KTM 1290 Super Duke R 2018 Manual

SETUP INSTRUCTIONS 2018
1290 Super Duke R
Art. no. 3213804en

INTRODUCTION
*3213804en*
3213804en
10/2017
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 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, deviations from figures and descriptions,
misprints, and other errors. The models portrayed partly contain special equipment that does not belong to the
regular scope of supply.
© 2017 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 assur-
ance processes that lead to the maximum possible quality of the products.
Issued by: TÜV Management Service
KTM Sportmotorcycle GmbH
Stallhofnerstraße 3
5230 Mattighofen, Austria
This document is valid for the following models:
1290 Super Duke R EU (F9903R9, F9903R2)
1290 Super Duke R JP (F9986R2)
1290 Super Duke R US (F9975R9, F9975R2)

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 Unpacking and setting up the vehicle
Preparatory work
–Remove the box.
S01841-10
Main work
–Remove the adhesive tape in the upper area of the motorcycle.
S01842-10
–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 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.
S01843-10
–Remove cable tie(s) 1.
–Remove screws 2and 3.
–Take off the controls from the transport holder.
S01844-10
–Disconnect connector 4.
–Remove screw 5.
–Take off the combination instrument support from the trans-
port holder.
S01845-10
–Remove the handlebar clamp screws 6.
–Take off the handlebar clamp and transport holder.
–Remove packaging on the right turn signal.

2 SETUP
4
S01846-10
–Position the handlebar.
The markings of the handlebar scale are located centrally
between the handlebar clamp.
–Position the handlebar clamp. Mount and tighten the screws
evenly.
Guideline
Screw, handlebar
clamp
M8 20 Nm (14.8 lbf ft)
S01847-10
–Position brake assembly on the handlebar.
–Position brake assembly clamp on the handlebar.
Clamp catch engages in the combination switch.
–Mount and tighten screws 7.
Guideline
Remaining screws,
chassis
M6 10 Nm (7.4 lbf ft)
S01848-10
–Position clutch assembly on the handlebar.
–Mount and tighten screw 8.
Guideline
Remaining screws,
chassis
M6 10 Nm (7.4 lbf ft)
S01849-10
–Position the combination instrument support on the handlebar.
–Mount screw 9but do not tighten yet.
–Move the combination instrument into the desired position.
–Tighten screw 9.
Guideline
Screw, combination
instrument clamping
M6 2 Nm (1.5 lbf ft)
–Plug in the connector bk with sleeve.
S01850-10
–Mount and tighten the rear mirror on both sides.

SETUP 2
5
S01851-10
–Mount splash protector bl with screws bm on license plate
holder bn.
Guideline
Remaining screws,
chassis
EJOT PT®
K50x12
1 Nm (0.7 lbf ft)
S01852-10
–Mount reflector bo with spring washers bp on holding
plate bq.
–Mount holding plate bq on license plate bracket br.
(All EU/JP models)
–Mount license plate bracket br on license plate
holder bn.
(1290 Super Duke R US)
–Bond the reflectors on the right and left side of the reflec-
tor holder.
–Mount the reflector holder and license plate bracket br on
license plate holder bn.
S01854-10
–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 pallet.
–Remove the radiator shield.

2 SETUP
6
S01856-10
–Take off the passenger seat. ( p. 7)
–Remove the front rider's seat. ( p. 7)
–Remove the black ignition key and KEYCODECARD and keep in a
safe place for the handover.
–Remove screw bs.
–Lift cover bt at the rear and pull toward the rear.
–Fold up the cover.
–Plug in the connector of starter relay ck.
–Recharge the battery. ( p. 12)
–Remove the protective film.
–Refuel. ( p. 13)
–Prepare the vehicle according to the specifications in the
KTM Dealer.net for handover to the customer.

WORK 3
7
3.1 Removing the passenger seat
E00693-10
–Insert the Race‑on key or the black ignition key into the seat
lock 1and turn clockwise.
–Lift the passenger seat at the front and pull it out of the
bracket toward the front.
–Take off the passenger seat.
–Remove the key.
3.2 Mounting the passenger seat
401922-10
–Attach the recesses of the passenger seat in guides 1and
lower the front of the seat while pushing it back.
–Position locking pin 2in the lock housing and push the pas-
senger seat down 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
–Take off the passenger seat. ( p. 7)
E00694-10
Main work
–Lift the rear of the front rider's seat.
–Detach the front of the front rider's seat and take it off.
3.4 Mounting the front rider's seat
401921-10
Main work
–Attach recesses 1on the front rider's seat to the fuel tank
and push the front rider's seat forward while lowering it.
Catch 2is located in the recess.
–Check that the front rider's seat is mounted correctly.
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 safety glasses.
–Avoid contact with battery acid and battery gases.
–Keep sparks or open flames away from the battery.
–Only charge 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 battery is
discharged or missing.
–Never operate the vehicle with a discharged battery or without a battery.
Preparatory work
–Switch off ignition - to do this briefly press the Race-on but-
ton (maximum of 1 second) with the ignition switched on.
–Take off the passenger seat. ( p. 7)
–Remove the front rider's seat. ( p. 7)
T00488-10
Main work
–Remove screw 1.
–Lift cover 2at the rear and pull toward the rear.
–Fold up the cover.
L01483-10
–Disconnect negative cable 3from the battery.
–Remove positive terminal cover 4and disconnect the posi-
tive cable from the battery.
–Take the battery 5out of the battery compartment.

WORK 3
9
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 safety glasses.
–Avoid contact with battery acid and battery gases.
–Keep sparks or open flames away from the battery.
–Only charge 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 battery is
discharged or missing.
–Never operate the vehicle with a discharged battery or without a battery.
L01484-10
Main work
–Fold up cover 1.
–Place battery 2in the battery compartment.
Battery (YTX14-BS)
L01483-11
–Position the positive cable and mount and tighten the screw.
Guideline
Screw, battery termi-
nal
M6 4.5 Nm
(3.32 lbf ft)
–Mount positive terminal cover 3.
–Position negative cable 4; mount and tighten the screw.
Guideline
Screw, battery termi-
nal
M6 4.5 Nm
(3.32 lbf ft)

3 WORK
10
V01154-10
–Position cover 1.
Screw heads Aengage in recesses B.
–Mount and tighten screw 5.
Finishing work
–Mount the front rider's seat. ( p. 7)
–Mount the passenger seat. ( p. 7)
–Set the time and date.
3.7 Disconnecting the negative cable of 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 safety glasses.
–Avoid contact with battery acid and battery gases.
–Keep sparks or open flames away from the battery.
–Only charge 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 battery is
discharged or missing.
–Never operate the vehicle with a discharged battery or without a battery.
Preparatory work
–Switch off ignition - to do this briefly press the Race-on but-
ton (maximum of 1 second) with the ignition switched on.
–Take off the passenger seat. ( p. 7)
–Remove the front rider's seat. ( p. 7)

WORK 3
11
T00488-10
Main work
–Remove screw 1.
–Lift cover 2at the rear and pull toward the rear.
–Fold up the cover.
T00491-11
–Disconnect negative cable 3from the battery.
3.8 Connecting the negative cable of 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 safety glasses.
–Avoid contact with battery acid and battery gases.
–Keep sparks or open flames away from the battery.
–Only charge 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 battery is
discharged or missing.
–Never operate the vehicle with a discharged battery or without a battery.
T00491-10
Main work
–Position negative cable 1; mount and tighten the screw.
Guideline
Screw, battery termi-
nal
M6 4.5 Nm
(3.32 lbf ft)

3 WORK
12
T00489-11
–Fold down cover 2.
–Mount and tighten screw 3.
Guideline
Remaining screws,
chassis
M5 5 Nm (3.7 lbf ft)
Finishing work
–Mount the front rider's seat. ( p. 7)
–Mount the passenger seat. ( p. 7)
–Set the time and date.
3.9 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 safety glasses.
–Avoid contact with battery acid and battery gases.
–Keep sparks or open flames away from the battery.
–Only charge 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.
Warning
Environmental hazard Batteries contain environmentally-hazardous materials.
–Do not dispose of batteries as household waste.
–Dispose of batteries at a collection point for used batteries.
Warning
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 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 sul-
fated, destroying the battery.
The battery is maintenance-free, i.e., the acid level does not have to be checked.
Preparatory work
–Switch off ignition - to do this briefly press the Race-on but-
ton (maximum of 1 second) with the ignition switched on.
–Take off the passenger seat. ( p. 7)

WORK 3
13
–Remove the front rider's seat. ( p. 7)
–Disconnect the negative cable of the battery. ( p. 10)
311910-10
Main work
–Connect the battery charger to the battery. Adjust the battery
charger.
EU battery charger XCharge-professional (00029095050)
Alternative 1
US battery charger XCharge-professional
(00029095051)
Alternative 2
UK battery charger XCharge-professional
(00029095052)
Alternative 3
CH battery charger XCharge-professional
(00029095053)
Info
Follow the instructions of the charger and the manual.
–Disconnect the battery charger after charging 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. 11)
–Mount the front rider's seat. ( p. 7)
–Mount the passenger seat. ( p. 7)
–Set the time and date.
3.10 Refueling
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
–Do not refuel the vehicle in the vicinity of open flames or lit cigarettes.
–Switch off the engine for refueling.
–Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
–If any fuel is spilled, wipe it off immediately.
–Observe the specifications for refueling.

3 WORK
14
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–Avoid skin, eye and clothing contact with fuel.
–Immediately consult a doctor if you swallow fuel.
–Do not inhale fuel vapors.
–In case of skin contact, rinse the affected area with plenty of water.
–Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
–Change your clothing in case of fuel spills on them.
Note
Material damage Inadequate fuel quality causes the fuel filter to quickly become clogged.
In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in
problems with the fuel system.
–Refuel only 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 enter the groundwater, the soil, or the sewage system.
E00705-10
–Switch off the engine.
–Open the filler cap. ( p. 14)
–Fill the fuel tank with fuel up to the lower edge Aof the filler
neck.
Total fuel tank
capacity, approx.
18 l
(4.8 US gal)
Super unleaded
(ROZ 95/RON
95/PON 91)
( p. 21)
–Close the filler cap. ( p. 15)
3.11 Opening the filler cap
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
–Do not refuel the vehicle in the vicinity of open flames or lit cigarettes.
–Switch off the engine for refueling.
–Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
–If any fuel is spilled, wipe it off immediately.
–Observe the specifications for refueling.

WORK 3
15
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–Avoid skin, eye and clothing contact with fuel.
–Immediately consult a doctor if you swallow fuel.
–Do not inhale fuel vapors.
–In case of skin contact, rinse the affected area with plenty of water.
–Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
–Change your clothing in case of fuel spills on them.
–Keep fuels correctly in a suitable canister, and out of the reach of children.
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
–Do not allow fuel to enter the groundwater, the soil, or the sewage system.
Condition
The motorcycle is stationary.
The engine is switched off.
The ignition has been switched on or off for less than 1 minute.
S01718-10
–Fold up cover 1slowly.
The filler cap unlocks.
–Fold open filler cap 2.
3.12 Closing the filler cap
S01719-10
Warning
Fire hazard Fuel is highly flammable, toxic and a
health hazard.
–Check the filler cap is locked correctly after clos-
ing.
–Change your clothing in case of fuel spills on them.
–Rinse the affected area immediately with plenty of
water in the event of contact with the skin.
–Fold down the filler cap 1and push it down.
The filler cap locks audibly in place.

3 WORK
16
3.13 Clock/Date
K00763-01
Condition
• The motorcycle is stationary.
–Press the SET button when the menu is closed.
–Press the UP or DOWN button until the Settings menu is marked
on the display. Press the SET button to open the menu.
–Press the UP or DOWN button until Clock/Date is marked on the
display. Press the SET button to open the menu.
–Press the UP or DOWN button to set the clock and confirm with
the SET button.
–Press the UP or DOWN button to set the date and confirm with
the SET button.
If the battery has been disconnected, the time and date must be
set.
Info
If the battery has been disconnected, the software version
is also displayed.

TECHNICAL DATA 4
17
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)
Remaining screws, chassis EJOT PT®K45x12 1 Nm (0.7 lbf ft)
Screw, air filter box cover EJOT PT®K60 2 Nm (1.5 lbf ft)
Screw, combination switch, left 5 Nm (3.7 lbf ft)
Screw, fastening, flue exhaust
valve cover
EJOT SF®M4x6‑K 4 Nm (3 lbf ft)
Screw, fuel tank cover, quick con-
nect nipple
EJOT PT®K60 2 Nm (1.5 lbf ft)
Screw, tail light EJOT PT®K50x14 2.5 Nm (1.84 lbf ft)
Screw, fixed grip, left M4 2 Nm (1.5 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 for throttle grip M5 3.5 Nm (2.58 lbf ft)
screw, absorbing element, combi-
nation instrument
M5 2 Nm (1.5 lbf ft)
Loctite®243™
Screw, cable channel M5 5 Nm (3.7 lbf ft)
Screw, chain sliding guard M5 5 Nm (3.7 lbf ft)
Screw, combination instrument M5 3.5 Nm (2.58 lbf ft)
Screw, combination switch, right M5 5 Nm (3.7 lbf ft)
Screw, filler cap M5 3 Nm (2.2 lbf ft)
Screw, front turn signal bracket M5 3 Nm (2.2 lbf ft)
Screw, fuel level indicator M5 3 Nm (2.2 lbf ft)
Screw, rear turn signal bracket M5 3 Nm (2.2 lbf ft)
Screw, shock absorber adjusting
ring
M5 5 Nm (3.7 lbf ft)
Screw, trim M5x12 3.5 Nm (2.58 lbf ft)
Cable disk nut, exhaust valve con-
trol unit
M6 14 Nm (10.3 lbf ft)
Ground fitting on frame M6 10 Nm (7.4 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, ABS unit fastening M6 5 Nm (3.7 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)

4 TECHNICAL DATA
18
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, front wheel speed sensor M6 4 Nm (3 lbf ft)
Screw, fuel pump M6 6 Nm (4.4 lbf ft)
Screw, instrument support M6 2 Nm (1.5 lbf ft)
Screw, license plate holder on
lower rear panel
M6 12 Nm (8.9 lbf ft)
Screw, radiator hose clip 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, rear M6 4 Nm (3 lbf ft)
Nut, exhaust valve throttle cable M6x1 5 Nm (3.7 lbf ft)
Cable disk nut, exhaust valve M8 7 Nm (5.2 lbf ft)
Nut, rear sprocket M8 36 Nm (26.6 lbf ft)
Nut, shift rod M8 12 Nm (8.9 lbf ft)
Nut, valve (1290 Super
Duke R JP)
M8 4 Nm (3 lbf ft)
Nut, valve (1290 Super
Duke R EU, 1290 Super
Duke R US)
M8 6 Nm (4.4 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 15 Nm (11.1 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)