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KTM 790 Adventure 2020 Setup Instructions

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SETUP INSTRUCTIONS
2020
790 Adventure
Art. no. 3214165en

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Summary of Contents for KTM 790 Adventure 2020

  • Page 1 SETUP INSTRUCTIONS 2020 790 Adventure Art. no. 3214165en...
  • Page 3 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.

  • Page 4: Means Of Representation

    1 MEANS OF REPRESENTATION 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.
  • Page 5 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.
  • Page 6 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.
  • Page 7 SETUP 2 Handlebar scale markings 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 6 Nm (4.4 lbf ft) Hand guard screw 25 Nm (18.4 lbf ft) F02129-01 –...
  • Page 8 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 Guideline Screw, brake assem- 5 Nm (3.7 lbf ft) F02131-10 –...
  • Page 9 SETUP 2 – Mount and tighten the rear mirror on both sides. F02144-01 – Mount rubber bushings on windshield – Mount windshield on windshield bracket The windshield engages on the left and right in the recesses of the windshield bracket. –...
  • Page 10 2 SETUP (790 Adventure EU) – Mount reflector with rubber bushings and tension washers on the license plate holder – Position the license plate bracket on the license plate sup- port. – Mount and tighten screws Guideline Screw, license 5 Nm (3.7 lbf ft) Loctite ®...
  • Page 11 SETUP 2 – Position the left fuel tank cover. – Mount and tighten screws with the collar bushings and the absorbing elements. Guideline Screw, fuel tank M6x18 5 Nm (3.7 lbf ft) Loctite ® 243™ cover – Position the right fuel tank cover. –...
  • Page 12 2 SETUP – Mount screws , but do not tighten yet. Guideline Screw, engine guard M6x8 8 Nm (5.9 lbf ft) F02140-10 – Mount screws , 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.
  • Page 13 Remove the labels from the brake line and the frame. – Remove the remaining films. – Check the headlight setting. ( p. 21) – Refuel. ( p. 23) – Prepare the vehicle according to the specifications in the KTM Dealer.net for handover to the customer. F02146-10...
  • Page 14 3 WORK Removing the passenger seat – Insert the ignition key in seat lock and turn it clockwise. – Raise the front of the passenger seat, pull it toward the tank, and take off from above. – Remove the ignition key from the seat lock. F01915-10 Mounting the passenger seat –...
  • Page 15 WORK 3 Mounting the front rider's seat Main work – Attach the recesses on the front rider's seat to the fuel tank at the desired seat position , and push the front rider's seat forward while lowering it at the rear. –...
  • Page 16 3 WORK Main work – Lift the elastic fastener and detach in area – Open storage compartment. F01898-10 Closing the storage compartment on the left Main work – Close the storage compartment. – Raise elastic fastener and hang up in area F01899-10 Finishing work –...
  • Page 17 WORK 3 Installing the left side cover Main work – Position the left side cover with holding lug on bushing and push backward. The left side cover engages under the tail part. – Press the left side cover in area into rubber bushing and press into rubber bushing in area...
  • Page 18 3 WORK Main work – Lift the elastic fastener and detach in area – Open storage compartment. F01900-10 3.11 Closing the storage compartment on the right Main work – Close the storage compartment. – Raise elastic fastener and hang up in area F01901-10 Finishing work –...
  • Page 19 WORK 3 3.12 Installing the right side cover Main work – Position the right side cover with holding lug on bush- and push backward. The right side cover engages under the tail part. – Press the right side cover in the area into rubber bush- and press into rubber bushing in area...
  • Page 20 3 WORK 3.14 Installing the battery cover Main work – Position the battery cover with holding lugs bushings and push downward. The battery cover engages on the left and right under the fuel tank spoiler. – Mount screws with the bushings and tighten. Guideline Screw, seat fixing 5 Nm (3.7 lbf ft)
  • Page 21 WORK 3 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.
  • Page 22 3 WORK 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. –...
  • Page 23 WORK 3 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 to the 12-V battery.
  • Page 24 3 WORK 3.19 Adjusting the headlight range Preparatory work – Check the headlight setting. ( p. 21) Main work – Remove screws – Remove the left mask spoiler. F01992-10 – Turn adjusting screw to adjust the headlight range. Info Turn clockwise to reduce the headlight range; turn counterclockwise to increase the headlight range.
  • Page 25 30) 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. 24) F01912-10...
  • Page 26 3 WORK 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 refuel the vehicle in the vicinity of open flames or lit cigarettes. –...
  • Page 27 WORK 3 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.

  • Page 28: Technical Data

    4 TECHNICAL DATA 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 ®...
  • Page 29 TECHNICAL DATA 4 Screw, battery support bracket 4.5 Nm (3.32 lbf ft) Screw, battery terminal 4.5 Nm (3.32 lbf ft) Screw, brake assembly 5 Nm (3.7 lbf ft) Screw, clutch assembly 5 Nm (3.7 lbf ft) Screw, cross member in rear M6x13 10 Nm (7.4 lbf ft) Loctite...
  • Page 30 4 TECHNICAL DATA Nut, manifold on cylinder head Tighten the nuts evenly. Do not bend the metal. 20 Nm (14.8 lbf ft) Copper paste Nut, rear sprocket screw 35 Nm (25.8 lbf ft) Loctite 243™ ® Pin, rear brake caliper 22 Nm (16.2 lbf ft) Loctite ®...
  • Page 31 TECHNICAL DATA 4 Screw, front footrest bracket M10x65 45 Nm (33.2 lbf ft) Loctite ® 243™ Screw, handlebar support 45 Nm (33.2 lbf ft) Loctite ® 243™ Screw, side stand 40 Nm (29.5 lbf ft) Loctite ® 243™ Screw, subframe 50 Nm (36.9 lbf ft) Loctite ®...
  • Page 32 5 SUBSTANCES 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.
  • Page 33 *3214165en* 3214165en 10/2019 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KISKA/KTM http://www.ktm.com...