KTM 890 ADVENTURE R 2023 Manual

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 model series. We reserve the right to make modifications in the interest of technical advancement without at the same time updating these setup instructions.

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 production of a particular model without prior notice. KTM accepts no liability for delivery options, deviations from figures and descriptions, misprints, and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of supply.

This document is valid for the following models:

• 890 ADVENTURE R EU (F9703X7) 890 ADVENTURE R AR (F9742X7)
• 890 ADVENTURE R CN (F9787X7)
• 890 ADVENTURE R US (F9775X7)
• 890 ADVENTURE R RALLY EU (F9703XD)
• 890 ADVENTURE R RALLY US (F9775XD)

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 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.

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

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 documented.
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.

Diagnostics connector

Diagnostics connector is located under the battery cover.

Unpacking and setting up the vehicle

• Remove the straps and the box.
  
• Remove the adhesive tape in the upper area of the motorcycle.
  
• Roll down the film at the sides.
  
  Guideline
  To avoid damaging the vehicle while setting it up, do not remove the protective film on each component until installing the component, and leave it on the vehicle until work has been completed.
• Remove the separate enclosure and unpack it. Check that the scope of supply is complete using the enclosed packing list.
  Info
  The procedure for 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 cable ties and protective film on the handlebar.
  
  
  Danger of accident
  A repaired handlebar poses a safety risk.
  If the handlebar is bent or straightened, the material 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 correctly. Position the handlebar clamps. Mount and tighten the screws evenly.

Guideline

Screw, handlebar clamp

M8

20 Nm (14.8 lbf ft)

• Markings face the rear.
• Handlebar scale markings are located centrally between the handlebar clamps.

Info
Keep the installed gap widths equal when tightening.

• Check the handlebar position.
  • If the handlebar position is not adjusted as required by the customer:
    • Adjust the handlebar position.
    • 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)

• 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)

• 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 assembly

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 correctly.

• Tie the cables and wires together with the rubber straps supplied.
• 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 .

Guideline

Screw, clutch assembly

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 correctly.

• Tie the cables and wires together with the rubber straps supplied.
• Mount and tighten the rear mirror on both sides.
  

(All EU/AR/CN models)

• Mount reflector with rubber bushings and tension washers on the license plate holder .
• Position the license plate bracket on the license plate support.
• Mount and tighten screws .
  

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.

(ADVENTURE R Rally EU/US)

• Remove main silencer.
• Install the main silencer.

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.

• Remove the seat.
• Remove spare key and KEYCODECARD from under the seat and keep in a safe place for the handover.
• Charge the 12-V battery.
  

Guideline
The 12-V battery must be fully charged before it is handed over to the customer.

Info
The first charging process may take longer with a new 12-V battery.

• Remove protection cap .
• Plug in the plug of the starter relay.
• Mount protection cap .
  

Info
The tool set is located in the storage compartment under seat .

• Remove the left side cover.
• Open storage compartment on the left.
• Store the tool set in the storage compartment.
• Close storage compartment on the left.
• Install the left side cover.
• Remove the labels from the brake line and the frame.
• Unpack and mount the KTM PowerParts included in the delivery (optional).
  

Info

Read the accompanying KTM PowerParts fitting instructions.

• Attach the stickers included in the scope of supply (optional).
• Install windshield.
• Check the headlight setting.
• Install the engine guard.
• Turn the knurled screws on both fuel cocks counterclockwise as far as possible.
• Refuel.
• Position all controls in their exact positions on the handlebar. Tighten all screws.
• Remove the remaining film, padding, the corrugated cardboard, and the other packaging material.
• Prepare the vehicle according to the specifications in KTM Dealer.net for handover to the customer.

Info
Transport mode must be deactivated to be able to start the motorcycle.

WORK

Adjusting the handlebar position

Danger of accidents
A repaired handlebar poses a safety risk.
If the handlebar is bent or straightened, the material becomes fatigued. The handlebar may break as a result.

• Change the handlebar if the handlebar is damaged or bent.

• Remove screws . Take off the handlebar clamps . Position the handlebar so that screws are accessible.

Info
Cover the components to protect them against damage. Do not kink the cables and lines.

• Remove screws . Take off handlebar supports .
• Move the handlebar supports into the desired position or . Mount and tighten screws .
  

Guideline
Mount the left and right handlebar supports in the same position.

Screw, handlebar support

M10

45 Nm (33.2 lbf ft) Loctite ® 243™

• Position the handlebar.
  

Info
Make sure the cables and wiring are positioned correctly.

• Position handlebar clamp. Mount screws and tighten evenly.

Guideline

Screw, handlebar clamp

M8

20 Nm (14.8 lbf ft)

Removing the seat

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

Mounting the seat

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

Removing the left side cover

Preparatory work

• Remove the seat.

Main work

• Remove left side cover from the rubber bushings in the areas and .
• Pull off the left side cover sideways and remove it toward the front.
  

Opening the storage compartment on the left

Preparatory work

• Remove the seat.
• Remove the left side cover.
  

Main work

• Lift the elastic fastener and detach in area .
• Open storage compartment.

Closing the storage compartment on the left

Main work

• Close the storage compartment.
• Raise elastic fastener and hang up in area .
  

Finishing work

• Install the left side cover.
• Mount the seat.

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 .
  

Finishing work

• Mount the seat.

Removing the right side cover

Preparatory work

• Remove the seat.

Main work

• Remove the side cover from the rubber bushings in areas and .
• Pull off the right side cover sideways and remove it toward the front.
  

Opening the storage compartment on the right

Preparatory work

• Remove the seat.
• Remove the right side cover.

Main work

• Lift the elastic fastener and detach in area .
  
• Open storage compartment.

Closing the storage compartment on the right

Main work

• Close the storage compartment.
• Raise elastic fastener and hang up in area .
  

Finishing work

• Install the right side cover.
• Mount the seat.

Installing the right side cover

Main work

• Position the right side cover with holding lug on bushing and push backward.
  • The right side cover engages under the tail part.
• Press the right side cover in the area into rubber bushing and press into rubber bushing in area .
  

Finishing work

• Mount the seat.

Removing the main silencer

(ADVENTURE R EU/AR/CN/US)

• Remove screw .
• Remove the clamp.
  
• Remove screw with the washer.
• Take off the main silencer.
  

(ADVENTURE R EU/AR/CN/US)

• Remove screw .
  
• Remove the clamp.
• Remove screw 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.

Installing the main silencer

(ADVENTURE R EU/AR/CN/US)

• Position the main silencer with the gasket.
• Mount screw with the washer, but do not tighten yet.
  

Guideline

Screw, main silencer holder

M8

25 Nm (18.4 lbf ft)

• Position the clamp.

Guideline

Distance

1 mm (0.04 in)

Info
The clamp must not touch the brake line when the rear wheel suspension compresses.

• Mount and tighten screw .
  

Guideline

Screw, presilencer exhaust clamp

M6

8 Nm (5.9 lbf ft) Copper paste

• Tighten screw .
  

Guideline

Screw, main silencer holder

M8

25 Nm (18.4 lbf ft)

(ADVENTURE R Rally EU/US)

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 with the washer, but do not tighten yet.
  

Guideline

Screw, main silencer holder

M8

25 Nm (18.4 lbf ft)

• Position the clamp.

Guideline

Distance

1 mm (0.04 in)

Info
The clamp must not touch the brake line when the rear wheel suspension compresses.

• Mount and tighten screw .
  

Guideline

Screw, presilencer exhaust clamp

M6

8 Nm (5.9 lbf ft) Copper paste

• Tighten screw
  

Guideline

Screw, main silencer holder

M8

25 Nm (18.4 lbf ft)

Removing the battery cover

Preparatory work

• Remove the seat.

Main work

• Remove screws with the bushings.
• Remove the battery cover from above.
  
  

Installing the battery cover

Main work

• Position the battery cover with holding lugs on 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

M6

6 Nm (4.4 lbf ft)

Finishing work

• Mount the seat.

Charging the 12-V battery

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.

Note

Danger of damage
An incorrectly selected charging mode will damage the 12-V battery.

• Always select a charging mode that is compatible with the type of battery.

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 when 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 immediately.
If the 12-V battery is left in a discharged state for an extended period, it will become deeply discharged and sulfating occurs, thus destroying the battery.
The 12-V battery is maintenance-free, i.e. the acid level does not have to be checked.

Preparatory work

• Remove the seat.
• Disconnect the negative cable of the 12-V battery.
  

Main work

• Connect a 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)
  Alternative 2
  UK battery charger XCharge‑professional (00029095052)

Info
Follow the instructions of the charger and the manual.

• Disconnect the battery charger after charging the 12-V battery. Guideline

The charging current, charging voltage, and charging time must not be exceeded.
Recharge the 12-V battery regularly when the motorcycle is not being used	6 months

Finishing work

• Connect the negative cable of the 12-V battery.
• Mount the seat.
• Set the time and date.

Disconnecting the negative cable of the 12-V battery

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.

Danger of accidents
Electronic components and safety devices will be damaged if the 12-V battery is discharged or missing.

If the 12-V battery is discharged or defective, malfunctions in the vehicle electronics can occur, especially when starting.

• Never operate the vehicle with a discharged 12-V battery or without a 12-V battery.

Preparatory work

• Remove the seat.

Main work

• Disconnect negative cable from the 12-V battery.
  

Connecting the negative cable of the 12-V battery

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.

Danger of accidents
Electronic components and safety devices will be damaged if the 12-V battery is discharged or missing.
If the 12-V battery is discharged or defective, malfunctions in the vehicle electronics can occur, especially when starting.

• 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.
  

Guideline

Screw, battery terminal

M6

4.5 Nm (3.32 lbf ft)

Finishing work

• Mount the seat.
• Set the time and date.

Installing the windshield

• Hook windshield into area .
• Mount and tighten screws .
  

Guideline

Remaining screws, chassis

M5

5 Nm (3.7 lbf ft)

• Mount and tighten screws .

Guideline

Remaining screws, chassis

M5

5 Nm (3.7 lbf ft)

Removing the windshield

• Remove screws .
• Remove screws and detach windshield in area .
  

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 under the first marking.

Guideline

Distance

5 cm (2 in)

• Position the vehicle upright at distance from the wall and switch on the low beam.
  

Guideline

Distance

5 m (16 ft)

• The rider now mounts the motorcycle with luggage and passenger if applicable.
• Check the headlight setting.
  The light-dark boundary must be exactly on the lower marking 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.

Adjusting the headlight range

Preparatory work

• Check the headlight setting.

Main work

• Turn adjusting screw 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.

• Set the headlight to marking .

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

Installing the engine guard

• Position the engine guard.
  • Damping rubbers engage in cut-outs on both sides.
    
• Mount screws , but do not tighten yet.
  

Guideline

Screw, engine guard

M6x10

10 Nm (7.4 lbf ft) Loctite®243™

• Mount screws , but do not tighten yet.
  

Guideline

Screw, engine guard

M6x8

8 Nm (5.9 lbf ft)

• 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™

• Attach tube to the angle piece.
  

Removing the engine guard

• Pull out hose from the angle piece.
  
• Remove screws .
  
• Remove screws .
  
• Remove engine guard .
  

Guideline
Pull the damping rubbers out of the cut-outs on both sides.

Refueling

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.

Danger of poisoning
Fuel is harmful to health.

• Avoid skin, eye and clothing contact with fuel.
• Immediately consult a doctor if you swallow fuel.
• Do not inhale fuel vapors.
• Rinse the affected area immediately with plenty of water in the event of contact with the skin.
• Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
• Change your clothing if 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.
• Fill the fuel tank with fuel up to the lower edge of the filler neck.
  

Total fuel tank capacity, approx.

19.5 l (5.15 US gal)

Super unleaded (ROZ 95)

• Close the fuel tank filler cap.

Opening the fuel tank filler cap

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.

Danger of poisoning
Fuel is harmful to health.

• Avoid skin, eye and clothing contact with fuel.
• Immediately consult a doctor if you swallow fuel.
• Do not inhale fuel vapors.
• Rinse the affected area immediately with plenty of water in the event of contact with the skin.
• Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
• Change your clothing if 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 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.
• Turn the ignition key 90° clockwise.
• Lift the fuel tank filler cap.

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.
  

Fire hazard
Fuel is highly flammable and a health hazard.

• Check that the fuel tank filler cap is locked correctly 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.

TECHNICAL SPECIFICATIONS

Chassis tightening torques

SUBSTANCES

Super unleaded (ROZ 95)

Standard/classification

• DIN EN 228 (ROZ 95)

Guideline

• Only use super unleaded fuel that matches or is equivalent to the specified standard.
• 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).

KTM.COM

Documents / Resources

References

• http://dealer.net
• KTM - READY TO RACE | United States

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