2016 KTM 1290 Super Adventure Service Repair Manual
Repair Manual – Important Information
Read Carefully Before Beginning Work
Read this repair manual carefully and thoroughly before starting any maintenance or repair tasks.
The vehicle will only perform at its best and meet operational demands if the specified service work is carried out regularly and properly.
About This Repair Manual
This manual has been written to reflect the latest state of the model series. However, we reserve the right to implement technical advancements without immediately updating the content of this repair manual.
Workshop Methods and Safety Rules
We do not provide descriptions of general workshop practices in this document. Similarly, standard workshop safety rules are not repeated here.
It is assumed that all repair work will be performed by a fully trained mechanic with appropriate knowledge and skills.
2016 KTM 1290 Super Adventure Service Repair Manual
Manufacturer’s Disclaimer
Non-Binding Specifications
All specifications in this manual are non-binding. KTM Sportmotorcycle GmbH reserves the right to:
Possible Modifications
Modify or delete technical specifications
Change prices, colors, forms, materials, services, and equipment
Adjust designs to meet local conditions
Stop production of specific models without prior notice
Liability Exclusions
KTM accepts no liability for:
Delivery options
Deviations from illustrations and descriptions
Misprints and other errors
Note: Some models shown may include special equipment not included in the standard scope of supply.
Applicable Models
This repair manual is valid for the following models:
KTM 1290 Super Adventure Series
1290 Super Adventure EU (F9903PA)
1290 Super Adventure FR (F9923PA)
1290 Super Adventure AU (F9960PA)
1290 Super Adventure JP (F9986PA)
1290 Super Adventure US (F9975PA)
1290 Super Adventure CN (F9987PA)
6.3 Bleeding the Fork Legs
6.4 Cleaning the Dust Boots of the Fork Legs
6.5 Loosening the Fork Protector
6.6 Positioning the Fork Protector
6.7 Removing the Fork Legs
6.8 Installing the Fork Legs
6.9 Removing the Fork Protector
6.10 Installing the Fork Protector
6.11 Performing a Fork Service
6.12 Disassembling the Fork Legs
6.13 Removing the Spring
6.14 Disassembling the Cartridge
6.15 Disassembling the Piston Rod
6.16 Disassembling the Hydrostop Unit
6.17 Disassembling the Seal Ring Retainer
6.18 Checking the Fork Legs
6.19 Assembling the Seal Ring Retainer
6.20 Assembling the Hydrostop Unit
6.21 Assembling the Piston Rod
6.22 Assembling the Cartridge
6.23 Assembling the Fork Legs
6.24 Lubricating the Steering Head Bearing
6.25 Removing the Lower Triple Clamp
6.26 Installing the Lower Triple Clamp
6.27 Checking the Steering Head Bearing Play
6.28 Changing the Steering Head Bearing
6.29 Adjusting the Play of the Steering Head Bearing
7. Handlebar and Controls
7.1 Handlebar Position
7.2 Adjusting the Handlebar Position
7.3 Adjusting the Basic Position of the Clutch Lever
7.4 Checking the Routing of the Throttle Cable
7.5 Checking the Play in the Throttle Cable
7.6 Adjusting the Play in the Throttle Cable
8. Frame
8.1 Removing the Engine Guard
8.2 Installing the Engine Guard
8.3 Checking the Frame
9. Shock Absorber and Swingarm
9.1 Adjusting the High-Speed Compression Damping
9.2 Adjusting the Low-Speed Compression Damping
9.3 Adjusting the Rebound Damping
9.4 Measuring Rear Wheel Sag (Unloaded)
9.5 Checking the Static Sag of the Shock Absorber
9.6 Checking the Riding Sag of the Shock Absorber
9.7 Adjusting the Spring Preload
9.8 Adjusting the Riding Sag
9.9 Removing the Shock Absorber
9.10 Installing the Shock Absorber
9.11 Checking the Shock Absorber Linkage
9.12 Servicing the Shock Absorber
9.13 Removing the Spring
9.14 Disassembling the Damper
9.15 Disassembling the Piston Rod
9.16 Disassembling the Seal Ring Retainer
9.17 Changing the Pilot Bushing
9.18 Checking the Damper
9.19 Removing the Heim Joint
9.20 Installing the Heim Joint
9.21 Assembling the Seal Ring Retainer
9.22 Assembling the Piston Rod
9.23 Assembling the Damper
9.24 Bleeding and Filling the Damper
9.25 Filling the Damper with Nitrogen
9.26 Installing the Spring
9.27 Checking the Swingarm
9.28 Removing the Swingarm
9.29 Installing the Swingarm
9.30 Changing the Swingarm Bearing
10. Exhaust
10.1 Removing the Manifold
10.2 Installing the Manifold
10.3 Removing the Main Silencer
10.4 Installing the Main Silencer
10.5 Changing the Glass Fiber Yarn Filling of the Main Silencer
11. Air Filter
11.1 Removing the Air Filter Box Cover
11.2 Installing the Air Filter Box Cover
11.3 Removing the Air Filter
11.4 Installing the Air Filter
11.5 Cleaning the Air Filter and Air Filter Box
