KTM 790 Adventure R 2020 Manual

SETUP INSTRUCTIONS 2020
790 Adventure R
790 Adventure R Rally
Art. no. 3214166en

INTRODUCTION
*3214166en*
3214166en
03/2020
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.
© 2020 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:
790 Adventure R EU (F9603T3)
790 Adventure R US (F9675T3)
790 Adventure R ASEAN (F9688T3)
790 Adventure R CN (F9687T3, F9687TC)
790 Adventure R PH (F9682TC)
790 Adventure R Rally EU (F9603T4)
790 Adventure R Rally US (F9675T4)

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 Diagnostics connector
F01981-10
Diagnostics connector 1is located under the battery cover.
(790 Adventure R CN)
At the factory, a diagnostics adapter was plugged in for con-
nection with a diagnostics interface which applies to all manu-
facturers.
Info
Unplug the diagnostics adapter to use the KTM diag-
nostics tool.
Following completion of the diagnosis, plug the diag-
nostics adapter back in.
2.3 Unpacking and setting up the vehicle
F01037-10
–Remove the straps and the box.
F02148-01
–Remove the adhesive tape in the upper area of the motorcycle.

2 SETUP
4
F02149-01
–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.
Info
The procedure in the event of missing components is
described in the customer service manual.
–Check the vehicle for transport damage.
Info
The procedure in the event of transport damage is
described in the customer service manual.
F02127-01
–Remove the cable tie. Place the handlebar at the front.
–Remove the clutch and the brake assembly from the transport
holder.
–Remove the screws from the handlebar clamps. Take off the
handlebar clamps and transport holder.
F02128-10
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.
–Unpack handlebar and position.
Info
Make sure the cables and wiring are positioned cor-
rectly.
–Position the handlebar clamps. Mount and tighten the screws
evenly.
Guideline
Screw, handlebar
clamp
M8 20 Nm (14.8 lbf ft)
Markings Aface backward.

SETUP 2
5
Handlebar scale markings Bare located centrally
between the handlebar clamps.
Info
Keep the installed gap widths equal when tightening.
F02129-01
–Mount the right hand guard.
Guideline
Hand guard fitting M6 6 Nm (4.4 lbf ft)
Hand guard screw M8 25 Nm (18.4 lbf ft)
F02130-01
–Mount the left hand guard.
Guideline
Hand guard fitting M6 6 Nm (4.4 lbf ft)
Hand guard screw M8 25 Nm (18.4 lbf ft)

2 SETUP
6
F02131-10
–Position the brake assembly on the handlebar.
–Position brake assembly clamp on the handlebar.
The holding lug of the clamp engages in the combination
switch.
–Mount and tighten screws 1.
Guideline
Screw, brake assem-
bly
M6 5 Nm (3.7 lbf ft)
–Tighten all the screws on the controls on the right half of the
handlebar.
Guideline
Screw for throttle
grip
M5 3.5 Nm
(2.58 lbf ft)
Screw, combination
switch, right
M5 5 Nm (3.7 lbf ft)
Info
Pay attention to the markings on the handlebar.
Make sure the cables and wiring are positioned cor-
rectly.
–Tie the cables and wires together with the rubber straps sup-
plied.
–Check the throttle grip for smooth operation.
F02132-10
–Position the clutch assembly on the handlebar.
Info
Pay attention to the markings on the handlebar.
–Position the clutch assembly clamp on the handlebar.
–Mount and tighten screws 2.
Guideline
Screw, clutch assem-
bly
M6 5 Nm (3.7 lbf ft)
–Tighten all the screws on the controls on the left half of the
handlebar.
Guideline
Screw, fixed grip, left M4 3 Nm (2.2 lbf ft)
Screw, combination
switch, left
M5 2 Nm (1.5 lbf ft)
Info
Pay attention to the markings on the handlebar.
Make sure the cables and wiring are positioned cor-
rectly.
–Tie the cables and wires together with the rubber straps sup-
plied.

SETUP 2
7
F02150-01
–Mount and tighten the rear mirror on both sides.
F02151-10
–Mount rubber bushings 3on windshield 4.
–Mount windshield 4on windshield bracket 5.
The windshield engages on the left and right in the
recesses of the windshield bracket.
–Mount and tighten screws 6.
Guideline
Remaining screws,
chassis
M5 5 Nm (3.7 lbf ft)
F02152-10
–Position the windshield bracket with the windshield in lower
recess C.
–Mount and tighten screw 7.
Guideline
Remaining screws,
chassis
M5 5 Nm (3.7 lbf ft)

2 SETUP
8
F02135-10
(790 Adventure R EU/ASEAN/CN/PH, 790 Adventure R Rally EU)
–Mount reflector 8with rubber bushings 9and tension
washers bk on the license plate holder bl.
–Position the license plate bracket on the license plate sup-
port.
–Mount and tighten screws bm.
Guideline
Screw, license
plate holder
M5 5 Nm (3.7 lbf ft)
Loctite®243™
–Carefully loosen and remove the rear tension belt.
Info
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.
F02136-10
–Mount rubber spacers bn on the retaining bracket bo.
–Position retaining bracket bo on the engine guard.
–Mount and tighten screws bp.
Guideline
Screw, engine
guard retaining
bracket
M6 10 Nm (7.4 lbf ft)
Loctite®243™

SETUP 2
9
F02137-10
–Position the left fuel tank cover.
–Mount and tighten screws bq with the collar bushings and the
absorbing elements.
Guideline
Screw, fuel tank
cover
M6x18 5 Nm (3.7 lbf ft)
Loctite®243™
–Position the right fuel tank cover.
–Mount and tighten screws bq with the collar bushings and the
absorbing elements.
Guideline
Screw, fuel tank
cover
M6x18 5 Nm (3.7 lbf ft)
Loctite®243™
F02138-10
–Mount and tighten fitting br with the collar bushings and the
absorbing elements.
Guideline
Screw, fuel tank
cover
M6 5 Nm (3.7 lbf ft)
Loctite®243™
F02153-10
–Position engine guard bs with the mounted fuel tank covers.
–Mount screws bt, but do not tighten yet.
Guideline
Screw, engine
guard
M6x10 10 Nm (7.4 lbf ft)
Loctite®243™

2 SETUP
10
F02140-10
–Mount screws ck, but do not tighten yet.
Guideline
Screw, engine guard M6x8 8 Nm (5.9 lbf ft)
F02141-10
–Mount screws cl, but do not tighten yet.
Guideline
Screw, fuel tank
cover
M6x12 8 Nm (5.9 lbf ft)
The engine guard is directed evenly toward the front.
–Tighten all the screws of the engine guard.
Guideline
Screw, engine
guard
M6x8 8 Nm (5.9 lbf ft)
Screw, engine
guard
M6x10 10 Nm (7.4 lbf ft)
Loctite®243™
Screw, fuel tank
cover
M6x12 8 Nm (5.9 lbf ft)
F02142-10
–Mount hose cm with the angle piece.
(All special models)
–Remove main silencer. ( p. 16)
–Install the main silencer. ( p. 17)
Info
The vehicle is assembled in the factory with the
original main silencer.
An accessory main silencer is also included in the
scope of supply.
Assemble the vehicle according to the customer's
requirements and point out legal regulations, e.g.
entry in the vehicle documents if necessary.
F02143-01
–Remove the seat. ( p. 12)
–Remove spare key and KEYCODECARD from under the seat and
keep in a safe place for the handover.
–Charge the 12-V battery. ( p. 19)

SETUP 2
11
F02145-10
–Remove protection cap cn.
–Plug in the plug co of the starter relay.
–Mount protection cap cn.
F02154-01
Info
The tool set can be stored in the left or right storage com-
partment.
The left storage compartment is described as an example.
–Remove the left side cover. ( p. 12)
–Open storage compartment on the left. ( p. 12)
–Store the tool set in the storage compartment.
–Close storage compartment on the left. ( p. 13)
–Install the left side cover. ( p. 14)
F02146-10
–Remove the labels from the brake line and the frame.
–Remove the remaining films.
–Check the headlight setting. ( p. 22)
–Refuel. ( p. 24)
–Prepare the vehicle according to the specifications in
the KTM Dealer.net for handover to the customer.

3 WORK
12
3.1 Removing the seat
H02022-10
–Insert the ignition key in seat lock 1and turn it clockwise.
–Raise the rear of the seat, pull the seat back, and lift it off.
–Remove the ignition key.
3.2 Mounting the seat
401677-10
–Hook holding lug 1of the seat onto the fuel tank, lower the
rear and push it forward.
–Insert locking pin 2into the lock housing and push down the
rear of the seat until the locking pin engages with a click.
–Check that the seat is correctly mounted.
3.3 Removing the left side cover
Preparatory work
–Remove the seat. ( p. 12)
F02032-10
Main work
–Remove left side cover from the rubber bushings in the
areas Aand B.
–Pull off the left side cover sideways and remove it toward the
front.
3.4 Opening the storage compartment on the left
Preparatory work
–Remove the seat. ( p. 12)
–Remove the left side cover. ( p. 12)

WORK 3
13
F02012-10
Main work
–Lift the elastic fastener 1and detach in area A.
–Open storage compartment.
3.5 Closing the storage compartment on the left
F02013-10
Main work
–Close the storage compartment.
–Raise elastic fastener 1and hang up in area A.
Finishing work
–Install the left side cover. ( p. 14)
–Mount the seat. ( p. 12)

3 WORK
14
3.6 Installing the left side cover
F02033-10
Main work
–Position the left side cover with holding lug 1on bushing 2
and push backward.
The left side cover engages under the tail part.
–Press the left side cover in area Ainto rubber bushing 3
and press into rubber bushing Bin area 4.
Finishing work
–Mount the seat. ( p. 12)
3.7 Removing the right side cover
Preparatory work
–Remove the seat. ( p. 12)
F02034-10
Main work
–Remove the side cover from the rubber bushings in areas A
and B.
–Pull off the right side cover sideways and remove it toward the
front.
3.8 Opening the storage compartment on the right
Preparatory work
–Remove the seat. ( p. 12)
–Remove the right side cover. ( p. 14)

WORK 3
15
F02014-10
Main work
–Lift the elastic fastener 1and detach in area A.
–Open storage compartment.
3.9 Closing the storage compartment on the right
F02015-10
Main work
–Close the storage compartment.
–Raise elastic fastener 1and hang up in area A.
Finishing work
–Install the right side cover. ( p. 16)
–Mount the seat. ( p. 12)

3 WORK
16
3.10 Installing the right side cover
F02035-10
Main work
–Position the right side cover with holding lug 1on bush-
ing 2and push backward.
The right side cover engages under the tail part.
–Press the right side cover in the area Ainto rubber bush-
ing 3and press into rubber bushing Bin area 4.
Finishing work
–Mount the seat. ( p. 12)
3.11 Removing the main silencer
G03694-10
(All standard models)
–Remove screw 1.
–Remove the clamp.
A00683-11
–Remove screw 2with the washer.
–Take off the main silencer.

WORK 3
17
A00681-10
(All special models)
–Remove screw 1.
–Remove the clamp.
A00668-11
–Remove screw 2with the washer.
–Take off the main silencer.
Info
Both the accessory main silencer as well as the
original main silencer are included in the scope of
supply.
3.12 Installing the main silencer
A00683-10
(All standard models)
–Position the main silencer with the gasket.
–Mount screw 1with the washer, but do not tighten yet.
Guideline
Screw, exhaust
clamp
M8 25 Nm
(18.4 lbf ft)
R05686-10
–Position the clamp.
Guideline
Distance A1 mm (0.04 in)
Info
The clamp must not touch the brake line when the
rear wheel suspension compresses.
–Mount and tighten screw 2.
Guideline
Screw, presi-
lencer exhaust
clamp
M6 8 Nm (5.9 lbf ft)
Copper paste

3 WORK
18
A00683-10
–Tighten screw 1.
Guideline
Screw, exhaust
clamp
M8 25 Nm
(18.4 lbf ft)
A00668-10
(All special models)
Info
Both the accessory main silencer as well as the original
main silencer are included in the scope of supply.
–Position the main silencer with the gasket.
–Mount screw 1with the washer, but do not tighten yet.
Guideline
Screw, exhaust
clamp
M8 25 Nm
(18.4 lbf ft)
A00682-10
–Position the clamp.
Guideline
Distance A1 mm (0.04 in)
Info
The clamp must not touch the brake line when the
rear wheel suspension compresses.
–Mount and tighten screw 2.
Guideline
Screw, presi-
lencer exhaust
clamp
M6 8 Nm (5.9 lbf ft)
Copper paste
A00668-10
–Tighten screw 1.
Guideline
Screw, exhaust
clamp
M8 25 Nm
(18.4 lbf ft)