KTM 1290 Super Duke GT Series Manual

SETUP INSTRUCTIONS 2016
1290 Super Duke GT
Art. no. 3213506en

INTRODUCTION 1
*3213506en*
3213506en
03/2016
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.
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, devi-
ations from illustrations and descriptions, misprints, and other errors. The models portrayed partly contain special equipment that does not
belong to the regular scope of supply.
© 2016 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
This document is valid for the following models:
1290 Super Duke GT EU (F9903P3, F9903PF)
1290 Super Duke GT AU (F9960P3, F9960PF)
1290 Super Duke GT JP (F9986P3, F9986PF)
1290 Super Duke GT US (F9975P3, F9975PF)

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.
Underlined terms Refer to technical details of the vehicle or indicate technical terms, which are explained
in the glossary.

2 SETUP 3
2.1 Unpacking and setting up the vehicle
Preparatory work
–Remove the box.
S01182-01
Main work
–Remove the adhesive tape in the upper area of the motorcycle.
S01183-01
–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 finished work on the vehicle.
–Remove the separate enclosure and unpack it. Check the separate enclosure for
completeness.
–Check the vehicle for transport damage.
S01184-01
–Remove the controls from the transport holder. Remove the screws of the handlebar
clamp. Take off the handlebar clamp and transport holder.
S01185-10
–Remove right-hand handlebar weight .
–Position the controls on the right half of the handlebar but do not tighten yet.
E00283-10
Warning
Danger of accidents Handlebar breakage.
–If the handlebar is bent or straightened it will cause material fatigue,
and the handlebar can break. Always replace handlebar.
–Position the handlebar.
Info
Make sure the cables and wiring are positioned correctly.
–Position the handlebar clamp. Mount screws but do not tighten yet.
Marking on the handlebar scale is aligned with the top edge of the handle-
bar clamp.
Center line on the handlebar scale is aligned with the center of the handle-
bar clamp.
–First bolt the handlebar support with screws onto the longer, higher side of the
handlebar supports so that both parts touch.

2 SETUP 4
–Tighten screws evenly.
Guideline
Screw, handlebar clamp M8 20 Nm
(14.8 lbf ft)
S01186-10
–Tighten screws and of the controls.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
Screw, combination switch, right M5 3.5 Nm
(2.58 lbf ft)
–Mount right handlebar weight, tighten screw.
Guideline
Screw, handlebar weight M6 10 Nm (7.4 lbf ft)
–Check the throttle grip for smooth operation.
E00278-01
–Mount and tighten the rear mirror on both sides.
E00279-10
–Position windshield .
–Mount and tighten screws .
Guideline
Screw, windshield M5 3.5 Nm
(2.58 lbf ft)
E00277-01
–Tape on the protective plastic sheet for the swingarm.
–Remove the cable ties of the rider footrests.
E00281-10
–Mount splash protector with screws on license plate holder .
Guideline
Remaining screws, chassis EJOT PT®K50x12 1 Nm (0.7 lbf ft)

2 SETUP 5
E00282-10
(1290 Super Duke GT US)
–Bond the reflectors on the right and left side of the reflector holder.
–Mount the reflector holder on license plate holder .
Guideline
Remaining screws, chassis M6 10 Nm
(7.4 lbf ft)
E00273-01
–Remove the passenger seat. ( p. 7)
–Remove spare key and KEYCODECARD and keep in a safe place for the handover.
–Secure the tool set with the rubber holder.
E00274-01
–Carefully loosen and remove the tension belt from the frame.
Info
An assistant prevents the motorcycle from falling over.
–Carefully loosen and remove the tension belts around the fork legs.
The vehicle is released at the front.
–Together with an assistant, take the vehicle off the palette.
–Remove the radiator shield.
S01188-10
–Position the front spoiler. Mount and tighten screws  with the washers.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
S01189-10
–Position metal sheets on the left and right. Mount and tighten screws .
Guideline
Remaining screws, chassis M5 5 Nm (3.7 lbf ft)
E00280-10
–Remove the front rider's seat. ( p. 7)
–Plug in the connector of starter relay .
(1290 Super Duke GT US)
–Mount the side cases.
Info
Observe the accompanying fitting instructions.
–Recharge the battery. ( p. 8)
–Remove the protective plastic.
–Refuel. ( p. 10)

2 SETUP 6
–Prepare the vehicle according to the specifications in the KTM Dealer.net for han-
dover to the customer.

3 WORK 7
3.1 Removing the passenger seat
S01106-10
–Insert the ignition key in seat lock and turn it clockwise.
–Raise front of the passenger seat, pull toward the tank, and remove upward.
–Remove the ignition key.
3.2 Mounting the passenger seat
402652-10
–Attach the hooks on the passenger seat to seat mounts .
–Lower the passenger seat and push back.
–Position locking pin in the lock housing and push down the passenger seat at
the front.
The locking pin engages with an audible click.
–Check that the passenger seat is correctly mounted.
3.3 Removing the front rider's seat
Preparatory work
–Remove the passenger seat. ( p. 7)
S01104-10
Main work
–Press seat release in the direction of the arrow and lift the front rider's seat at
the rear at the same time.
–Detach the front of the front rider's seat and remove it.
3.4 Mounting the front rider's seat
401921-10
Main work
–Attach recesses on the front rider's seat to the fuel tank, push the front rider's
seat forward.
–Position locking pin in the lock housing and push down the front rider's seat at
the rear.
The locking pin engages with an audible click.
–Check that the front rider's seat is correctly mounted.
Finishing work
–Mount the passenger seat. ( p. 7)

3 WORK 8
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 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 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 sulfated, 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 passenger seat. ( p. 7)
–Remove the front rider's seat. ( p. 7)
–Disconnect the negative cable of the battery. ( p. 9)
311910-10
Main work
–Connect the battery charger to the battery. Switch on the battery charger.
Battery charger XCharge-professional EU (00029095050)
Battery charger XCharge-professional US (00029095051)
Battery charger XCharge-professional GB (00029095052)
Battery charger XCharge-professional CH (00029095053)
Info
Follow the charger's instructions exactly.
–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
Finishing work
–Connect the negative cable of the battery. ( p. 9)
–Mount the front rider's seat. ( p. 7)
–Mount the passenger seat. ( p. 7)
–Set the time and date.