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Month: August 2019

Chain tension

The manual is not very clear on how to check the chain tension. I mean, at first glance this doesn’t look obvious, and if you don’t know that “link fork” means “swing arm” in KTM lingo, this is even more obtuse.

Manual page about chain tension

Also, to use this procedure, you need the rear lifted from the ground, from the swing arm with your favorite lifting gear. Using this procedure with a center stand or side stand will make the chain too loose or too tight!

It’s not that complicated once the process is understood: with the top portion of the chain taunt to begin with, you lift the lower chain in the position they indicate at the rear end of the B arrows, 2.5cms after the end of the slide. The gap (‘A’) needs to be 2-5mm between the swing arm and the chain (source).

There is another view of the same method, this one documented on a sticker affixed to the swingarm:

If in doubt prefer a loose chain. At rest on the side stand, the chain should be very slack.

Tires. Tyres. Pneus. Rueda. Rubber.

What tire should you use?

There are as many opinions about tires than they are pilots on the road. What tires to get? Well, it depends. This FAQ will not go into the trap of recommending a particular set.

Here is an exhaustive list of tires, most of them with a size compatible with the 790 (it’s in French, just ignore the text). It goes from 10% off-road to 95% off-road. Each notch sacrifices a bit of road manner to improve some off-road capabilities. Make your own choice.

If you are really desperate, there is a thread about it on advrider.

Size, speed rating, load index, and factory fit.

The 790 Adventure R and Rally comes with Metzeler Karoo3 (Due to the M+S status of those tires, speed must be kept under 170km/h (106mph), as denoted by the ‘R’ speed rating in the tire denomination). The Rally version, due to its narrower rims and lack of air sealant, uses tubes inside those tires. The R version is tubeless.

  • Front 90/90-21 M/C 54R M+S TL
  • Rear 150/70-18 M/C 70R M+S TL

The 790 Adventure S comes with Avon Trailriders (Those are ‘V’ rated, up to 240 km/h – 149mph)

  • Front 90/90-21 M/C 54V TL
  • Rear 150/70R18 M/C 70V TL

Both share the same load index, 54 front, 70 rear, meaning a max weight of 212kg (467lbs) in the front, and 335kg (739lbs) on the rear. This should be plenty, and if you buy a new set, it must match or exceed those values.

For example (and this is just an example, not a recommendation!) the Motoz Rallz are available in the following size:

  • Front 90/90-21 M/C 54Q TL
  • Rear 150/70B18 M/C 70Q TL

Right size for the bike, and same load index of 54 and 70. Note that the rear tire is Belted instead of Bias ply for the Karoo3 and Radial for the Trailriders. But most importantly the speed is further limited to 160km/h (99mph) with these tires.

Using tubes on tubeless rims

On the front wheels, no issues in using tubes. On the rear wheel for the non rally models the valve is offset. A tube might work for a bit, but it’s not ideal, and may lead to the tube valve breaking. The only known way to solve this is to use the Motoz TUUOV 18-150-170, which has an offset valve (it’s also 4mm rubber, which is very very thick).

Tire pressure

It’s all in the manual, and the same pressure for all models (The S manual doesn’t mention off-road)

Adventure R manual, page 257

Fuel cap hack

It is annoying to not being able to click the fuel cap back in place, you need to use the key to open and to close the cap. For people with a Scott Damper in place this is highly annoying as the cap is hinged forward: you need to use the key to open the cap, remove the key so it doesn’t hit the damper, open fully, fill the tank and then put the key back in the lock to close the cap.

One solution is to install the KTM screw fuel cap (P/N 63507908044), but this means the tank is no longer locked (and the cap is not attached to the bike). Or get one from a powercell, CJ Design or slingshot racing.

KTM screw fuel cap (P/N 63507908044)

An excellent solution is a hack that allows for closing the fuel cap by just pressing on it, no key necessary. The key is still required to open the cap, but you can remove it right away as you don’t need it to close.

First you need to take out the 2 Phillips screws to remove the cover over the latch pawl: watch out the spring and pawl will probably go flying, as they did on this pic. This can be done on the bike, but make sure you cover and protect the hole so nothing can fell in the fuel tank. An alternative is to first remove the assembly from the bike.

Removing the cover

When you have retrieved the pawl and spring, take the pawl and mark the black area, which will have to be removed to allow the pawl to move when the key is removed:

Marked area to remove

Drill, grind, file with your favorite tools (drilling first to the floor, then dremel to finish seems the easiest way to do so) until you get to this result:

Expected result

You then reassemble the lock by carefully maintaining the spring and pawl in place while you slid and screw the cover back on top.

[This is all a copy of the AdvRonski hard work on All credits to him for the idea, the realisation and the photos, all on this post. And to Braaap! who followed the instructions successfully and encouraged me to put this in the FAQ]

Toolkit and fasteners

The following comes in the tool kit with the bike:

  • H6 T-Handle
  • H6 Allen Key
  • T25 Allen Key
  • 17mm Skt (H6 Drive)
  • T30 – (H6 drive)
  • T40 – (H6 drive)
  • T45 – (H6 drive)
  • Flat – (H6 drive)
  • PH2 – (H6 drive)
  • 8 & 13mm Wrench
  • 10 & 14mm Wrench
  • 32mm Wrench
  • Suspension tool (In all toolkits, but only useful on the ‘S’ Model)

The following are the dimensions for the fasteners most likely to be touched while riding:

  • T25 Brake Lever Height
  • T30 Bodywork
  • T30 / H6 Hand Guards
  • T30 / 10mm Skid Plate
  • T40 Handlebars
  • H5 / 14mm Mirrors
  • 10mm / 13mm Chain Tension
  • 32mm Rear Axle
  • 32mm Front Axle
  • T40 Front Axle Clamp
  • T40 Triple Clamps
  • 32mm Wrench Headstock
  • 12mm Wrench Clutch cable
  • 10mm Wrench Brake & Clutch Levers
  • T45 Subframe
  • T45 Luggage Rack
  • T45 Brake Caliper
  • T30 ABS Sensor
  • 17mm Skt Shock High Speed Compression (R only)
  • Flat Head Shock Low Speed Compression (R only)
  • Flat Head Shock Rebound Damping (R only)
  • H5 Shock Pre-Load (R only)

(Thanks to riverlink for the compilation)