SETUP INSTRUCTIONS 2020

790 Adventure R
790 Adventure R Rally
Art. no. 3214166en
 INTRODUCTION

Perform the work described in these setup instructions before the vehicle is delivered to the customer.
INTRODUCTION

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)

*3214166en*
3214166en

03/2020
1 MEANS OF REPRESENTATION

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.

2
 SETUP 2

2.1 Transport mode

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
H02713-01 Make sure that the vehicle is permanently enabled before
handing it over to the customer.

2.2 Diagnostics connector

Diagnostics connector 1 is 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.
F01981-10 Following completion of the diagnosis, plug the diag-
nostics adapter back in.

2.3 Unpacking and setting up the vehicle

– Remove the straps and the box.

F01037-10

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

F02148-01

3
2 SETUP

– 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.
F02149-01
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.

– 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.

F02127-01

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
F02128-10 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 M8 20 Nm (14.8 lbf ft)
clamp

Markings A face backward.

4
 SETUP 2

Handlebar scale markings B are located centrally

between the handlebar clamps.

Info
Keep the installed gap widths equal when tightening.

– 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)

F02129-01

– 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)

F02130-01

5
2 SETUP

– 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- M6 5 Nm (3.7 lbf ft)
bly
F02131-10
– Tighten all the screws on the controls on the right half of the
handlebar.
Guideline
Screw for throttle M5 3.5 Nm
grip (2.58 lbf ft)
Screw, combination M5 5 Nm (3.7 lbf ft)
switch, right

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.
– 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
F02132-10
Screw, clutch assem- M6 5 Nm (3.7 lbf ft)
bly
– 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 M5 2 Nm (1.5 lbf ft)
switch, left

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.

6
 SETUP 2

– Mount and tighten the rear mirror on both sides.

F02150-01

– 3 on windshield 4.
Mount rubber bushings
– Mount windshield 4 on 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, M5 5 Nm (3.7 lbf ft)
chassis

F02151-10

– Position the windshield bracket with the windshield in lower

recessC .
– Mount and tighten screw 7.
Guideline
Remaining screws, M5 5 Nm (3.7 lbf ft)
chassis

F02152-10

7
2 SETUP

(790 Adventure R EU/ASEAN/CN/PH, 790 Adventure R Rally EU)

– Mount reflector 8
with rubber bushings 9
and 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 M5 5 Nm (3.7 lbf ft)
plate holder 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.
F02135-10

– 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 M6 10 Nm (7.4 lbf ft)
guard retaining Loctite®243™
bracket

F02136-10

8
 SETUP 2

– Position the left fuel tank cover.

– Mount and tighten screws bq with the collar bushings and the
absorbing elements.
Guideline
Screw, fuel tank M6x18 5 Nm (3.7 lbf ft)
cover 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 M6x18 5 Nm (3.7 lbf ft)
cover Loctite®243™

F02137-10

– Mount and tighten fitting br with the collar bushings and the
absorbing elements.
Guideline
Screw, fuel tank M6 5 Nm (3.7 lbf ft)
cover Loctite®243™

F02138-10

– Position engine guard bs with the mounted fuel tank covers.

– Mount screws bt, but do not tighten yet.
Guideline
Screw, engine M6x10 10 Nm (7.4 lbf ft)
guard Loctite®243™

F02153-10

9
2 SETUP

– Mount screws ck, but do not tighten yet.

Guideline
Screw, engine guard M6x8 8 Nm (5.9 lbf ft)

F02140-10

– Mount screws cl, but do not tighten yet.

Guideline
Screw, fuel tank M6x12 8 Nm (5.9 lbf ft)
cover
The engine guard is directed evenly toward the front.
– Tighten all the screws of the engine guard.
Guideline
F02141-10
Screw, engine M6x8 8 Nm (5.9 lbf ft)
guard
Screw, engine M6x10 10 Nm (7.4 lbf ft)
guard Loctite®243™
Screw, fuel tank M6x12 8 Nm (5.9 lbf ft)
cover

– 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
F02142-10
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.

– 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)

F02143-01

10
 SETUP 2

– Remove protection cap cn.

– Plug in the plugco of the starter relay.
– Mount protection cap cn.

F02145-10

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.
F02154-01 – Close storage compartment on the left. ( p. 13)
– Install the left side cover. ( p. 14)
– 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.

F02146-10

11
3 WORK

3.1 Removing the seat

– Insert the ignition key in seat lock 1 and turn it clockwise.
– Raise the rear of the seat, pull the seat back, and lift it off.
– Remove the ignition key.

H02022-10

3.2 Mounting the seat

– Hook holding lug 1 of the seat onto the fuel tank, lower the
rear and push it forward.
– Insert locking pin 2 into 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.

401677-10

3.3 Removing the left side cover

Preparatory work
– Remove the seat. ( p. 12)
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.

F02032-10

3.4 Opening the storage compartment on the left

Preparatory work
– Remove the seat. ( p. 12)
– Remove the left side cover. ( p. 12)

12
 WORK 3

Main work
– Lift the elastic fastener 1 and detach in area A.
– Open storage compartment.

F02012-10

3.5 Closing the storage compartment on the left

Main work
– Close the storage compartment.
– Raise elastic fastener 1 and hang up in area A.

F02013-10

Finishing work
– Install the left side cover. ( p. 14)
– Mount the seat. ( p. 12)

13
3 WORK

3.6 Installing the left side cover

Main work
– Position the left side cover with holding lug 1 on bushing 2
and push backward.
The left side cover engages under the tail part.
– Press the left side cover in areaA into rubber bushing 3
and press into rubber bushing B in area 4.

F02033-10

Finishing work
– Mount the seat. ( p. 12)

3.7 Removing the right side cover

Preparatory work
– Remove the seat. ( p. 12)
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.

F02034-10

3.8 Opening the storage compartment on the right

Preparatory work
– Remove the seat. ( p. 12)
– Remove the right side cover. ( p. 14)

14
 WORK 3

Main work
– Lift the elastic fastener 1 and detach in area A.
– Open storage compartment.

F02014-10

3.9 Closing the storage compartment on the right

Main work
– Close the storage compartment.
– Raise elastic fastener 1 and hang up in area A.

F02015-10

Finishing work
– Install the right side cover. ( p. 16)
– Mount the seat. ( p. 12)

15
3 WORK

3.10 Installing the right side cover

Main work
– Position the right side cover with holding lug 1 on bush-
ing 2 and push backward.
The right side cover engages under the tail part.
– A into rubber bush-
Press the right side cover in the area
ing 3 and press into rubber bushingB in area 4.

F02035-10

Finishing work
– Mount the seat. ( p. 12)

3.11 Removing the main silencer

(All standard models)
– Remove screw 1.
– Remove the clamp.

G03694-10

– Remove screw 2 with the washer.

– Take off the main silencer.

A00683-11

16
 WORK 3

(All special models)

– Remove screw 1.
– Remove the clamp.

A00681-10

– Remove screw 2 with 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.

A00668-11

3.12 Installing the main silencer

(All standard models)
– Position the main silencer with the gasket.
– Mount screw 1 with the washer, but do not tighten yet.
Guideline
Screw, exhaust M8 25 Nm
clamp (18.4 lbf ft)

A00683-10

– Position the clamp.

Guideline
Distance A 1 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- M6 8 Nm (5.9 lbf ft)
lencer exhaust Copper paste
clamp

R05686-10

17
3 WORK

– Tighten screw 1.
Guideline
Screw, exhaust M8 25 Nm
clamp (18.4 lbf ft)

A00683-10

(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 1 with the washer, but do not tighten yet.
Guideline
A00668-10
Screw, exhaust M8 25 Nm
clamp (18.4 lbf ft)

– Position the clamp.

Guideline
Distance A 1 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- M6 8 Nm (5.9 lbf ft)
lencer exhaust Copper paste
clamp

A00682-10

– Tighten screw 1.
Guideline
Screw, exhaust M8 25 Nm
clamp (18.4 lbf ft)

A00668-10

18
 WORK 3

3.13 Removing the battery cover

Preparatory work
– Remove the seat. ( p. 12)
Main work
– Remove screws 1 with the bushings.
– Remove the battery cover from above.

F02044-10

3.14 Installing the battery cover

Main work
– Position the battery cover with holding lugs 1 on
bushings 2
and push downward.
The battery cover engages on the left and right under the
fuel tank spoiler.
– Mount screws 3 with the bushings and tighten.
Guideline
Screw, seat fixing M6 5 Nm (3.7 lbf ft)

F02045-10

Finishing work
– Mount the seat. ( p. 12)

3.15 Charging the 12-V battery

Warning
Risk of injury Battery acid and battery gases cause serious chemical burns.
– Keep 12 V 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 12 V battery.
– Only charge 12 V 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.

19
3 WORK

Note
Environmental hazard 12 V batteries contain environmentally hazardous materials.
– Do not dispose of 12 V batteries as household waste.
– Dispose of 12 V batteries at a collection point for used batteries.

Note
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 if there is no load on the 12-V battery, it discharges steadily each day.
The charging level and the method of charging are very important for the service life of the 12-V 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 12-V battery will be
destroyed.
If the 12-V battery is depleted from starting the vehicle repeatedly, the battery must be charged immedi-
ately.
If the 12-V battery is left in a discharged state for an extended period, it will become deeply discharged
and sulfating occurs, destroying the battery.
The 12-V battery is maintenance-free, i.e. the acid level does not have to be checked.

Preparatory work
– Switch off the ignition by turning the ignition key to the posi-
tion .
– Remove the seat. ( p. 12)
– Disconnect the negative cable of the 12-V battery. ( p. 21)
Main work
– Connect the battery charger to the 12-V battery. Adjust the
battery charger.
EU battery charger XCharge‑professional (00029095050)
Alternative 1
US battery charger XCharge‑professional
(00029095051)

311910-10
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 12-V battery.

20
 WORK 3

Guideline
The charging current, charging voltage, and charging time
must not be exceeded.
Recharge the 12-V battery 3 months
regularly when the motorcy-
cle is not being used

Finishing work
– Connect the negative cable of the 12-V battery. ( p. 22)
– Mount the seat. ( p. 12)
– Set the time and date.

3.16 Disconnecting the negative cable of the 12-V battery

Warning
Risk of injury Battery acid and battery gases cause serious chemical burns.
– Keep 12 V 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 12 V battery.
– Only charge 12 V 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 12-V battery is dis-
charged or missing.
– Never operate the vehicle with a discharged 12-V battery or without a 12-V battery.

Preparatory work
– Switch off the ignition by turning the ignition key to the posi-
tion .
– Remove the seat. ( p. 12)
Main work
– Disconnect negative cable 1 from the 12-V battery.

G03707-10

21
3 WORK

3.17 Connecting the negative cable of the 12-V battery

Warning
Risk of injury Battery acid and battery gases cause serious chemical burns.
– Keep 12 V 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 12 V battery.
– Only charge 12 V 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 12-V battery is dis-
charged or missing.
– Never operate the vehicle with a discharged 12-V battery or without a 12-V battery.

Main work
– Connect negative cable 1 to the 12-V battery.
Guideline
Screw, battery termi- M6 4.5 Nm
nal (3.32 lbf ft)

G03707-10

Finishing work
– Mount the seat. ( p. 12)
– Set the time and date.

3.18 Checking the headlight setting

– 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 upright at distance A from the wall and

switch on the low beam.
400726-10
Guideline
Distance A 5 m (16 ft)

– The rider now mounts the motorcycle with luggage and passen-
ger if applicable.
– Check the headlight setting.

22
 WORK 3

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

ing when the motorcycle is ready to be operated 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 headlight range. ( p. 23)

3.19 Adjusting the headlight range

Preparatory work
– Check the headlight setting. ( p. 22)
Main work
– Remove screws 1.
– Remove the left mask spoiler.

F02085-10

– Turn adjusting screw 2 to adjust the headlight range.

Info
Turn clockwise to reduce the headlight range; turn
counterclockwise to increase the headlight range.
If you have a payload, you may have to correct the
headlight range.

F02086-10

– Set the headlight to marking B.

Guideline
The light-dark boundary must lie exactly on lower mark-
ingB when the motorcycle is ready to operate with the
rider mounted along with any luggage and a passenger, if
applicable.

400726-11

– Position left mask spoiler.

– Mount and tighten screws 1.
Guideline
Remaining screws, M5 5 Nm (3.7 lbf ft)
chassis

F02085-10

23
3 WORK

3.20 Refueling

Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
– Do not fuel 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.

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.

Note
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.

– Switch off the engine.

– Open the fuel tank filler cap. ( p. 25)
– Fill the fuel tank with fuel up to the lower edge A of the filler
neck.
Total fuel tank 20 l Super unleaded
capacity, approx. (5.3 US gal) (ROZ 95/RON
95/PON 91)
( p. 31)

Info
An optional flash file allows lower quality fuel to be
used.
Further information, for example relating to octane
number, is available from an authorized KTM dealer.

– Close the fuel tank filler cap. ( p. 25)

F02023-10

24
 WORK 3

3.21 Opening the fuel tank 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 fuel 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.

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.

Note
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.

– Lift cover 1 of the fuel tank filler cap and insert the ignition
key into the lock.

Note
Danger of damage The ignition key may break if overloaded.
Damaged ignition keys must be replaced.
– Push down on the fuel tank filler cap to take pressure off
the ignition key.
F02010-10
– Turn the ignition key 90° clockwise.
– Lift the fuel tank filler cap.

3.22 Closing the fuel tank filler cap

– Fold down the fuel tank filler cap.
– Turn the ignition key 90° clockwise.
– Push down the fuel tank filler cap and turn the ignition key
counterclockwise until the lock closes.

F02011-01

25
3 WORK

Warning
Fire hazard Fuel is highly flammable, toxic and a
health hazard.
– Check that the fuel tank filler cap is locked cor-
rectly after closing.
– Change your clothing if fuel spills on them.
– Rinse the affected area immediately with plenty of
water in the event of contact with the skin.

– Remove the ignition key and close the cover.

26
 TECHNICAL DATA 4

4.1 Chassis tightening torques

Nut, valve ISO 10V2 12 Nm (8.9 lbf ft)
Loctite®2701™
Remaining screws, chassis EJOTPT® K45x12 1 Nm (0.7 lbf ft)
Remaining screws, chassis EJOTPT® K50x12 1 Nm (0.7 lbf ft)
Remaining screws, chassis EJOTPT® K50x14 1 Nm (0.7 lbf ft)
Remaining screws, chassis EJOTPT® K50x16 2 Nm (1.5 lbf ft)
Remaining screws, chassis EJOTPT® K50x18 2 Nm (1.5 lbf ft)
Screw, tail light EJOT DELTA PT® 45x12‑Z 1.5 Nm (1.11 lbf ft)
Remaining nuts, chassis M4 3 Nm (2.2 lbf ft)
Remaining screws, chassis M4 3 Nm (2.2 lbf ft)
Screw, fixed grip, left M4 3 Nm (2.2 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, air filter box M5 3 Nm (2.2 lbf ft)
Screw, brake fluid reservoir for rear M5 5 Nm (3.7 lbf ft)
brake Loctite®243™
Screw, cable on starter motor M5 3 Nm (2.2 lbf ft)
Screw, combination instrument M5 4 Nm (3 lbf ft)
Screw, combination switch, left M5 2 Nm (1.5 lbf ft)
Screw, combination switch, right M5 5 Nm (3.7 lbf ft)
Screw, engine sprocket cover M5 5 Nm (3.7 lbf ft)
Loctite®243™
Screw, foot brake lever stub M5 5 Nm (3.7 lbf ft)
Loctite®243™
Screw, fork protector M5x12 5 Nm (3.7 lbf ft)
Screw, fork protector M5x17 5 Nm (3.7 lbf ft)
Screw, heat guard M5 5 Nm (3.7 lbf ft)
Loctite®243™
Screw, license plate holder M5 5 Nm (3.7 lbf ft)
Loctite®243™
Screw, side stand sensor M5 2 Nm (1.5 lbf ft)
Loctite®243™
Screw, trim M5 3 Nm (2.2 lbf ft)
Spoke nipple M5 5 Nm (3.7 lbf ft)
Nut, hand brake lever M6 Attach torque to nut.
10 Nm (7.4 lbf ft)
Nut, push rod, foot brake lever M6 6 Nm (4.4 lbf ft)
Nut, shift rod M6 6 Nm (4.4 lbf ft)
Nut, shift rod M6LH 6 Nm (4.4 lbf ft)
Remaining nuts, chassis M6 10 Nm (7.4 lbf ft)
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
Screw, angle sensor M6 5 Nm (3.7 lbf ft)
Screw, ball joint of push rod on M6 10 Nm (7.4 lbf ft)
foot brake cylinder Loctite®243™
Screw, battery support bracket M6 4.5 Nm (3.32 lbf ft)

27
4 TECHNICAL DATA

Screw, battery terminal M6 4.5 Nm (3.32 lbf ft)

Screw, brake assembly M6 5 Nm (3.7 lbf ft)
Screw, clutch assembly M6 5 Nm (3.7 lbf ft)
Screw, cross member in rear M6x13 10 Nm (7.4 lbf ft)
Loctite®243™
Screw, engine guard M6x8 8 Nm (5.9 lbf ft)
Screw, engine guard M6x10 10 Nm (7.4 lbf ft)
Loctite®243™
Screw, foot brake cylinder M6 10 Nm (7.4 lbf ft)
Loctite®243™
Screw, footrest bracket, rear M6 9 Nm (6.6 lbf ft)
Loctite®243™
Screw, front brake disc M6 14 Nm (10.3 lbf ft)
Loctite®243™
Screw, front wheel speed sensor M6 6 Nm (4.4 lbf ft)
Screw, fuel tank cover M6x12 8 Nm (5.9 lbf ft)
Screw, fuel tank cover M6x18 5 Nm (3.7 lbf ft)
Loctite®243™
Screw, fuel tank cover M6 5 Nm (3.7 lbf ft)
Loctite®243™
Screw, fuel tank spoiler attach- M6 3 Nm (2.2 lbf ft)
ment
Screw, ground wire on frame M6 6 Nm (4.4 lbf ft)
Screw, ground wire to starter motor M6 10 Nm (7.4 lbf ft)
Screw, headlight mask M6 10 Nm (7.4 lbf ft)
Loctite®243™
Screw, ignition lock (tamper-proof M6 Tighten until the head tears off.
screw)
Loctite®243™
Screw, magnetic holder on side M6 2 Nm (1.5 lbf ft)
stand Loctite®243™
Screw, manifold clamp M6 8 Nm (5.9 lbf ft)
Copper paste
Screw, radiator bracket, bottom M6 5 Nm (3.7 lbf ft)
Screw, rear brake disc M6 14 Nm (10.3 lbf ft)
Loctite®243™
Screw, rear wheel speed sensor M6 6 Nm (4.4 lbf ft)
Screw, seat fixing M6 5 Nm (3.7 lbf ft)
Screw, seat lock M6 10 Nm (7.4 lbf ft)
Loctite®243™
Screw, shift rod M6 10 Nm (7.4 lbf ft)
Loctite®243™
Screw, shift shaft deflector on shift M6 10 Nm (7.4 lbf ft)
shaft Loctite®243™
Foot brake lever, fitting M8 25 Nm (18.4 lbf ft)
Loctite®2701™
Nut, manifold on cylinder head M8 Tighten the nuts evenly. Do not
bend the metal.
20 Nm (14.8 lbf ft)
Copper paste

28
 TECHNICAL DATA 4

Nut, rear sprocket screw M8 35 Nm (25.8 lbf ft)

Loctite®2701™
Pin, rear brake caliper M8 22 Nm (16.2 lbf ft)
Remaining nuts, chassis M8 25 Nm (18.4 lbf ft)
Remaining screws, chassis M8 25 Nm (18.4 lbf ft)
Screw, bottom triple clamp M8 12 Nm (8.9 lbf ft)
Screw, engine fixing arm linkage M8 25 Nm (18.4 lbf ft)
bracket Loctite®243™
Screw, engine guard frame M8 25 Nm (18.4 lbf ft)
Loctite®243™
Screw, fork stub M8 15 Nm (11.1 lbf ft)
Screw, grab handle M8 25 Nm (18.4 lbf ft)
Loctite®243™
Screw, handlebar clamp M8 20 Nm (14.8 lbf ft)
Screw, main silencer fastening M8 15 Nm (11.1 lbf ft)
Screw, passenger seat bracket M8 25 Nm (18.4 lbf ft)
Loctite®243™
Screw, presilencer on frame M8 25 Nm (18.4 lbf ft)
Loctite®243™
Screw, rear footrest bracket M8 25 Nm (18.4 lbf ft)
Loctite®243™
Screw, shift lever M8 25 Nm (18.4 lbf ft)
Loctite®2701™
Screw, spring holder plate on side M8 15 Nm (11.1 lbf ft)
stand bracket Loctite®2701™
Screw, steering damper on holder M8 8 Nm (5.9 lbf ft)
Loctite®243™
Screw, steering damper on triple M8 8 Nm (5.9 lbf ft)
clamp Loctite®243™
Screw, steering stem M8 20 Nm (14.8 lbf ft)
Loctite®243™
Screw, top triple clamp M8 15 Nm (11.1 lbf ft)
Securing bolt for brake linings M8 10 Nm (7.4 lbf ft)
Remaining nuts, chassis M10 45 Nm (33.2 lbf ft)
Remaining screws, chassis M10 45 Nm (33.2 lbf ft)
Screw, engine bracket M10 45 Nm (33.2 lbf ft)
Loctite®243™
Screw, front footrest bracket M10x30 45 Nm (33.2 lbf ft)
Loctite®243™
Screw, front footrest bracket M10x40 45 Nm (33.2 lbf ft)
Loctite®243™
Screw, front footrest bracket M10x65 45 Nm (33.2 lbf ft)
Loctite®243™
Screw, handlebar support M10 45 Nm (33.2 lbf ft)
Loctite®243™
Screw, side stand M10 40 Nm (29.5 lbf ft)
Loctite®243™
Screw, subframe M10 50 Nm (36.9 lbf ft)
Loctite®243™
Banjo bolt, brake line M10x1 25 Nm (18.4 lbf ft)

29
4 TECHNICAL DATA

Screw, front brake caliper M10x1.25 45 Nm (33.2 lbf ft)

Loctite®243™
Screw, bottom shock absorber M12 80 Nm (59 lbf ft)
Loctite®2701™
Screw, swingarm pivot M12 100 Nm (73.8 lbf ft)
Screw, top shock absorber M12 80 Nm (59 lbf ft)
Loctite®2701™
Lambda sensor M18x1.5 50 Nm (36.9 lbf ft)
Adjusting screw, swingarm M20LHx1.5 10 Nm (7.4 lbf ft)
Nut, rear wheel spindle M25x1.5 90 Nm (66.4 lbf ft)
Thread and contact area of wheel
spindle greased
Screw, front wheel spindle M25x1.5 45 Nm (33.2 lbf ft)
Thread greased
Screw, steering head M25x1.5 18 Nm (13.3 lbf ft)

30
 SUBSTANCES 5

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).

31
*3214166en*
3214166en

03/2020

KTM Sportmotorcycle GmbH

5230 Mattighofen/Austria Photo: Mitterbauer/KISKA/KTM
http://www.ktm.com