SETUP INSTRUCTIONS 2018

1090 Adventure R

Art. no. 3213803en

INTRODUCTION

*3213803en*

3213803en

11/2017

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 illustrations and descrip-

tions, 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:

1090 Adventure R EU (F9903RD)

1090 Adventure R US (F9975RD)

1090 Adventure R CN (F9987RD)

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

S01880-10

–

Remove the straps and box.

A00227-10

–

Remove the adhesive tape in the upper area of the motorcycle.

A00228-10

–

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.

A00229-10

–

Remove the controls from the transport holder.

–

Remove the screws and handlebar clamps.

–

Remove the transport holder.

S01881-10

–

Remove the right hand guard.

–

Position the controls on the right half of the handlebar.

Tighten the screws.

Guideline

Screw, combination

switch, right

M5

3.5 Nm

(2.58 lbf ft)

Remaining chassis

screws

M6

10 Nm (7.4 lbf ft)

The catch on the combination switch engages in the

recess of the mirror clamp.

–

Mount the right hand guard.

2

SETUP

4

Guideline

Hand guard screw

M8

15 Nm (11.1 lbf ft)

Hand guard fitting

M6

6 Nm (4.4 lbf ft)

S01878-10

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.

–

Position the handlebar.

Info

Make sure the cables and wiring are positioned cor-

rectly.

–

Position the handlebar clamps. Tighten the screws evenly.

Guideline

Screw, handlebar

clamp

M8

20 Nm (14.8 lbf ft)

Markings A face backwards.

Handlebar scale markings B are located centrally

between the handlebar clamps.

–

Check the throttle grip for smooth operation.

A00226-10

–

Mount and tighten the rear mirror on both sides.

–

Install the wind shield. (

p. 8)

S01875-10

–

Mount reflector 1 with spring washers 2 on holding

plate 3.

–

Mount the retaining plate on the license plate holder.

SETUP

2

5

S01876-10

(1090 Adventure R EU, 1090 Adventure R CN)

–

Mount the license plate holder.

S01877-10

(1090 Adventure R US)

–

Bond the reflectors on the right and left side of the reflec-

tor holder.

–

Mount the reflector holder on license plate bracket.

–

Carefully loosen and remove the tension belt over the

swingarm.

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.

–

Take the vehicle off the palette together with an assistant.

S01870-01

–

Remove radiator shield 4.

–

Remove screws 5.

–

Position radiator guard.

Info

Pay attention to the guides and the holding lugs.

–

Mount and tighten screws 5 and 6.

Guideline

Screw, cooler retain-

ing bracket

M6

7 Nm (5.2 lbf ft)

2

SETUP

6

S01871-10

–

Mount the frame protector elements 7 on both sides.

–

Position the left crash bar with frame protector and attach the

clamp to the frame tube.

Info

Cover the components to protect them against damage.

–

Mount screw 8 but do not tighten yet.

Guideline

Remaining chassis

screws

M10

45 Nm (33.2 lbf ft)

–

Position clamps and mount the new screws 9but do not

tighten them yet.

Guideline

Remaining chassis

screws

M6

10 Nm (7.4 lbf ft)

–

Mount screw bk but do not tighten yet.

Guideline

Remaining chassis

screws

M6

10 Nm (7.4 lbf ft)

S01872-10

–

Position the right crash bar with frame protector and attach

the clamp to the frame tube.

Info

Cover the components to protect them against damage.

–

Mount screw bl but do not tighten yet.

Guideline

Remaining chassis

screws

M10

45 Nm (33.2 lbf ft)

–

Position clamps and mount the new screws bmbut do not

tighten them yet.

Guideline

Remaining chassis

screws

M6

10 Nm (7.4 lbf ft)

–

Mount screw bn but do not tighten yet.

Guideline

Remaining chassis

screws

M6

10 Nm (7.4 lbf ft)

S01873-10

–

Mount and tighten screws bo with nuts.

The crash bars are equally 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

M10

45 Nm (33.2 lbf ft)

SETUP

2

7

S01874-10

–

Mount rubber dampers bp on the engine guard.

–

Position the engine guard. Mount and tighten the screws with

the distance sleeves.

Guideline

Screw, engine guard

M6

10 Nm (7.4 lbf ft)

S01882-10

–

Position footrest rubber bq.

–

Mount locking plate br and nut bs.

–

Tighten nut bs.

–

Repeat the operation on the opposite side.

–

Remove the seat. (

p. 8)

–

Remove spare key and KEYCODECARD under the seat and keep

in a safe place for the handover.

–

Recharge the battery. (

p. 8)

–

Remove the remaining films.

–

Check the headlight setting. (

p. 12)

–

Refuel. (

p. 15)

–

Prepare the vehicle according to the specifications in the

KTM Dealer.net for handover to the customer.

3

WORK

8

3.1

Installing the wind shield

A00225-10

–

Position wind shield 1.

–

Mount and tighten screws 2.

Guideline

Screw, wind shield

M5

3.5 Nm

(2.58 lbf ft)

3.2

Removing the seat

S01782-10

–

Insert the ignition key in the seat lock 1 and turn it clock-

wise by 45 °.

–

Raise the rear of the seat, pull the seat back, and lift it off.

–

Remove the ignition key.

3.3

Mounting the seat

0

2

0

1

401677-10

–

Hook the catch 1 of the seat onto the fuel tank, lower the

rear and push it forward.

–

Insert the locking pin 2 into the lock housing and push down

the rear of the seat until the locking pin engages with an audi-

ble click.

–

Check that the seat is correctly mounted.

3.4

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.

WORK

3

9

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 the ignition by turning the black ignition key to the

position OFF

.

–

Remove the seat. (

p. 8)

–

Remove 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

3

WORK

10

Finishing work

–

Install the battery. (

p. 11)

–

Mount the seat. (

p. 8)

–

Set the time and date.

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 the ignition by turning the black ignition key to the

position OFF

.

–

Remove the seat. (

p. 8)

S01811-10

Main work

–

Pull locking mechanism 1 in the direction of the arrow.

–

Fold open cover 2.

S01812-10

–

Disconnect both negative cables 3 from the battery.

–

Disconnect both positive cables 4 from the battery.

–

Take the battery and battery case 5 out of the battery com-

partment.

WORK

3

11

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.

S01812-11

Main work

–

Position the battery in battery case 1.

Guideline

The even side of the battery case must be opposite the

poles.

–

Position the battery and battery case in the battery compart-

ment.

–

Position the positive cable 2 and mount and tighten the

screw.

Guideline

Screw, battery termi-

nal

M6

4.5 Nm

(3.32 lbf ft)

–

Position the negative cable 3 and mount and tighten the

screw.

Guideline

Screw, battery termi-

nal

M6

4.5 Nm

(3.32 lbf ft)

S01813-10

–

Close the cover 4 and push down slightly.

The cover engages with an audible click.

Finishing work

–

Mount the seat. (

p. 8)

–

Set the time and date.

3

WORK

12

3.7

Checking the headlight setting

400726-10

–

Park the vehicle on a horizontal surface in front of a light-

colored wall and make a mark at the height of the center of

the low beam headlight.

–

Make another mark at a distance B under the first marking.

Guideline

Distance B

5 cm (2 in)

–

Position the vehicle perpendicular to the wall at a distance A

from the wall and switch on the low beam.

Guideline

Distance A

5 m (16 ft)

–

The rider, with luggage and passenger if applicable, now

mounts the motorcycle.

–

Check the headlight setting.

The light-dark boundary 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. 12)

3.8

Adjusting the headlight range

Preparatory work

–

Check the headlight setting. (

p. 12)

–

Remove the bottom triple clamp cover. (

p. 13)

S01826-10

Main work

–

Turn adjusting screw 1 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.

400726-11

–

Set the headlight to marking B.

Guideline

The light-dark boundary must lie exactly on the lower mark

B ^{when the motorcycle is ready to operate with the rider}

mounted along with any luggage and a passenger if applica-

ble.

Finishing work

–

Install the bottom triple clamp cover. (

p. 13)

WORK

3

13

3.9

Removing the bottom triple clamp cover

M00557-10

–

Remove screws 1.

–

Lower triple clamp cover 2 slightly.

M00558-10

–

Disconnect plugs 3 of the horn.

–

Detach temperature sensor 4.

–

Remove the triple clamp cover.

3.10

Installing the bottom triple clamp cover

M00558-11

–

Plug in connectors 1 of the horn.

–

Attach temperature sensor 2.

M00557-11

–

Position the triple clamp cover 3.

–

Mount and tighten screws 4.

Guideline

Remaining chassis

screws

M6

10 Nm (7.4 lbf ft)