KTM 1290 Super Duke R 2016 Manual

SETUP INSTRUCTIONS 2016
1290 Super Duke R
Art. no. 3213441en

INTRODUCTION 1
*3213441en*
3213441en
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 R EU (F9903P9, F9903P2)
1290 Super Duke R Special Edition EU (F9903P0)
1290 Super Duke R FR (F9923P9, F9923P2)
1290 Super Duke R AU (F9960P9, F9960P2)
1290 Super Duke R Special Edition AU (F9960P0)
1290 Super Duke R US (F9975P9, F9975P2)
1290 Super Duke R Special Edition US (F9975P0)
1290 Super Duke R CN (F9987P9)

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.
L01494-01
Main work
–Remove the adhesive tape in the upper area of the motorcycle.
L01495-01
–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.
L01496-01
–Remove the controls from the transport holder. Remove the screws of the handlebar
clamp. Take off the handlebar clamp and transport holder.
L01497-01
–Remove the right-hand handlebar weight.
–Position the controls on the right half of the handlebar but do not tighten yet.
L01499-10
–Position the handlebar.
The markings of the handlebar scale are located centrally between the handle-
bar clamp.
–Position the handlebar clamp. Mount and tighten the screws evenly.
Guideline
Screw, handlebar clamp M8 20 Nm
(14.8 lbf ft)

2 SETUP 4
L01506-01
–Tighten the controls on the right half of the handlebar.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
Screw, combination switch, right M5 3.5 Nm
(2.58 lbf ft)
(Super Duke R Special Edition)
–Remove the mounted clutch and brake levers.
V00184-01
–Unpack and mount the KTM PowerParts levers included in the delivery.
V00185-10
–Mount the clutch and brake lever protection.
–Check the throttle grip for smooth operation.
V00186-01
–Mount and tighten the rear mirror on both sides.

2 SETUP 5
L01502-01
–Tape on the protective plastic sheet for the swingarm.
–Remove the cable ties of the rider footrests.
V00187-01
(Super Duke R Special Edition)
–Take off the mounted clutch reservoir and brake fluid reservoir lids.
–Unpack and mount the KTM PowerParts lids included in the delivery.
E00143-01
–Take off the mounted foot brake cylinder lid.
–Unpack and mount the KTM PowerParts lid included in the delivery.
V00188-01
–Mount the clutch and alternator cover protection.
Guideline
Screw, clutch cover M6 10 Nm
(7.4 lbf ft)
Remaining screws, engine M6 10 Nm
(7.4 lbf ft)
L01501-10
–Mount splash protector with screws on license plate holder .
Guideline
Remaining screws, chassis EJOT PT®K50x12 1 Nm (0.7 lbf ft)

2 SETUP 6
L01500-10
–Mount reflector with spring washers on holding plate .
–Mount holding plate on license plate bracket .
(EU/AU/FR)
–Mount license plate bracket on license plate holder .
(US/CN)
–Bond the reflectors on the right and left side of the reflector holder.
–Mount the reflector holder and license plate bracket on license plate
holder .
L01507-01
(EU/AU/FR)
–Remove the passenger seat. ( p. 7)
–Secure the tool set with the rubber holder.
L01505-01
–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.
L01508-10
–Remove the front rider's seat. ( p. 7)
–Remove screw .
–Lift cover at the rear and pull toward the rear.
–Fold up the cover.
–Plug in the connector of starter relay .
–Recharge the battery. ( p. 9)
–Remove the protective plastic.
–Refuel. ( p. 10)
–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
L01428-10
–Insert the ignition key in seat lock and turn it clockwise.
–Lift the passenger seat at the front and pull it out of the holder toward the front.
–Remove the passenger seat.
–Remove the ignition key.
3.2 Mounting the passenger seat
401922-10
–Attach the recesses of the passenger seat in the guides and lower at the front
while pushing it 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)
B02310-10
Main work
–Raise the rear of the front rider's seat.
–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 and push the front rid-
er's seat forward while lowering it.
Catch is located in the recess.
–Check that the front rider's seat is correctly mounted.
Finishing work
–Mount the passenger seat. ( p. 7)

3 WORK 8
3.5 Removing 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.
Caution
Danger of accidents If the vehicle is operated with a discharged battery or without a battery, electronic components and safety
equipment may be damaged.
–Never operate the vehicle with a discharged battery or without a battery.
Preparatory work
–Switch off all power consumers and switch off the engine.
–Remove the passenger seat. ( p. 7)
–Remove the front rider's seat. ( p. 7)
L01482-10
Main work
–Remove screw .
–Lift cover at the rear and pull toward the rear.
–Fold up the cover.
L01483-10
–Disconnect negative cable of the battery.
–Remove positive terminal cover and disconnect the positive cable from the bat-
tery.
–Take the battery out of the battery compartment.
3.6 Installing 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.
Caution
Danger of accidents If the vehicle is operated with a discharged battery or without a battery, electronic components and safety
equipment may be damaged.
–Never operate the vehicle with a discharged battery or without a battery.

3 WORK 9
L01484-10
Main work
–Fold up cover .
–Place battery in the battery compartment.
L01483-11
–Position the positive cable and mount and tighten the screw.
Guideline
Screw, battery terminal M6 4.5 Nm
(3.32 lbf ft)
–Mount positive terminal cover .
–Position negative cable and mount and tighten the screw.
Guideline
Screw, battery terminal M6 4.5 Nm
(3.32 lbf ft)
L01486-10
–Position cover .
Screw heads engage in recesses .
–Mount and tighten screw .
Finishing work
–Mount the front rider's seat. ( p. 7)
–Mount the passenger seat. ( p. 7)
–Set the time and date.
3.7 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.

3 WORK 10
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 all power consumers and switch off the engine.
–Remove the passenger seat. ( p. 7)
–Remove the front rider's seat. ( p. 7)
–Remove the battery. ( p. 8)
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
–Install the battery. ( p. 8)
–Mount the front rider's seat. ( p. 7)
–Mount the passenger seat. ( p. 7)
–Set the time and date.
3.8 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.

3 WORK 11
–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.
L01422-10
–Switch off the engine.
–Open the filler cap. ( p. 11)
–Fill the fuel tank with fuel up to the lower edge of the filler neck.
Total fuel tank
capacity, approx.
18 l (4.8 US gal) Super unleaded (ROZ 95/RON 95/PON
91) ( p. 15)
–Close the filler cap. ( p. 12)
3.9 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.
L01418-10
–Lift cover of the filler cap and insert ignition key in the fuel tank lock.
L01419-10
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 clockwise.
–Fold open filler cap .

3 WORK 12
3.10 Closing the filler cap
L01420-10
–Fold down filler cap .
–Turn ignition key clockwise.
L01421-10
–Press down the filler cap and turn back ignition key until 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 and close cover .
3.11 "Clock/Date"
401990-01
Condition
• The vehicle is stationary.
–Press the UP or DOWN button until the "Settings" menu appears on the matrix dis-
play. Pressing the SET button opens the menu.
–Press the UP or DOWN button until "Clock/Date" is highlighted in black on the matrix
display. Pressing the SET button again opens the menu.
–Use the UP or DOWN button to navigate through the menu. Use the SET button to
set the time and date.
If the battery was disconnected, the time and date must be set in the matrix display.

4 TECHNICAL DATA 13
4.1 chassis tightening torques
Remaining screws, chassis EJOT PT®K50x12 1 Nm (0.7 lbf ft) –
Remaining screws, chassis EJOT PT®K50x14 1 Nm (0.7 lbf ft) –
Remaining screws, chassis EJOT PT®K50x16 2 Nm (1.5 lbf ft) –
Remaining screws, chassis EJOT PT®K50x18 2 Nm (1.5 lbf ft) –
Screw, fuel tank cover, quick connect
nipple
EJOT PT®K60 2 Nm (1.5 lbf ft) –
Screw, tail light EJOT PT®K50x14 2.5 Nm (1.84 lbf ft) –
Screw, combination switch, left M4 2.5 Nm (1.84 lbf ft) –
Screw, side stand switch M4 2 Nm (1.5 lbf ft) –
Remaining nuts, chassis M5 5 Nm (3.7 lbf ft) –
Remaining screws, chassis M5 5 Nm (3.7 lbf ft) –
Screw, cable channel M5 5 Nm (3.7 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 3 Nm (2.2 lbf ft) –
Screw, fuel level indicator M5 3 Nm (2.2 lbf ft) –
Screw, shock absorber adjusting ring M5 5 Nm (3.7 lbf ft) –
Ground fitting on frame M6 10 Nm (7.4 lbf ft) –
Nut, ABS unit attachment M6 5 Nm (3.7 lbf ft) –
Nut, cable on starter motor M6 4 Nm (3 lbf ft) –
Remaining nuts, chassis M6 10 Nm (7.4 lbf ft) –
Remaining screws, chassis M6 10 Nm (7.4 lbf ft) –
Screw, ball joint of push rod on foot
brake cylinder
M6 5 Nm (3.7 lbf ft) Loctite®243™
Screw, battery terminal M6 4.5 Nm (3.32 lbf ft) –
Screw, clutch assembly M6 5 Nm (3.7 lbf ft) Loctite®243™
Screw, connecting piece, rear brake
line
M6 10 Nm (7.4 lbf ft) Loctite®243™
Screw, cooler retaining bracket M6 7 Nm (5.2 lbf ft) –
Screw, exhaust clamp on main silencer M6 8 Nm (5.9 lbf ft) –
Screw, exhaust clamp on manifold M6 8 Nm (5.9 lbf ft) –
Screw, foot brake cylinder M6 10 Nm (7.4 lbf ft) Loctite®243™
Screw, fuel pump M6 6 Nm (4.4 lbf ft) –
Screw, headlight mask, rear wall M6 5 Nm (3.7 lbf ft) –
Screw, license plate holder on lower
rear panel
M6 12 Nm (8.9 lbf ft) –
Screw, radiator hose clamp M6 3 Nm (2.2 lbf ft) –
Screw, sensor box M6 6 Nm (4.4 lbf ft) Loctite®243™
Screw, shift lever stub M6 10 Nm (7.4 lbf ft) Loctite®243™
Screw, shift rod M6 5 Nm (3.7 lbf ft) Loctite®243™
Screw, shift shaft deflector on shift
shaft
M6 18 Nm (13.3 lbf ft) Loctite®243™
Screw, side stand stub M6 6 Nm (4.4 lbf ft) Loctite®243™
Screw, steering damper, holder, on
frame
M6 8 Nm (5.9 lbf ft) Loctite®243™
Screw, step plate for foot brake lever M6 10 Nm (7.4 lbf ft) Loctite®243™
Screw, wheel speed sensor, front M6 4 Nm (3 lbf ft) –
Screw, wheel speed sensor, rear M6 4 Nm (3 lbf ft) –
Nut, manifold on cylinder head M8 Tightening sequence:
Tighten the nuts evenly. Do
not warp the metal plate.
25 Nm (18.4 lbf ft)
–

4 TECHNICAL DATA 14
Nut, rear sprocket M8 36 Nm (26.6 lbf ft) –
Nut, shift rod M8 12 Nm (8.9 lbf ft) –
Nut, shift rod M8LH 12 Nm (8.9 lbf ft) –
Nut, valve, angled M8 4 Nm (3 lbf ft) –
Remaining nuts, chassis M8 25 Nm (18.4 lbf ft) –
Remaining screws, chassis M8 25 Nm (18.4 lbf ft) –
Screw, axle clamp M8 15 Nm (11.1 lbf ft) –
Screw, bottom triple clamp M8 12 Nm (8.9 lbf ft) –
Screw, foot brake lever M8 20 Nm (14.8 lbf ft) Loctite®243™
Screw, front brake disc M8 30 Nm (22.1 lbf ft) Loctite®2701™
Screw, front rider 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) –
Screw, rear brake caliper M8 25 Nm (18.4 lbf ft) Loctite®2701™
Screw, rear brake disc M8 30 Nm (22.1 lbf ft) Loctite®243™
Screw, shift lever on footrest bracket M8 20 Nm (14.8 lbf ft) Loctite®243™
Screw, shift shaft deflector on frame M8 10 Nm (7.4 lbf ft) Loctite®243™
Screw, side stand bracket M8 25 Nm (18.4 lbf ft) Loctite®243™
Screw, side stand spring M8 15 Nm (11.1 lbf ft) Loctite®2701™
Screw, steering damper on holder M8 8 Nm (5.9 lbf ft) Loctite®243™
Screw, steering damper on triple clamp M8 8 Nm (5.9 lbf ft) Loctite®243™
Screw, top triple clamp M8 15 Nm (11.1 lbf ft) –
Remaining nuts, chassis M10 45 Nm (33.2 lbf ft) –
Remaining screws, chassis M10 45 Nm (33.2 lbf ft) –
Screw, engine bearer M10 45 Nm (33.2 lbf ft) Loctite®243™
Screw, front brake caliper M10 45 Nm (33.2 lbf ft) Loctite®243™
Screw, instrument 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™
Screw, side stand retaining plate M10 45 Nm (33.2 lbf ft) Loctite®243™
Banjo bolt, brake line M10x1 25 Nm (18.4 lbf ft) –
Banjo bolt, brake line, connecting
piece, rear
M10x1 15 Nm (11.1 lbf ft) –
Nut, rear hub shock absorber carrier 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
Screw, eccentric M16 70 Nm (51.6 lbf ft) –
Nut, swingarm pivot M19x1.5 130 Nm (95.9 lbf ft) Thread greased
Nut, seat lock M22x1.5 6 Nm (4.4 lbf ft) –
Screw, steering head, top M22x1.5 50 Nm (36.9 lbf ft) –
Bolt, front axle M25x1.5 45 Nm (33.2 lbf ft) Thread greased
Nut, steering head M28x1.0 Step 1
10 Nm (7.4 lbf ft)
Step 2 (loosen, counter-
clockwise)
60°
–
Nut, rear axle, shock absorber side M35x1.5 200 Nm (147.5 lbf ft) Loctite®262™/lock the lock-
ing wire with locking varnish
Nut, rear axle M50x1.5 250 Nm (184.4 lbf ft) Thread greased/lock locking
wire with locking varnish

5 SUBSTANCES 15
Super unleaded (ROZ 95/RON 95/PON 91)
Standard/classification
–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).

*3213441en*
3213441en
03/2016
KTM Sportmotorcycle GmbH
5230 Mattighofen/Austria
http://www.ktm.com
Photo: Mitterbauer/KTM