
tions, 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 descriptions, as well as misprints and other errors. The models portrayed partly contain spe-
cial equipment that does not belong to the regular scope of supply.
© 2013 KTM-Sportmotorcycle AG, 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 assurance processes that lead
to the maximum possible quality of the products.
Issued by: TÜV Management Service
KTM-Sportmotorcycle AG
5230 Mattighofen, Austria

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.
Denotes a voltage measurement.
Denotes a current measurement.
Denotes a resistance measurement.
1.2 Formats used
The typographical formats used in this document are explained below.
Proprietary name Identifies a proprietary name.
Name®Identifies a protected name.
Brand™ Identifies a trademark.

2 SETUP 3
2.1 Unpacking and setting up the vehicle
Preparatory work
–Remove the box.
202178-10
Main work
–Remove the adhesive tape in the upper area of the motorcycle.
202179-10
–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 finished work on the vehicle.
–Remove the separate enclosure and unpack it. Check the separate enclosure for
completeness.
–Check the vehicle for transport damage.
202180-10
–Remove the controls from the transport holder. Remove the screws and handlebar
clamps. Remove the transport holder.
202181-10
–Remove the right hand guard.
–Position the controls on the right half of the handlebar. Tighten the screws.
Guideline
Remaining screws, chassis M5 5 Nm (3.7 lbf ft)
Remaining chassis screws M6 10 Nm (7.4 lbf ft)
–Mount the right hand guard.
202182-10
–Position the handlebar.
The markings 1of the scale of the handlebar are located centrally between
the handlebar clamps.
–Position the handlebar clamps. Tighten the screws evenly.
Guideline
Screw, handlebar clamp M8 20 Nm
(14.8 lbf ft)
–Check the throttle grip for smooth operation.

2 SETUP 4
202183-10
–Remove the film from the headlight. Position the screen. Mount and tighten
screws 2.
202184-10
–Mount and tighten the rear mirror on both sides.
202185-10
–Mount reflector 3on retaining plate 5with spring washers 4.
–Mount the retaining plate on the license plate holder. Mount the license plate
holder.
–An assistant holds the motorcycle.
–Carefully loosen and remove the tensioning belt over the swingarm.
Info
An assistant prevents the motorcycle from falling over.
–Carefully loosen and remove the tensioning belts around the lower triple clamp.
The vehicle is released at the front.
–Together with an assistant, take the vehicle off the pallet.
202197-10
–Remove the radiator shield.
202186-10
–Mount rubber dampers 6on the engine guard.
–Position the engine guard. Mount and tighten the screws with the distance sleeves.
Guideline
Screw, underride guard M6 10 Nm (7.4 lbf ft)
–Recharge the battery. ( p. 7)
–Store the tool set below the seat.
–Remove the remaining films.
–Refuel. ( p. 8)

2 SETUP 5
–Print out the current PDI form found on KTM DEALER.NET and perform the delivery
inspection.

3 WORK 6
3.1 Removing the passenger seat
S00349-10
–Insert the ignition key in seat lock 1and turn it clockwise.
–Raise the front of the passenger seat, pull it toward the tank, and remove it
upward.
–Remove the ignition key.
3.2 Mounting the passenger seat
401680-10
–Attach the hooks on the passenger seat to the brackets on the subframe, and lower
at the front while pushing toward the rear.
–Insert locking pin 1into the lock housing and push down the front of the passen-
ger seat until the locking pin engages with a click.
–Check that the passenger seat is correctly mounted.
3.3 Removing the driver's seat
Preparatory work
–Remove the passenger seat. ( p. 6)
S00350-01
Main work
–Raise the rear of the driver's seat.
–Detach the front of the driver's seat and remove it.
3.4 Mounting the driver's seat
401704-10
Main work
–Attach the recesses on the driver's seat to the fuel tank at the desired seat posi-
tion Aor B, and push the driver's seat forward while lowering it at the rear.
–Finally, check that the driver's seat is correctly mounted.
Finishing work
–Mount the passenger seat. ( p. 6)

3 WORK 7
3.5 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 goggles.
–Avoid contact with battery acid and battery gases.
–Keep sparks and open flames away from the battery. Only charge in well-ventilated rooms.
–In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least
15 minutes and contact a physician.
Warning
Environmental hazard The battery contains elements that are harmful to the environment.
–Do not discard batteries with the household waste. Dispose of faulty batteries in an environmentally compatible manner.
Give the battery to your authorized KTM dealer or dispose of it at a collection point for used batteries.
Warning
Environmental hazard Hazardous substances cause environmental damage.
–Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
Info
Even when there is no load on the battery, it discharges steadily.
The charge state and the type of charge are very important for the service life of the battery.
Rapid recharging with a high charging current shortens the battery's service life.
If the charging current, charging voltage, and charging time are exceeded, electrolyte escapes through the safety valves. This
reduces the battery capacity.
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 sulfate, destroying the
battery.
The battery is maintenance-free, i.e., the acid level does not have to be checked.
If the battery is not charged using the KTM battery charger, the battery must be removed for charging. Otherwise, overvoltage
may damage electronic components. Charge the battery according to the instructions on the battery housing.
Preparatory work
–Switch off all power consumers and switch off the engine.
–Remove the passenger seat. ( p. 6)
–Remove the driver's seat. ( p. 6)
S00373-10
Main work
–Pull locking mechanism 1in the direction of the arrow.
–Fold open cover 2.
602677-11
–Disconnect the negative cable 3of the battery to avoid damage to the motorcy-
cle's electronics.

3 WORK 8
602678-01
–Connect the battery charger to the battery. Switch on the battery charger.
Battery charger (58429074000)
You can also use the battery charger to test the open-circuit voltage and start
potential of the battery, and to test the alternator. With this device, you cannot
overcharge the battery.
Info
Charge the battery with a maximum of 10% of the capacity specified on the
battery housing.
–Switch off and disconnect the battery charger after charging.
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
602677-11
–Connect both negative cables 3.
Guideline
Screw, battery terminal M6 4.5 Nm
(3.32 lbf ft)
S00374-10
–Fold down cover 4and let it lock by pushing down lightly.
Finishing work
–Mount the driver's seat. ( p. 6)
–Mount the passenger seat. ( p. 6)
–Set the time and date.
3.6 Refueling
Danger
Fire hazard Fuel is highly flammable.
–Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no
fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
–The fuel in the fuel tank expands when warm and may emerge if overfilled. Follow the instructions on refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with
the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with
soap and water. If fuel is swallowed, contact a physician immediately. Change clothing that is contaminated with fuel.
Note
Material damage Premature clogging of the fuel filter.
–In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with
the fuel system.
–Only refuel with clean fuel that meets the specified standards.

3 WORK 9
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
–Do not allow fuel to get into the ground water, the ground, or the sewage system.
S00346-10
–Switch off the engine.
–Open the filler cap. ( p. 9)
–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. 13)
–Close the filler cap. ( p. 10)
3.7 Opening the filler cap
Danger
Fire hazard Fuel is highly flammable.
–Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no
fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
–The fuel in the fuel tank expands when warm and may emerge if overfilled. Follow the instructions on refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with
the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with
soap and water. If fuel is swallowed, contact a physician immediately. Change clothing that is contaminated with fuel.
Store fuel properly in a suitable canister and keep away from children.
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
–Do not allow fuel to get into the ground water, the ground, or the sewage system.
602612-10
–Lift cover 1of the filler cap and insert ignition key 2in the fuel tank lock.
S00351-10
Note
Danger of damage Ignition key breakage.
–To take pressure off of the ignition key, push down on the filler cap. Damaged
ignition keys must be replaced.
–Turn ignition key 2clockwise.
–Fold open filler cap 3.

3 WORK 10
3.8 Closing the filler cap
S00352-10
–Fold down filler cap 1.
–Turn ignition key 2clockwise.
S00353-10
–Press down the filler cap and turn back ignition key 2until the fuel tank lock
locks.
Warning
Fire hazard Fuel is highly flammable, poisonous and harmful to your
health.
–After closing the filler cap, ensure that it is locked properly. Change
clothing that has been contaminated with fuel. Immediately clean con-
taminated areas on the skin with soap and water.
–Remove ignition key 2and close cover 3.

4 TECHNICAL DATA - TIGHTENING TORQUES FOR CHASSIS 11
Nut, tire pressure sensor 12 Nm (8.9 lbf ft) –
Screw, combination switch, left M4 2 Nm (1.5 lbf ft) –
Screw, side stand switch M4 2 Nm (1.5 lbf ft) –
Remaining screws, chassis M5 5 Nm (3.7 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 sen-
sor, 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 M5x12 3.5 Nm (2.58 lbf ft) –
Screw, filler cap M5 5 Nm (3.7 lbf ft) –
Screw, foot brake lever stub M5 6 Nm (4.4 lbf ft) Loctite®243™
Screw, fuel level indicator 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 unit fixation 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, battery terminal M6 4.5 Nm (3.32 lbf ft) –
Screw, brake line holder on bottom
triple clamp
M6 8 Nm (5.9 lbf ft) Loctite®243™
Screw, cable channel M6 5 Nm (3.7 lbf ft) –
Screw, chain guide M6 5 Nm (3.7 lbf ft) Loctite®243™
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, exhaust pipe bracket M6 12 Nm (8.9 lbf ft) Loctite®243™
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, 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, 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, underride guard M6 10 Nm (7.4 lbf ft) –
Screw, voltage regulator M6 6 Nm (4.4 lbf ft) –
Screw, wheel speed sensor, front M6 10 Nm (7.4 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 12 Nm (8.9 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, handlebar clamp M8 20 Nm (14.8 lbf ft) –
Screw, ignition lock (tamper-proof
screw)
M8 25 Nm (18.4 lbf ft) Loctite®243™

4 TECHNICAL DATA - TIGHTENING TORQUES FOR CHASSIS 12
Screw, rear footrest bracket M8 25 Nm (18.4 lbf ft) Loctite®243™
Screw, steering damper clamp M8 12 Nm (8.9 lbf ft) –
Screw, suitcase hook M8 20 Nm (14.8 lbf ft) –
Screw, top triple clamp M8 15 Nm (11.1 lbf ft) –
Engine carrying screw M10 45 Nm (33.2 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) –
Screw, subframe M10x1.25 45 Nm (33.2 lbf ft) Loctite®243™
Lambda sensor M12x1.25 25 Nm (18.4 lbf ft) –
Screw, bottom shock absorber M14x1.5 80 Nm (59 lbf ft) Thread greased
Screw, top shock absorber M14x1.5 80 Nm (59 lbf ft) Thread greased
Nut, socket M18x1 4 Nm (3 lbf ft) –
Nut, swingarm pivot M19x1.5 130 Nm (95.9 lbf ft) Thread greased
Screw, steering head, top M22x1.5 50 Nm (36.9 lbf ft) –
Nut, rear wheel spindle M25x1.5 90 Nm (66.4 lbf ft) Thread greased
Screw, front wheel spindle M25x1.5 45 Nm (33.2 lbf ft) –
Nut, steering head, top M28x1.0 12 Nm (8.9 lbf ft) –

5 SUBSTANCES 13
Super unleaded (ROZ 95/RON 95/PON 91)
According to
–DIN EN 228 (ROZ 95/RON 95/PON 91)
Guideline
–Only use unleaded super fuel that matches or is equivalent to the specified fuel grade.
–Fuel with an ethanol content of up to 10 % (E10 fuel) is safe to use.
Info
Do not use fuel containing methanol (e. g. M15, M85, M100) or more than 10 % ethanol (e. g. E15, E25, E85, E100).

*3213057en*
3213057en
02/2013
KTM-Sportmotorcycle AG
5230 Mattighofen/Austria
http://www.ktm.com
Photo: Mitterbauer/KTM