KTM Super Adventure 2016 Manual

SETUP INSTRUCTIONS 2016
1290 Super Adventure
Art. no. 3213444en

INTRODUCTION 1
*3213444en*
3213444en
10/2015
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.
© 2015 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 Adventure EU (F9903PA)
1290 Super Adventure FR (F9923PA)
1290 Super Adventure AU (F9960PA)
1290 Super Adventure JP (F9986PA)
1290 Super Adventure CN (F9987PA)
1290 Super Adventure US (F9975PA)

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.
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.

2 SETUP 3
2.1 Unpacking and setting up the vehicle
S00694-10
–Remove the straps and box.
S00695-10
–Remove the adhesive tape in the upper area of the motorcycle.
S00696-10
–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 finished work on the vehicle.
–Remove the separate enclosure and unpack it. Check the separate enclosure for
completeness.
–Check the vehicle for transport damage.
S00697-10
–Remove the controls from the transport holder.
–Remove the screws and handlebar clamps.
–Remove the transport holder.
M00791-01
–Remove the right hand guard.
–Position the controls on the right half of the handlebar. Tighten the screws.
Guideline
Remaining screws, chassis M5 5 Nm (3.7 lbf ft)
Remaining chassis screws M6 10 Nm (7.4 lbf ft)
–Mount the right hand guard.
S00698-10
–Position the handlebar.
–Position the handlebar clamps. Tighten the screws evenly.
Guideline
Screw, handlebar clamp M8 20 Nm
(14.8 lbf ft)
Markings face backwards.
Markings of the handlebar scale are located centrally between the handle-
bar clamps.

2 SETUP 4
–Check the throttle grip for smooth operation.
M00792-01
–Mount and tighten the rear mirror on both sides.
V00130-10
–Mount reflector with spring washers on holding plate .
–Mount the holding plate on the license plate bracket.
–Mount the license plate holder.
–Carefully loosen and remove the tension belt over the swingarm.
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 palette.
–Loosen the mask spoiler. ( p. 7)
V00134-10
–Remove screws .
M00748-10
–Swing the headlight toward the front.
–Disconnect plug-in connector .
–Put down the headlight on a soft cloth.
M00794-10
–Position headlight mask .
The screw connection points are correctly aligned to the headlight.
The holder locks onto the headlight.

2 SETUP 5
M00795-10
–Mount and tighten screws .
–Install the headlight mask with the headlight. ( p. 9)
–Position the mask spoiler. ( p. 8)
M00749-10
–Position fuel tank support ring on the left and right crash bars.
–Mount and tighten screws  on the left and right crash bars.
–Install the crash bar. ( p. 10)
–Install the wind shield. ( p. 10)
M00750-10
–Remove radiator shield .
–Recharge the battery. ( p. 11)
(Super Adventure EU/FR/AU/JP)
–Store the tool set below the seat.
–Remove the remaining films.
–Mount the front rider's seat. ( p. 7)
–Mount the passenger seat. ( p. 6)
(1290 Super Adventure US)
–Mount reflector. ( p. 18)
–Refuel. ( p. 15)
–Prepare the vehicle according to the specifications in the KTM Dealer.net for han-
dover to the customer.

3 WORK 6
3.1 Removing the passenger seat
V00088-10
–Insert the ignition key in seat lock and turn it clockwise.
–Raise front of the passenger seat, pull toward the tank, and remove upward.
Info
Pay attention to the seat heating cable.
V00089-10
–Disconnect plug-in connector .
–Remove the ignition key.
3.2 Mounting the passenger seat
V00089-11
–Connect plug-in connector .
401680-11
–Attach the hooks on the passenger seat to the hanger on the subframe.
Info
Ensure that the seat heating cable is correctly routed.
–Lower passenger seat and push back at the same time.
–Position locking pin in lock housing and press passenger seat forward until 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. 6)
0
0
AA
M00856-10
Main work
–Lift the rider's seat back and unhook in the area.
Info
Pay attention to the seat heating cable.

3 WORK 7
M00804-10
–Disconnect plug-in connector .
3.4 Mounting the front rider's seat
M00804-10
Main work
–Connect plug-in connector .
401704-10
–Attach the recesses on the driver's seat to the fuel tank at the desired seat posi-
tion or , and push the driver's seat forward while lowering it at the rear.
Info
Ensure that the seat heating cable is correctly routed.
–Finally, check that the driver's seat is correctly mounted.
Finishing work
–Mount the passenger seat. ( p. 6)
3.5 Loosening the mask spoiler
M00858-10
–Remove screw .
V00131-10
–Remove screw .

3 WORK 8
V00132-10
–Pull the front part of the mask spoiler laterally out of the supports.
V00133-10
–Carefully remove catch upward from bracket .
Info
Pay attention to the turn signal cable.
–Repeat these steps on the opposite side.
3.6 Positioning the mask spoiler
V00125-10
–Push two rear catches on the mask spoiler into supports provided.
–Push the mask spoiler up and position catch in bracket .
Info
Ensure that the turn signal cable is placed correctly.
Carefully push the mask spoiler up to avoid breaking the component or
bending catch .
Make sure that the rear catches on the mask spoiler remain in the supports
provided.
V00111-11
–Push the front part of the mask spoiler laterally into the supports.
V00091-11
–Mount and tighten screw .
Guideline
Screw, mask spoiler M5x17 3.5 Nm
(2.58 lbf ft)
M00858-11
–Mount and tighten screw .
Guideline
Screw, mask spoiler M5x17 3.5 Nm
(2.58 lbf ft)
–Repeat these steps on the opposite side.

3 WORK 9
3.7 Removing the bottom triple clamp cover
M00557-10
–Remove screws .
–Lower triple clamp cover slightly.
M00558-10
–Disconnect plugs of the horn.
–Detach temperature sensor .
–Remove the triple clamp cover.
3.8 Installing the bottom triple clamp cover
M00558-11
–Plug in connectors of the horn.
–Attach temperature sensor .
M00557-11
–Position the triple clamp cover .
–Mount and tighten screws .
Guideline
Remaining chassis screws M6 10 Nm (7.4 lbf ft)
3.9 Installing the headlight mask with the headlight
M00748-11
Main work
–Connect plug-in connector of the headlight.
–Check that the lighting is functioning properly.
–Position the headlight mask.

3 WORK 10
V00105-11
–Mount and tighten screws .
Guideline
Screw, headlight M6 5 Nm (3.7 lbf ft)
V00104-10
–Mount and tighten screws .
Guideline
Screw, headlight M6 5 Nm (3.7 lbf ft)
V00110-10
–Position windshield adapter .
–Mount and tighten screws .
Guideline
Screw, cover part M5 3.5 Nm
(2.58 lbf ft)
Finishing work
–Position the mask spoiler.
–Install the wind shield. ( p. 10)
–Check the setting of the lighting system. ( p. 15)
3.10 Installing the wind shield
M00769-10
–Position wind shield .
–Mount and tighten screws .
Guideline
Screw, wind shield M5 3.5 Nm
(2.58 lbf ft)
3.11 Installing the crash bar
V00098-10
–Position the right crash bar with the frame protector.
The fuel tank support ring should be correctly positioned on the fuel tank.
Info
Cover the components to protect them against damage.
–Mount screw , but do not tighten yet.
Guideline
Remaining chassis screws M8 25 Nm
(18.4 lbf ft)
–Mount screws , but do not tighten yet.
Guideline
Remaining chassis screws M6 10 Nm (7.4 lbf ft)

3 WORK 11
V00096-10
–Position the left crash bar with the frame protector.
The fuel tank support ring should be correctly positioned on the fuel tank.
Info
Cover the components to protect them against damage.
–Mount screw , but do not tighten yet.
Guideline
Remaining chassis screws M8 25 Nm
(18.4 lbf ft)
–Mount screws , but do not tighten yet.
Guideline
Remaining chassis screws M6 10 Nm (7.4 lbf ft)
V00113-11
–Mount and tighten fittings .
Guideline
Remaining chassis screws M6 10 Nm (7.4 lbf ft)
The crash bars are evenly aligned with each other.
–Tighten all the screws of the crash bar.
Guideline
Remaining chassis screws M6 10 Nm (7.4 lbf ft)
Remaining chassis screws M8 25 Nm
(18.4 lbf ft)
3.12 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 all power consumers and switch off the engine.
–Remove the passenger seat. ( p. 6)
–Remove the front rider's seat. ( p. 6)
–Remove the battery. ( p. 12)

3 WORK 12
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. 13)
–Mount the front rider's seat. ( p. 7)
–Mount the passenger seat. ( p. 6)
–Set the time and date.
3.13 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. 6)
–Remove the front rider's seat. ( p. 6)
S00737-10
Main work
–Pull locking mechanism in the direction of the arrow.
–Fold open cover .

3 WORK 13
M00610-10
–Disconnect negative cable from the battery.
–Disconnect positive cable from the battery.
–Take the battery and battery case out of the battery compartment.
3.14 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.
M00610-11
Main work
–Position the battery in battery case .
Guideline
The even side of the battery case must be opposite the poles.
–Position the battery and battery case in the battery compartment.
–Position the positive cable and mount and tighten the screw.
Guideline
Screw, battery terminal M6 4.5 Nm
(3.32 lbf ft)
–Position the negative cable and mount and tighten the screw.
Guideline
Screw, battery terminal M6 4.5 Nm
(3.32 lbf ft)
S00736-10
–Close the cover and push down slightly.
The cover engages with an audible click.
Finishing work
–Mount the front rider's seat. ( p. 7)
–Mount the passenger seat. ( p. 6)
–Set the time and date.

3 WORK 14
3.15 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.
M00799-10
–Lift cover of the filler cap and insert ignition key in the fuel tank lock.
M00801-10
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 .
3.16 Closing the filler cap
M00802-10
–Fold down filler cap .
–Turn ignition key clockwise.
M00800-10
–Push down the filler cap and turn the ignition key counterclockwise until the
tank lock closes.
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.

3 WORK 15
–Remove ignition key and close cover .
3.17 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.
–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.
M00798-10
–Switch off the engine.
–Open the filler cap. ( p. 14)
–Fill the fuel tank with fuel up to the lower edge of the filler neck.
Total fuel tank
capacity, approx.
30 l (7.9 US gal) Super unleaded (ROZ 95/RON 95/PON
91) ( p. 22)
–Close the filler cap. ( p. 14)
3.18 Checking the setting of the lighting system
402424-10
–Position the vehicle upright on a horizontal surface in front of a light wall and make
a mark at the height of the center of the low beam headlight.
–Make a second mark at a distance under the first mark.
Guideline
Distance 5 cm (2 in)
0
0
AA
0
0
BB0
0
BB
402426-10
–Make two further marks spaced apart to the left and the right of the second
marking.
Guideline
Distance 71.5 cm (28.15 in)

3 WORK 16
402425-10
–Position the vehicle perpendicular to the wall at a distance from the wall and
switch on the low beam.
Guideline
Distance 5 m (16 ft)
–The rider, with luggage and passenger if applicable, now mounts the motorcycle.
–Check the headlight setting.
The light-dark boundary of the low beam must lie exactly on the lower mark when
the motorcycle is ready to operate with the rider mounted along with any luggage
and a passenger if applicable.
» If the boundary between light and dark does not meet specifications:
–Adjust the headlight range. ( p. 16)
–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 "cLightTest" is highlighted in black on the matrix
display. Pressing the SET button again starts the cornering light test.
–Wait for a few seconds until the upper segment of the left cornering light lights up
continuously.
402427-01
–Checking the left cornering light setting.
The light-dark boundary of the upper segment must run exactly through the left
marking.
» If the boundary between light and dark does not meet specifications:
–Adjust the cornering light range. ( p. 17)
–Press the SET button.
The left cornering light is switched off.
The right cornering light test is started.
–Wait for a few seconds until the upper segment of the right cornering light lights up
continuously.
402428-01
–Checking the right cornering light setting.
The light-dark boundary of the upper segment must run exactly through the right
marking.
» If the boundary between light and dark does not meet specifications:
–Adjust the cornering light range. ( p. 17)
–Press the SET button.
The cornering light is switched off.
3.19 Adjusting the headlight range
Preparatory work
–Check the setting of the lighting system. ( p. 15)
–Remove the bottom triple clamp cover. ( p. 9)
M00807-10
Main work
–Turn adjusting screw to adjust the headlight range.
Info
Turn clockwise to increase the headlight range; turn counterclockwise to
reduce the headlight range.
If you have a payload, you may have to correct the headlight range.

3 WORK 17
402424-10
–Set the headlight to marking .
Guideline
The light-dark boundary must lie exactly on the lower mark when the motor-
cycle is ready to operate with the rider mounted along with any luggage and a
passenger if applicable.
Finishing work
–Install the bottom triple clamp cover. ( p. 9)
3.20 Adjusting the cornering light range
Preparatory work
–Check the setting of the lighting system. ( p. 15)
Main work
–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 "cLightTest" is highlighted in black on the matrix
display. Pressing the SET button again starts the cornering light test.
–Wait for a few seconds until the upper segment of the left cornering light lights up
continuously.
V00106-10
–Turn adjusting screw to adjust the left cornering light range.
Info
Turn clockwise to increase the headlight range; turn counterclockwise to
reduce the headlight range.
402427-01
–Set the upper segment on the left marking.
Guideline
The light-dark boundary of the upper segment must run exactly through the left
marking.
–Press the SET button.
The left cornering light is switched off.
The right cornering light test is started.
–Wait for a few seconds until the upper segment of the right cornering light lights up
continuously.
V00107-10
–Turn adjusting screw to adjust the right cornering light range.
Info
Turn clockwise to increase the headlight range; turn counterclockwise to
reduce the headlight range.

3 WORK 18
402428-01
–Set the upper segment on the left marking.
Guideline
The light-dark boundary of the upper segment must run exactly through the right
marking.
–Press the SET button.
The cornering light is switched off.
3.21 Mount reflector (1290 Super Adventure US)
Preparatory work
–Clean and degrease the surface of the suitcase.
C00931-10
Main work
–Remove protective film from the back of reflector .
C00932-10
–Position reflector in the upper third of the rear recess of the left-hand suitcase,
and then press down on the reflector.