KTM 1290 Super Adventure EU 2015 Manual

SETUP INSTRUCTIONS 2015
1290 Super Adventure EU
1290 Super Adventure FR
1290 Super Adventure AU
1290 Super Adventure JP
1290 Super Adventure CN
1290 Super Adventure US
Art. no. 3213315en

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 GmbH 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, misprints, and other errors. The models portrayed partly contain special equip-
ment that does not belong to the regular scope of supply.
© 2015 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 assurance processes that lead
to the maximum possible quality of the products.
Issued by: TÜV Management Service
KTM Sportmotorcycle GmbH
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
S00694-10
–Remove straps and box.
S00695-10
–Remove the adhesive tape in the upper area of the motorcycle.
S00696-10
–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.
S00697-10
–Remove the controls from the transport holder.
–Remove the screws and handlebar clamps.
–Remove the transport holder.
M00791-01
–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.
S00698-10
–Position the handlebar.
–Position the handlebar clamps. Tighten the screws evenly.
Guideline
Screw, handlebar clamp M8 20 Nm
(14.8 lbf ft)
The markings of the handlebar scale are located centrally between the han-
dlebar clamps.
Markings face backwards.

2 SETUP 4
–Check the throttle grip for smooth operation.
M00792-01
–Mount and tighten the rear mirror on both sides.
S00699-10
–Mount reflector with spring washers on holding plate .
–Mount the holding plate on the license plate bracket.
–Mount the license plate holder.
–Carefully loosen and remove the tension belt over the swingarm.
Guideline
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.
–Together with an assistant, take the vehicle off the palette.
–Remove the front side cover. ( p. 7)
–Remove the tank cover. ( p. 9)
–Remove the mask spoiler. ( p. 11)
M00793-10
–Remove screws .
M00748-10
–Swing the headlight toward the front.
–Disconnect plug-in connector .
–Put down the headlight on a soft cloth.
M00794-10
–Position the headlight mask .
The screw connection points are correctly aligned to the headlight.
The holder locks onto the headlight.

2 SETUP 5
M00795-10
–Mount and tighten screws .
–Refit the headlight mask with the headlight. ( p. 14)
–Install the mask spoiler. ( p. 12)
–Install the tank cover. ( p. 10)
–Install the front side cover. ( p. 8)
M00749-10
–Position the fuel tank support ring on the left and right crash bars.
–Mount and tighten the screws  on the left and right crash bars.
–Install the crash bar. ( p. 15)
–Install the wind shield. ( p. 15)
M00750-10
–Remove the radiator shield .
–Recharge the battery. ( p. 16)
–Store the tool set below the seat.
–Remove the remaining films.
–Mount the front rider's seat. ( p. 6)
–Mount the passenger seat. ( p. 7)
–Refuel. ( p. 18)
–Print out the current PDI form found on the KTM Dealer.net and perform the pre-
delivery inspection.

3 WORK 6
3.1 Removing the front rider's seat
Preparatory work
–Remove the passenger seat. ( p. 6)
0
0
AA
M00856-10
Main work
–Lift the rider's seat back and unhook in the area.
Info
Pay attention to the seat heating cable.
M00804-10
–Disconnect plug-in connector .
3.2 Mounting the front rider's seat
M00804-10
Main work
–Connect plug-in connector .
401704-10
–Attach the recesses on the driver's seat to the fuel tank at the desired seat posi-
tion or , and push the driver's seat forward while lowering it at the rear.
Info
Ensure that the seat heating cable is correctly routed.
–Finally, check that the driver's seat is correctly mounted.
Finishing work
–Mount the passenger seat. ( p. 7)
3.3 Removing the passenger seat
M00805-10
–Insert the ignition key in seat lock and turn it clockwise.
–Raise front of the passenger seat, pull toward the tank, and remove upward.
Info
Pay attention to the seat heating cable.

3 WORK 7
M00806-10
–Disconnect plug-in connector .
–Remove the ignition key.
3.4 Mounting the passenger seat
M00806-11
–Connect plug-in connector .
401680-11
–Attach the hooks on the passenger seat to the hanger on the subframe.
Info
Ensure that the seat heating cable is correctly routed.
–Lower passenger seat and push back at the same time.
–Position locking pin in lock housing and press passenger seat forward until the
locking pin engages with an audible click.
–Check that the passenger seat is correctly mounted.
3.5 Removing the front side cover
Preparatory work
–Remove the crash bar. ( p. 15)
M00751-10
Main work
–Remove screw .
M00831-10
–Remove screw .

3 WORK 8
M00752-10
–Remove screws .
–Remove side cover .
Info
Pay attention to the cornering light cable.
M00766-10
–Unplug connector .
–Repeat the operation on the opposite side.
3.6 Installing the front side cover
M00766-11
Main work
–Plug in connector .
M00753-10
–Position the side cover in the area under the tank cover.
The holes and are adjacent to each other.
M00754-10
–Attach catch of the side cover to bracket and position on the fuel tank.
M00751-11
–Mount and tighten screw .
Guideline
Screw, cover part M5 3.5 Nm
(2.58 lbf ft)

3 WORK 9
M00831-11
–Mount and tighten screw .
Guideline
Screw, cover part M5 3.5 Nm
(2.58 lbf ft)
M00752-11
–Mount and tighten screws .
Guideline
Screw, cover part M5 3.5 Nm
(2.58 lbf ft)
–Repeat the operation on the opposite side.
Finishing work
–Install the crash bar. ( p. 15)
3.7 Removing the tank cover
Preparatory work
–Remove the passenger seat. ( p. 6)
–Remove the front rider's seat. ( p. 6)
–Remove the crash bar. ( p. 15)
–Remove the front side cover. ( p. 7)
M00757-10
Main work
–Remove screw .
–Remove screw .
M00756-10
–Remove screw .
–Remove screw .
M00755-11
–Remove screw .

3 WORK 10
M00758-01
–Raise the tank cover at the rear and remove it in a forward direction.
3.8 Installing the tank cover
S00719-10
Main work
–Position the tank cover.
Catch engages under the tank .
Info
Pay attention to the sealing lip and the bleeder hose.
M00755-10
–Mount and tighten screw .
Guideline
Screw, cover part M5 3.5 Nm
(2.58 lbf ft)
M00756-11
–Mount and tighten screw .
Guideline
Screw, cover part M5 3.5 Nm
(2.58 lbf ft)
–Mount and tighten screw .
Guideline
Screw, cover part M6 6 Nm (4.4 lbf ft)
M00757-11
–Mount and tighten screw .
Guideline
Screw, cover part M6 6 Nm (4.4 lbf ft)
–Mount and tighten screw .
Guideline
Screw, cover part M5 3.5 Nm
(2.58 lbf ft)
Finishing work
–Install the front side cover. ( p. 8)
–Install the crash bar. ( p. 15)
–Mount the front rider's seat. ( p. 6)
–Mount the passenger seat. ( p. 7)

3 WORK 11
3.9 Removing the mask spoiler
Preparatory work
–Remove the passenger seat. ( p. 6)
–Remove the front rider's seat. ( p. 6)
–Remove the crash bar. ( p. 15)
–Remove the front side cover. ( p. 7)
–Remove the tank cover. ( p. 9)
M00858-10
Main work
–Remove screw .
M00859-10
–Remove screw .
M00857-10
–Loosen holding lug from the inside cover.
M00860-01
–Remove the mask spoiler laterally from the supports.
M00764-10
–Remove catch upward from the bracket .
Info
Pay attention to the turn signal cable.

3 WORK 12
M00765-10
(1290 Super Adventure EU, 1290 Super Adventure FR, 1290 Super Adventure AU,
1290 Super Adventure JP)
–Disconnect plug-in connector .
–Remove the mask spoiler with the turn signal.
–Repeat these steps on the opposite side.
S00740-10
(1290 Super Adventure CN, 1290 Super Adventure US)
–Disconnect plug-in connector .
–Remove the mask spoiler with the turn signal.
–Repeat these steps on the opposite side.
3.10 Installing the mask spoiler
M00765-11
Main work
(1290 Super Adventure EU, 1290 Super Adventure FR, 1290 Super Adventure AU,
1290 Super Adventure JP)
–Connect plug-in connector .
S00740-11
(1290 Super Adventure CN, 1290 Super Adventure US)
–Connect plug-in connector .
M00764-11
–Position the catch in the bracket .
Info
Ensure that the turn signal cable is placed correctly.
M00861-01
–Press the mask spoiler laterally into the supports.

3 WORK 13
M00857-11
–Position holding lug in the drill hole.
M00859-11
–Mount and tighten screw .
Guideline
Screw, mask spoiler M5x17 3.5 Nm
(2.58 lbf ft)
M00858-11
–Mount and tighten screw .
Guideline
Screw, mask spoiler M5x17 3.5 Nm
(2.58 lbf ft)
–Repeat the operation on the opposite side.
Finishing work
–Install the tank cover. ( p. 10)
–Install the front side cover. ( p. 8)
–Install the crash bar. ( p. 15)
–Mount the front rider's seat. ( p. 6)
–Mount the passenger seat. ( p. 7)
3.11 Removing the bottom triple clamp cover
M00557-10
–Remove screws .
–Lower the triple clamp cover slightly.
M00558-10
–Disconnect the connector of the horn.
–Detach temperature sensor .
–Remove the triple clamp cover.

3 WORK 14
3.12 Installing the bottom triple clamp cover
M00558-11
–Connect the connector of the horn.
–Attach temperature sensor .
M00557-11
–Position the triple clamp cover .
–Mount and tighten screws .
Guideline
Remaining chassis screws M6 10 Nm (7.4 lbf ft)
3.13 Refitting the headlight mask with the headlight
M00748-11
Main work
–Connect plug-in connector of the headlight.
–Check that the lighting is functioning properly.
–Position the headlight mask.
M00767-10
–Mount and tighten screws .
Guideline
Remaining chassis screws M6 10 Nm (7.4 lbf ft)
M00768-10
–Position the windshield adapter .
–Mount and tighten screws .
Guideline
Screw, cover part M5 3.5 Nm
(2.58 lbf ft)
Finishing work
–Install the mask spoiler. ( p. 12)
–Install the tank cover. ( p. 10)
–Install the front side cover. ( p. 8)
–Install the crash bar. ( p. 15)
–Mount the front rider's seat. ( p. 6)
–Mount the passenger seat. ( p. 7)
–Install the wind shield. ( p. 15)

3 WORK 15
–Check the setting of the lighting system. ( p. 19)
3.14 Installing the wind shield
M00769-10
–Position wind shield .
–Mount and tighten screws .
Guideline
Screw, wind shield M5 3.5 Nm
(2.58 lbf ft)
3.15 Removing the crash bar
M00770-10
–Remove screw connections .
M00771-10
–Remove screws and take off the clamp halves.
–Remove screw .
–Take off the left crash bar.
M00773-10
–Remove screws and take off the clamp halves.
–Remove screw .
–Take off the right crash bar.
3.16 Installing the crash bar
M00774-10
–Position the right crash bar with the frame protector.
The fuel tank support ring should be correctly positioned on the fuel tank.
Info
Cover the components to protect them against damage.
–Mount screw , but do not tighten yet.
Guideline
Remaining chassis screws M8 25 Nm
(18.4 lbf ft)
–Mount screws , but do not tighten yet.
Guideline
Remaining chassis screws M6 10 Nm (7.4 lbf ft)

3 WORK 16
M00772-10
–Position the left crash bar with the frame protector.
The fuel tank support ring should be correctly positioned on the fuel tank.
Info
Cover the components to protect them against damage.
–Mount screw , but do not tighten yet.
Guideline
Remaining chassis screws M8 25 Nm
(18.4 lbf ft)
–Mount screws , but do not tighten yet.
Guideline
Remaining chassis screws M6 10 Nm (7.4 lbf ft)
M00770-11
–Mount and tighten fittings .
Guideline
Remaining chassis screws M6 10 Nm (7.4 lbf ft)
The crash bars are evenly 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 M8 25 Nm
(18.4 lbf ft)
3.17 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 dispose of batteries with the household waste. Dispose of a defective battery in an environmentally friendly 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.

3 WORK 17
Preparatory work
–Switch off all power consumers and switch off the engine.
–Remove the passenger seat. ( p. 6)
–Remove the front rider's seat. ( p. 6)
S00737-10
Main work
–Pull locking mechanism in the direction of the arrow.
–Fold open cover .
M00797-10
–Disconnect negative cable of the battery to avoid damage to the motorcycle's
electronics.
M00775-01
–Connect the battery charger to the battery. Switch on the battery charger.
Battery charger (58429074000)
Info
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.
Charge the battery with a maximum of 10% of the capacity specified on the
battery housing.
–Switch off the battery charger after charging and disconnect from 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
M00797-10
–Connect both negative cables with the battery.
Guideline
Screw, battery terminal M6 4.5 Nm
(3.32 lbf ft)
S00736-10
–Close cover and push down slightly.
The cover engages with an audible click.
Finishing work
–Mount the front rider's seat. ( p. 6)
–Mount the passenger seat. ( p. 7)

3 WORK 18
–Set the time and date.
3.18 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.
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.
M00798-10
–Switch off the engine.
–Open the filler cap. ( p. 18)
–Fill the fuel tank with fuel up to the lower edge of the filler neck.
Total fuel tank
capacity, approx.
30 l (7.9 US gal) Super unleaded (ROZ 95/RON 95/PON
91) ( p. 25)
–Close the filler cap. ( p. 19)
3.19 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 has been 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.