KTM 1190 Adventure 2014 Manuel

SETUP INSTRUCTIONS 2014

1190 Adventure EU

1190 Adventure FR

1190 Adventure AU

1190 Adventure JP

1190 Adventure US

Art. no. 3213162en

INTRODUCTION 1

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.

Print out the current PDI form found on the KTM DEALER.NET.

These setup instructions were written to correspond to the latest state of this series. We reserve the right to make changes in the inter-

est 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 AG specifically reserves the right to modify or delete technical specifica-

tions, 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 descriptions, as well as misprints and other errors. The models portrayed partly contain spe-

cial equipment that does not belong to the regular scope of supply.

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 AG

5230 Mattighofen, Austria

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.

Denotes a voltage measurement.

Denotes a current measurement.

Denotes a resistance measurement.

1.2 Formats used

The typographical formats used in this document are explained below.

Proprietary name Identifies a proprietary name.

Name®Identifies a protected name.

Brand™ Identifies a trademark.

2 SETUP 3

2.1 Unpacking and setting up the vehicle

Preparatory work

–Remove the box.

202178-10

Main work

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

202179-10

–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.

202180-10

–Remove the controls from the transport holder. Remove the screws and handlebar

clamps. Remove the transport holder.

202181-10

–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.

202182-10

–Position the handlebar.

The markings of the scale of the handlebar are located centrally between

the handlebar clamps.

–Position the handlebar clamps. Tighten the screws evenly.

Guideline

Screw, handlebar clamp M8 20 Nm

(14.8 lbf ft)

–Check the throttle grip for smooth operation.

2 SETUP 4

202183-10

–Remove the film from the headlight. Position the screen. Mount and tighten

screws .

202184-10

–Mount and tighten the rear mirror on both sides.

202185-10

–Mount reflector on retaining plate with spring washers .

–Mount the retaining plate on the license plate holder. Mount the license plate

holder.

–Carefully loosen and remove the tensioning belt over the swingarm.

Info

An assistant prevents the motorcycle from falling over.

–Carefully loosen and remove the tensioning belts around the lower triple clamp.

The vehicle is released at the front.

–Together with an assistant, take the vehicle off the pallet.

202197-10

–Remove the radiator shield.

202186-10

–Mount rubber dampers 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)

–Recharge the battery. ( p. 7)

–Store the tool set below the seat.

–Remove the remaining films.

–Refuel. ( p. 8)

2 SETUP 5

–Print out the current PDI form found on KTM DEALER.NET and perform the delivery

inspection.

3 WORK 6

3.1 Removing the passenger seat

G00574-10

–Insert the ignition key in seat lock and turn it clockwise.

–Raise the front of the passenger seat, pull it toward the tank, and remove it

upward.

–Remove the ignition key.

3.2 Mounting the passenger seat

401680-10

–Attach the hooks on the passenger seat to the brackets on the subframe, and lower

at the front while pushing toward the rear.

–Insert locking pin into the lock housing and push down the front of the passen-

ger seat until the locking pin engages with a click.

–Check that the passenger seat is correctly mounted.

3.3 Removing the driver's seat

Preparatory work

–Remove the passenger seat. ( p. 6)

G00575-10

Main work

–Raise the rear of the driver's seat.

–Detach the front of the driver's seat and remove it.

3.4 Mounting the driver's seat

401704-10

Main work

–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.

–Finally, check that the driver's seat is correctly mounted.

Finishing work

–Mount the passenger seat. ( p. 6)

3 WORK 7

3.5 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 discard batteries with the household waste. Dispose of faulty batteries in an environmentally compatible 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 charge state and the type of charge are very important for the service life of the battery.

Rapid recharging with a high charging current shortens the battery's service life.

If the charging current, charging voltage, and charging time are exceeded, electrolyte escapes through the safety valves. This

reduces the battery capacity.

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 sulfate, destroying the

battery.

The battery is maintenance-free, i.e., the acid level does not have to be checked.

If the battery is not charged using the KTM battery charger, the battery must be removed for charging. Otherwise, overvoltage

may damage electronic components. Charge the battery according to the instructions on the battery housing.

Preparatory work

–Switch off all power consumers and switch off the engine.

–Remove the passenger seat. ( p. 6)

–Remove the driver's seat. ( p. 6)

S00373-10

Main work

–Pull locking mechanism in the direction of the arrow.

–Fold open cover .

602677-11

–Disconnect the negative cable of the battery to avoid damage to the motorcy-

cle's electronics.

3 WORK 8

602678-01

–Connect the battery charger to the battery. Switch on the battery charger.

Battery charger (58429074000)

You can also use the battery charger to test the open-circuit voltage and start

potential of the battery, and to test the alternator. With this device, you cannot

overcharge the battery.

Info

Charge the battery with a maximum of 10% of the capacity specified on the

battery housing.

–Switch off and disconnect the battery charger after charging.

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

602677-11

–Connect both negative cables .

Guideline

Screw, battery terminal M6 4.5 Nm

(3.32 lbf ft)

202567-10

–Fold down cover and let it lock by pushing down lightly.

Finishing work

–Mount the driver's seat. ( p. 6)

–Mount the passenger seat. ( p. 6)

–Set the time and date.

3.6 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.

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