KTM 1290 SUPER ADVENTURE S 2021 Manual

SETUP INSTRUCTIONS 2021
1290 SUPER ADVENTURE S
Art. no. 3214445en

INTRODUCTION
*3214445en*
3214445en
03/2021
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 contained herein 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 produc-
tion of a particular model without prior notice. KTM accepts no liability for delivery options, deviations from fig-
ures and descriptions, misprints, and other errors. The models portrayed partly contain special equipment that
does not belong to the regular scope of supply.
© 2021 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)
KTM applies quality assurance processes that lead to the highest possible product quality as
defined in the ISO 9001 international quality management standard.
Issued by: TÜV Management Service
KTM Sportmotorcycle GmbH
Stallhofnerstraße 3
5230 Mattighofen, Austria
This document is valid for the following models:
1290 SUPER ADVENTURE S EU (F9903U4, F9903U5)
1290 SUPER ADVENTURE S JP (F9986U4)
1290 SUPER ADVENTURE S CN (F9987U4, F9987U5)

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 Transport mode
H02713-01
This vehicle was blocked for transport in the software.
To operate the vehicle, the vehicle electronics must be enabled.
This process is conducted during initial setup in KTM Dealer.net.
Enabling ensures that the initial setup in KTM Dealer.net is docu-
mented.
Enabling can be performed either temporarily, e.g. for a test ride,
or permanently for vehicle handover.
Info
Make sure that the vehicle is permanently enabled before
handing it over to the customer.
2.2 Unpacking and setting up the vehicle
F01344-10
–Remove the straps and the box.
E02426-01
–Remove the adhesive tape in the upper area of the motorcycle.
E02427-01
–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.

2 SETUP
4
E02428-01
–Remove the handbrake pump from the transport holder.
–Remove the screws and handlebar clamps.
–Remove the transport holder.
E02429-10
–Position the handbrake pump. Tighten the screws.
Guideline
Anti-rotation lock Aengages in the right switch unit.
Screw, brake assem-
bly
M6 5 Nm (3.7 lbf ft)
E02430-10
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
M8x25 20 Nm (14.8 lbf ft)
Markings Bface backward.
Handlebar scale markings Care located centrally
between the handlebar clamps.
–Check the throttle grip for smooth operation.

SETUP 2
5
E02431-10
–Position the cable for the right-hand controls and secure with
cable ties.
–Attach the clutch line to the holder.
E02432-01
–Preassemble the hand guards with screws and bushings.
E02433-10
–Position the right hand guard.
–Mount and tighten the rear mirror.
–Tighten screw 1.
Guideline
Screw, handle bar
end hand guard
M8x40 25 Nm (18.4 lbf ft)
–Repeat these steps on the opposite side.
–Carefully loosen and remove the tension belt from the rear
wheel spindle.
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 pallet.

2 SETUP
6
E02434-10
–Mount damping rubbers 2, rubber grommets 3and speed
nuts 4on the engine guard.
–Mount spacers 5.
Guideline
The spacer collar is facing inward.
E02437-10
–Mount rubber grommets 6and spacers on the lower fuel tank
covers.
Guideline
The spacer collar is facing inward.
E02436-10
–Position holder 7.
Guideline
The ridge is facing outwards.
–Mount and tighten screws 8.
Guideline
Remaining engine
screws
M6 10 Nm (7.4 lbf ft)
–Install the engine guard. ( p. 8)
E02435-10
–Mount rubber grommets 9on the windshield.
–Install the windshield. ( p. 8)
–Remove the RACE ON key and the RACE ON chip from the
storage compartment and keep in a safe place for the han-
dover.

SETUP 2
7
E02438-10
–Remove the rear right side cover. ( p. 8)
–Pull catch bk on the seat release.
The seat is unlocked.
–Install the rear right side cover. ( p. 8)
–Charge the 12-V battery. ( p. 10)
–Remove the remaining films.
–Unpack and mount the KTM PowerParts included in the deliv-
ery (optional).
Info
Read the accompanying KTM PowerParts fitting instruc-
tions.
–Attach the stickers included in the scope of supply (optional).
–Check the headlight setting. ( p. 16)
–Turn the knurled screws on both fuel petcocks counterclock-
wise as far as possible.
–Refuel. ( p. 20)
–Prepare the vehicle according to the specifications in
KTM Dealer.net for handover to the customer.

3 WORK
8
3.1 Installing the windshield
E02252-11
–Position windshield 1.
–Mount and tighten screws 2with the rubber bushings.
Guideline
Screw, windshield M5x14 3.5 Nm
(2.58 lbf ft)
3.2 Removing the rear right side cover
Preparatory work
–Remove the passenger seat. ( p. 9)
–Remove the front rider's seat. ( p. 9)
E02423-10
Main work
–Take off cover 1in area Aand B.
–Take off the cover.
3.3 Installing the rear right side cover
E02425-10
–Position cover 1and attach it in areas A,B,Cand D.
The cover engages with an audible click.
3.4 Installing the engine guard
E02254-11
–Position engine guard 1, mount screws 2with bushings
and tighten.
Guideline
Screw, engine guard M6 10 Nm (7.4 lbf ft)

WORK 3
9
3.5 Removing the passenger seat
Condition
The motorcycle is stationary.
The engine is off.
The ignition has been switched on or off for less than 1 minute.
E02246-10
–Press seat release button 1.
–Raise the front of the passenger seat, pull it toward the fuel
tank and take off from above.
3.6 Mounting the passenger seat
401680-11
–Attach the hooks on the passenger seat 1to the hanger on
the subframe.
Info
Ensure that the seat heating cable is correctly routed.
–Lower the front of the passenger seat and push it toward the
rear at the same time.
–Position locking pin 2in the lock housing and press the pas-
senger seat forward until the locking pin engages with an audi-
ble click.
–Check that the passenger seat is mounted correctly.
3.7 Removing the front rider's seat
Preparatory work
–Remove the passenger seat. ( p. 9)
M00856-10
Main work
–Lift the rider's seat back and unhook in the Aarea.

3 WORK
10
3.8 Mounting the front rider's seat
401704-10
Main work
–Attach the recesses on the front rider's seat to the fuel tank at
the desired seat position Aor B, and push the front rider's
seat forward while lowering it at the rear.
–Finally, check that the front rider's seat is correctly mounted.
Finishing work
–Mount the passenger seat. ( p. 9)
3.9 Charging the 12-V battery
Warning
Risk of injury Battery acid and battery gases cause serious chemical burns.
–Keep 12 V 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 12 V battery.
–Only charge 12 V 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.
Note
Environmental hazard 12 V batteries contain environmentally hazardous materials.
–Do not dispose of 12 V batteries as household waste.
–Dispose of 12 V batteries at a collection point for used batteries.
Note
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 12-V battery, it discharges steadily each day.
The charging level and the method of charging are very important for the service life of the 12-V 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 12-V battery will be
destroyed.
If the 12-V battery is depleted from starting the vehicle repeatedly, the battery must be charged immedi-
ately.
If the 12-V battery is left in a discharged state for an extended period, it will become deeply discharged
and sulfating occurs, destroying the battery.
The 12-V battery is maintenance-free, i.e. the acid level does not have to be checked.

WORK 3
11
Preparatory work
–Remove the passenger seat. ( p. 9)
–Remove the front rider's seat. ( p. 9)
–Disconnect the negative cable of the 12-V battery. ( p. 13)
311910-10
Main work
–Connect a battery charger to the 12-V battery. Adjust the bat-
tery charger.
EU battery charger XCharge‑professional (00029095050)
Alternative 1
US battery charger XCharge‑professional
(00029095051)
Alternative 2
UK battery charger XCharge‑professional
(00029095052)
Info
Follow the instructions of the charger and the manual.
–Disconnect the battery charger after charging the 12-V battery.
Guideline
The charging current, charging voltage, and charging time
must not be exceeded.
Recharge the 12-V battery
regularly when the motorcy-
cle is not being used
3 months
Finishing work
–Connect the negative cable of the 12-V battery. ( p. 14)
–Mount the front rider's seat. ( p. 10)
–Mount the passenger seat. ( p. 9)
–Set time and date.
3.10 Removing the 12 V battery
Warning
Risk of injury Battery acid and battery gases cause serious chemical burns.
–Keep 12 V 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 12 V battery.
–Only charge 12 V 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.

3 WORK
12
Caution
Danger of accidents Electronic components and safety devices will be damaged if the 12-V battery is dis-
charged or missing.
If the 12-V battery is discharged or defective, malfunctions in the vehicle electronics can occur, espe-
cially when starting.
–Never operate the vehicle with a discharged 12-V battery or without a 12-V battery.
Preparatory work
–Remove the passenger seat. ( p. 9)
–Remove the front rider's seat. ( p. 9)
E02231-10
Main work
–Detach battery retainer rubber 1.
–Remove positive terminal cover 2.
E02232-10
–Disconnect negative cable 3from the 12 V battery.
–Disconnect positive cable 4from the 12-V battery.
–Take the 12-V battery out of the battery compartment.
3.11 Installing the 12-V battery
Warning
Risk of injury Battery acid and battery gases cause serious chemical burns.
–Keep 12 V 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 12 V battery.
–Only charge 12 V 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 12-V battery is dis-
charged or missing.
If the 12-V battery is discharged or defective, malfunctions in the vehicle electronics can occur, espe-
cially when starting.
–Never operate the vehicle with a discharged 12-V battery or without a 12-V battery.

WORK 3
13
E02232-11
Main work
–Position the 12-V battery in the battery compartment.
–Position positive cable 1and mount and tighten the screw.
Guideline
Screw, battery termi-
nal
M6x12 4.5 Nm
(3.32 lbf ft)
–Position negative cable 2and mount and tighten the screw.
Guideline
Screw, battery termi-
nal
M6x12 4.5 Nm
(3.32 lbf ft)
E02231-11
–Mount positive terminal cover 3.
–Attach battery retainer rubber 4.
Finishing work
–Mount the front rider's seat. ( p. 10)
–Mount the passenger seat. ( p. 9)
–Set time and date. ( p. 15)
3.12 Disconnecting the negative cable of the 12-V battery
Warning
Risk of injury Battery acid and battery gases cause serious chemical burns.
–Keep 12 V 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 12 V battery.
–Only charge 12 V 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 12-V battery is dis-
charged or missing.
If the 12-V battery is discharged or defective, malfunctions in the vehicle electronics can occur, espe-
cially when starting.
–Never operate the vehicle with a discharged 12-V battery or without a 12-V battery.
Preparatory work
–Remove the passenger seat. ( p. 9)
–Remove the front rider's seat. ( p. 9)

3 WORK
14
E02231-13
Main work
–Disconnect negative cable 1of the 12-V battery.
3.13 Connecting the negative cable of the 12-V battery
Warning
Risk of injury Battery acid and battery gases cause serious chemical burns.
–Keep 12 V 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 12 V battery.
–Only charge 12 V 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 12-V battery is dis-
charged or missing.
If the 12-V battery is discharged or defective, malfunctions in the vehicle electronics can occur, espe-
cially when starting.
–Never operate the vehicle with a discharged 12-V battery or without a 12-V battery.
E02231-13
Main work
–Position negative cable 1and mount and tighten the screw.
Guideline
Screw, battery termi-
nal
M6x12 4.5 Nm
(3.32 lbf ft)
Finishing work
–Mount the front rider's seat. ( p. 10)
–Mount the passenger seat. ( p. 9)
–Set time and date.

WORK 3
15
3.14 Setting the time and date
Condition
The motorcycle is stationary.
E02192-01
–Press the SET button or RIGHT button when the menu is closed.
–Press the UP button or DOWN button until Settings is marked.
–Press the RIGHT or SET button to open the menu.
–Press the UP button or DOWN button until Clock & Date is
marked.
–Press the SET button to open the menu.
E02193-01
Setting the clock
–Press the UP or DOWN button until Set Clock is marked.
–Press the SET button to open the menu.
–Press the UP or DOWN button until Hours is marked.
–Press the RIGHT or LEFT button until the current hour is set.
–Press the UP or DOWN button until Minutes is marked.
–Press the RIGHT or LEFT button until the current minute is
set.
–Press the BACK button to exit the menu.
The time is stored.

3 WORK
16
E02194-01
Setting the date
–Press the UP or DOWN button until Set Date is marked.
–Press the SET button to open the menu.
–Press the UP or DOWN button until Day is marked.
–Press the RIGHT or LEFT button until the current day is set.
–Press the UP or DOWN button until Month is marked.
–Press the RIGHT or LEFT button until the current month is
set.
–Press the UP or DOWN button until Year is marked.
–Press the RIGHT or LEFT button until the current year is set.
–Press the BACK button to exit the menu.
The date is stored.
3.15 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 now mounts the motorcycle with luggage and passen-
ger if applicable.
–Check the headlight setting.
The light-dark boundary must be exactly on the lower mark-
ing when the motorcycle is ready to be operated 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. 17)

WORK 3
17
3.16 Adjusting the headlight range
Preparatory work
–Check the headlight setting. ( p. 16)
F00892-10
Main work
–Turn adjusting wheel 1to adjust the headlight range.
Info
Turn counterclockwise to increase the headlight range;
turn clockwise 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 lower mark-
ing Bwhen the motorcycle is ready to operate with the
rider mounted along with any luggage and a passenger if
applicable.
3.17 Starting
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
–Always make sure there is sufficient ventilation when running the engine.
–Use effective exhaust extraction when starting or running the engine in an enclosed space.
Caution
Danger of accidents Electronic components and safety devices will be damaged if the 12-V battery is dis-
charged or missing.
If the 12-V battery is discharged or defective, malfunctions in the vehicle electronics can occur, espe-
cially when starting.
–Never operate the vehicle with a discharged 12-V battery or without a 12-V battery.
Note
Engine damage High revving speed with a cold engine negatively impacts the lifespan of the engine.
–Always run the engine warm at a low speed.
E02245-01
–Take the motorcycle off the side stand and sit on the motorcy-
cle.
–Bring the RACE ON key within range of the antenna.
Info
If the anti-relay attack mode is activated, the button
on the RACE ON key must be pressed for the RACE ON
key to send a response signal.
–Ensure that the RACE ON key stays in range while riding.

3 WORK
18
Guideline
Maximum range of the RACE
ON key around the antenna
1.5 m (4.9 ft)
Info
The range may be reduced by decreases in RACE ON
key battery voltage and by interfering radio waves.
If the battery voltage of the RACE ON key is too low,
one of the ignition keys must be held in the area of
the antenna and must be safely stored again after start-
ing.
–Make sure that the start button/emergency OFF switch is in the
middle position .
–Switch on ignition; to do this, briefly press the RACE-ON but-
ton (maximum of 1 second).
The steering is unlocked.
The function check of the combination instrument is run.
The ABS warning lamp goes out when starting off.
Tip
If the handlebar does not unlock, move the handlebar
slightly.
–Shift the transmission into neutral .
The green idle indicator lamp lights up.
E02220-01
–Press the start button/emergency OFF switch into the lower
position .
Info
Only press the start button/emergency OFF switch into
the lower position when the combination instrument
function control has been completed.
Do not open the throttle to start.
Press the start button/emergency OFF switch into the
lower position for a maximum of five seconds. Wait
for a least 5 seconds before trying again.
This motorcycle is equipped with a safety starting sys-
tem. You can only start the engine if the transmission
is in neutral or if the clutch lever is pulled when a gear
is engaged. If the side stand is folded out and you shift
into gear, the engine stops.