KTM 1290 Super Adventure User manual

SETUP INSTRUCTIONS 2021
1290 SUPER ADVENTURE R
Art. no. 3214446en

INTRODUCTION
*3214446en*
3214446en
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 R EU (F9903U6, F9903U7)
1290 SUPER ADVENTURE R JP (F9986U7)
1290 SUPER ADVENTURE R CN (F9987U7)

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.
E02439-10
–Remove the adhesive tape in the upper area of the motorcycle.
E02440-01
–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
E02441-01
–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)
E02442-10
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 cables 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
E02444-10
–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)

SETUP 2
7
E02445-10
–Position holder 9.
–Mount and tighten screw bk.
–Install the engine guard. ( p. 10)
E02447-10
–Mount rubber grommets bl on the windshield.
–Install the windshield. ( p. 9)
–Install the crash bar. ( 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.
E02446-10
–Remove the rear right side cover. ( p. 9)
–Pull catch bm on the seat release.
The seat is unlocked.
–Install the rear right side cover. ( p. 9)
–Charge the 12-V battery. ( p. 11)
–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 crash bar
E02352-11
–Position the left crash bar with the frame protector.
Info
Cover the components to protect them against damage.
–Mount screw 1, but do not tighten yet.
Guideline
Remaining screws,
chassis
M8 25 Nm (18.4 lbf ft)
–Position clamps and mount screw 2, but do not tighten yet.
Guideline
Remaining screws,
chassis
M6 10 Nm (7.4 lbf ft)
E02351-11
–Position the right crash bar with the frame protector.
Info
Cover the components to protect them against damage.
–Mount screw 3, but do not tighten yet.
Guideline
Remaining screws,
chassis
M8 25 Nm (18.4 lbf ft)
–Position clamps and mount screw 4, but do not tighten yet.
Guideline
Remaining screws,
chassis
M6 10 Nm (7.4 lbf ft)
E02350-11
–Mount and tighten fittings 5.
Guideline
Remaining screws,
chassis
M6 10 Nm (7.4 lbf ft)
The crash bars are equally aligned with each other.
–Tighten all the screws of the crash bar.
Guideline
Remaining screws,
chassis
M6 10 Nm (7.4 lbf ft)
Remaining screws,
chassis
M8 25 Nm (18.4 lbf ft)