KTM 790 Adventure R 2019

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REPAIR

MANUAL

2019

790

Adventure

Art.

no.

3206373en

Main Page

Table of Contents4
Syste M, in Struments4
Representation10
Symbols Used10
Formats Used10
Advice11
Repair Manual11
Safety Advice 211
Degrees of Risk and Symbols11
Work Rules11
Notes12
Manufacturer and Impl Ied Warranty12
L, aux Ili Ary Substances12
Spare Parts, Accessories12
Figures12
L Numbers13
Icle Identificat Ion Number13
La Bel13
Number13
Engine Number14
Fork Part Number14
Shock Absorber Article Number14
Steering Damper Article Number15
Cover15
The Motorcyc le with the Front16
Tak Ililg the Motorcyc le off the Front Lifting Gea R16
Lifting Gear17
The II Fti Ng Gear17
The Work Stand17
Removing the Motorcyc le from Th E Stand at the Rear18
Raising the Motorcycle at T He Front Using the Work Stand18
Removing the Motorcyc le from the Work Stand at the F Ront19
Starting the Vehicl E20
Starting T He Motorcycle to Check the Ction21
Ning the Dust Boots of the Fork Legs22
Usting the Compress Ion Damp Ing F Ork22
Adjusting the Rebound Damp Ing of the Fork23
Adjustin G the Spring Pretens Ion of K23
Protector25
Installin G T He Fork Legs 6 .9 Servic Ing the Fork29
Fork Legs30
Cartridge33
Compression36
Compression38
Rtridge39
Legs43
Preparing for Use after Storage43
Bearing48
Triple Clamp50
Triple Clamp52
Ing Head Bea Ri Ng56
Clamp58
Cha Ngi Ng the Steering58
Damper58
Handlebar, Controls 759
Ad Just Ing the Clutch Lever59
Checki Ng the Free Travel59
Lever60
Tiand Lebar Position60
Cha Nging T He Thrott le61
Grip61
Frame64
Checking the Frame64
Shock Absorber, Link Fork 965
Adj Usting T He Low-Speed65
Of T He Shoc K65
Damping of T He Shoc K65
The Shoc K Absorber66
Of the ...... .... .. ... ...... 65 Joint for Play67
The Shock Absorber68
Shock Absorber70
Joint72
Piston Rod77
Chec King the Damper80
13.12 Installing80
Removing Th E Heim Joint81
Installing the Heim Joint82
Assemb Li Ng the Rebound Adjust er82
The Damper90
Installing the Spring91
Checking the Link Fork92
For Play92
Removing the Lin K Fork93
Bearing95
Installing the Link Fork99
10 Exhaust System102
Installing the Main Silencer102
Lencer102
System103
System105
Air Filter 11111
Removing the Air Filter111
Installing the Air Filter112
A Ir Fil Ter Box112
Fuel Tank, Seat, Trim 12115
Ler Cap115
R Cap115
Removi Ng the Seat116
Mounting the Seat116
Removing the Fu el Ta Nk116
Installing the Fuel Tank119
Refueling119
Nsor124
13 Mask, Fender, Decal132
Removing the Left Side Cover132
Cover132
Ler134
K Spoiler135
Spoiler136
Removing Left Fuel Tank Cover138
The Left Fu el Tank Cover138
Removing Ri Ght Fuel tan K Cover139
Alling Th E Right F Uel tan K Cover139
Removing Engine Guard140
Install Ing the Engine Guard140
Removing the Front Fen der142
Ng the Front Fende R142
Removing the Windshie Ld143
The Windshield143
Checking Tire Pressure144
King the Tire Condition144
Checking T He Rim Run-Out145
Checking the Wh Eel Bearing for ........ ..... .. ............................. 144 Tubeless Ti Re System146
Checking Spoke Tension147
Ng Brake DI Scs148
Programm Ing the T Ire Press Ure Sensor (Option : with TP MS)148
Wheel149
Removing the Front Wheel149
Lnstall I Ng the Front Whee L150
Changi Ng the Fro Nt Whee I Bearing151
Changing the Front Brake Discs153
Changing the Front Tubeless Sealing Profile154
Sensor (Option : with TPMS)157
Wh Eel158
Removi Ng the Rear Whee I158
14.10.2 Installing the Rear Wheel159
Removi Ng the Rear Whee I (Work Stand, Front)160
Insta Lli Ng the Rear Whee L161
Removi Ng the Rear Whee I (Work Stand , Rea R)163
Lnsta L II Ng the Re Ar Whee L (Work Stand , Rear)164
14.10.7 C Hanging the Rear Wheel Bearing165
Sprocket Carrier167
14.10.9 Changing the Rear Brake Disc168
Changi Ngtherear Tu Beless Sealing Profile169
Changi Ng the Rear T Ire Pressure Se Nsor (Option: with TPMS)172
Checking the Chai N Tension173
14.10.13 Adjusting the Chain Tension174
Checking the Cha In, Rear175
Cleaning the Chain177
01Pening the Chain178
Riveting the Chain178
Checking the Rear Hub Damping179
Rubber Pieces179
14.10.19 Changing All the Damping Rubber Pieces of the Rear Hub180
Changing the Drivetrain Kit181
Battery184
Removing the 12-V Battery184
Alling the 12-V Battery185
The 12-V Battery186
The 12-V Battery187
Chargi Ng the 12-V Battery188
Changing the Ma in Fuse189
Consumers192
King the Charging Voltage192
Checking the Open-Circu It Current192
Checking T He Front Brake Li ni Ngs193
Changing the Front Brake Lin Ings193
Checking the Front Bra Ke Fluid195
Ing the Fron T Brake Fluid196
Changing the Front Bra Ke Fluid197
Adjusting the Basic Position of the Hand Brake Lever199
Checking T He Rear Brake Linings199
Rear Wheel Brake200
Brake Lever203
Checking the Rear Brake Flu204
Adding Rear Brake F Lui- D205
Bleeding the Brake System208
Rem Oving the Headl Ight Mask with Head Light209
Alling the Headlight Mask with Head Light211
Combination Instrument 18215
Activation and Test215
Day-Night Mocle215
Warnings216
Ice Warning216
Indicator Lamps217
Display218
RALLY Display219
Speed220
Sh Ift Warning Light220
Speedometer220
Cru Ise Control Indicator221
Ride Display221
ABS Display221
MTC Display221
Coolant Temperature Indicator222
Fuel Level Display222
Ambien T Air Temperature223
Time223
Favorites DI Splay223
Quick Selector223
Navigation Display224
Menu225
Ktm My Ri225
Audio (Optional)225
Navigation Setup226
Volume (Optional)227
Pairing228
Phone228
Headset (Optional)228
18.25.9 Telephony230
Trip231
Motorcycle231
18.25.23 Abs236
Abs237
Quick Shift+ (Optional)237
Settings237
18.25.27 Favorites238
Quick Selector 1238
Quick Selector238
Bluetooth241
18.25.37 Drl241
18.25.40 Temperature243
Fuel Cons243
18.25.42 Language243
18.25.43 Service244
Engine 19245
Removing T He Engine245
Engine Disassembly262
Engine Assembly Stand262
The262
Into the262
Dra Ining the Engine Oil263
Removing the Oil Filter263
Motor264
Removing Shift Shaft Sensor265
Removing the Spacer266
19.3.11 Removing the Crankshaft267
Removing the Thermostat268
Removing the Clutch269
19.3.16 Removing the Clutch Discs270
19.3.17 Removing the Clutch Basket271
Removing Locking Lever272
Removing the Shift272
Removing the Spark Plugs273
Removing the Camshafts273
Removi Ng the T Iming Chain Rai Ls276
19.3.24 Removing the Rotor276
19.3.25 Removing the Oil Pan277
Removing the Oil Pump Unit278
Removing the Engine Case Downwards279
Removing the Transmission Shafts280
Removing Oil Spray Tube282
Removing the Piston282
Working on Ind Ividual Parts284
Check Ing T He Radia L Clearance of284
Changing the Main Bearing Shells285
Checking the Balancer Shaft286
Engine Case286
Working on the Lower Section of289
Engine Case289
Shells289
Lnsta L II Ng the Primary Gear Whee L290
Changing the Shaft Seal Ri Ng of Water Pump290
Check Ing the Rad Ia L Clearance of Lowerconrod Bearing292
Changing the Conrod Beari Ng292
Inder - Nikasil@ Coating294
Checking/Measuring the Cylinder294
Checking/Measuring the Piston295
Check Ing the Piston Ri Ng End296
19.4.15 Determining the Piston/Cylinder Mounting Clearance296
Removi Ng the Oil Pumps297
Checking the Oil Pumps for Wear298
Check Ing the Oi I Pressure Control Valve299
Installing the Oil Pumps300
Prepari Ng Tim Ing Chai N Tensioner Instal Lation301
Checking the Timing Assembly302
19.4.22 Working on the Camshaft Bearing Bridge303
19.4.23 Working on the Cylinder Head304
C Hecking the Cylinder Head309
19.4.25 C Hecking the Clutch311
19.4.26 Removing the Shift Drum Locating Unit312
19.4.27 C Hecking the Shift Mechanism313
Preassembl Ing the Shift Shaft314
Installing the Shift Drum315
Locating Unit315
Disassembling the Main Shaft316
Disassembling the Countershaft317
Checking the Transmission318
Assembling the Main Shaft319
Assembling the Countershaft320
Checking the Electric Starter Drive322
19.4.36 C Hecking the Freewheel323
19.4.37 Working on the Alternator Cover323
Engine Assemb Ly324
Installing the Piston324
Installing the Oil Spray Tube326
Installing the Transmission Shafts326
Installing the Lower Engine Case328
Installing the Oil Pump Unit331
Installing the Oil Pan331
Installing the Rotor332
Installing the Timing Chain Ra Ils333
Installing the Cylinder Head333
Installing the Camshafts335
Checking the Valve Clearance338
Adjusting the Valve Clearance339
Installing the Spark Plugs340
19.5.14 Installing the Shift Shaft340
19.5.15 Installing the Locking Lever341
Installing the Elute H Basket341
Installing the Clutch Discs342
Installing the Elute H Cover343
Mounting the Water Pump Cover344
Install Ing the Thernnostat344
Installing the Heat Exchanger345
Installing the Crankshaft Speed Sensor345
Installing Torque Limiter and Starter Idler Gear346
Installing the Alternator Cover346
Installing the Spacer347
Installing the Gear Position Sensor347
Installing the Shift Shaft Sensor348
19.5.28 Installing the Valve Cover349
19.5.29 Installing the Starter Motor350
19.5.30 Installing the Oil Filter350
19.5.31 Installing the Oil Drain Plug351
Removing the Engine from the Engine Assembly Stand351
Adjusting the Clutch Release Lever352
Ion Sensor361
Sh Ift Shaft Sensor364
Ll Leve L and366
The Va Lve Clearance373
Clearance380
Oil Level381
Pressure382
And Oil383
The Stator391
Plugs394
Initial Ization Run398
Lim Its401
Capacities405
Engine Oil405
Fuel405
Chassis405
Electrical System406
Diagnostics Connector406
Accl and ACC 2 Rear407
Tires407
Fork407
Shock Absorber408
Chassis Tightening Torque S408
28 Cleaning/Protective Treatment412
Cleaning the Motorcycle412
Checks and Maintenance Steps for Winter Operation413
29 Storage414
Service Schedule 30415
Additional Information415
Recommended Work416
Eu)418
Eu)420
Wiring Diagram 31421
Eu)422
Eu)424
Eu)426
Of (EU)428
Of (EU)430
31.8 Page 8 of 12 (EU)432
Eu)434
Eu)436
Eu)438
E U)440
Of 12 (US)442
Of (US)448
U S)454
1.2 1 Page 9 of 12 (US)458
12 (U S)462
Of 12 (US)464
32 Substances466
Auxiliary Substances469
34 Special Tools470
35 Standards488
Index of Special Terms 36489
37 List of Abbreviations490
List of Symbols 38491
Red Symbols491
Yell Ow and Orange Symbo Ls491
Green and Blue Symbols491
Index492

KTM 790 Adventure R 2019 - Repair Manual

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