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2015 KTM 1190 Adventure Service Repair Manual
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🏷️ Basic Information Identification Make: KTM Model: 1190 Adventure Year: 2015 Sub Model: Standard / R Codes Vin Code: V2 👋 Introduction Market Position Category: Large-displacement adventure touring motorcycle. Target...
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🏷️ Basic Information
Identification
Make:
KTM
Model:
1190 Adventure
Year:
2015
Sub Model:
Standard / R
Codes
Vin Code:
V2
👋 Introduction
Market Position
Category:
Large-displacement adventure touring motorcycle.
Target Audience:
Riders seeking long-distance touring, off-road capability, and performance.
Competitive Analysis
Competitors:
BMW R1200GS, Ducati Multistrada, Yamaha Super Tenere, Triumph Tiger Explorer.
Key Features
Engine Type:
V-Twin LC8 engine, known for its power and torque.
Suspension:
WP electronic semi-active suspension (optional on standard, standard on R) offering adaptive damping.
Electronics:
Advanced rider aids including multi-level traction control and ABS.
Chassis Design:
Lightweight chassis with focus on agility and off-road prowess.
📋 Manual Details
Coverage Areas
All Systems:
Comprehensive coverage of all major motorcycle systems
Page Count
Pages:
450+
Manual Type
Type:
Factory Service Manual / Repair Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Engine:
Complete engine disassembly, assembly, inspection, and repair procedures for the LC8 V-Twin engine.
Fuel System:
Fuel injection system diagnostics, component testing, throttle body synchronization, and fuel pump operation.
Exhaust System:
Catalytic converter inspection, lambda sensor replacement, and exhaust component torque specifications.
Cooling System:
Coolant type, capacity, bleeding procedures, thermostat operation, and radiator fan diagnostics.
Ignition System:
Spark plug specifications, ignition coil testing, and ECU ignition mapping information.
Electrical System:
Full wiring diagrams, component testing, starter motor, alternator, battery maintenance, fuse box layout, and lighting systems.
Transmission:
Clutch operation, gearbox disassembly/assembly, shift drum and fork inspection, and gearbox oil specifications.
Suspension Front:
WP USD fork disassembly, seal replacement, oil levels, damping adjustments, and spring rate information.
Suspension Rear:
WP rear shock absorber servicing, linkage bearing inspection/replacement, spring preload adjustment, and damping control.
Brakes Front:
Brembo radial calipers, brake pad replacement, fluid type (DOT 4), bleeding procedures, and rotor specifications.
Brakes Rear:
Brembo caliper service, pad replacement, fluid type, bleeding, and disc specifications.
ABS System:
Bosch ABS system diagnostics, sensor troubleshooting, and deactivation procedures.
Wheels Tires:
Spoke wheel maintenance, tire pressure recommendations, rim sizes, and wheel bearing service.
Frame Chassis:
Frame inspection, swingarm service, steering head bearing maintenance, and torque specifications for critical fasteners.
Bodywork:
Fairing removal/installation, seat adjustment, fuel tank mounting, and plastic component care.
Instrumentation:
Dashboard functions, error code display, and sensor calibration.
Lighting:
Headlight, taillight, turn signal, and auxiliary lighting troubleshooting and replacement.
Procedures Included
Maintenance Schedule:
Detailed routine maintenance intervals for oil changes, filter replacements, valve clearance checks, and chain adjustment.
Troubleshooting:
Systematic diagnostic guides for common performance issues, starting problems, and electrical faults.
Engine Rebuild:
Complete step-by-step instructions for engine disassembly, component measurement (piston, bore, crankshaft), and reassembly.
Suspension Adjustment:
Guidance on adjusting suspension settings for various riding conditions and rider weight.
Brake Bleeding:
Detailed instructions for bleeding the hydraulic brake system, including ABS units.
Valve Clearance:
Step-by-step procedure for checking and adjusting valve clearances, including required tools and specifications.
Electrical Diagnostics:
Using a multimeter for component testing and diagnosing electrical circuit faults.
Fuel Injector Cleaning:
Procedures for removing and cleaning fuel injectors.
Chain Adjustment:
Proper procedure for adjusting and lubricating the final drive chain.
Wheel Bearing Replacement:
Instructions for removing and installing front and rear wheel bearings.
Steering Head Bearing Service:
Procedure for checking, adjusting, and replacing steering head bearings.
Technical Depth
Depth:
Deep technical coverage suitable for professional mechanics and experienced DIY enthusiasts.
Specifications:
Includes detailed torque values, clearances, tolerances, fluid capacities, and electrical specifications.
Diagrams:
Extensive use of exploded diagrams, wiring schematics, and assembly illustrations.
📊 Manual Specifications
File Format
Type:
Searchable PDF
Quality:
High-resolution, clear text and images for easy readability and printing.
Print Quality
Printability:
Printable pages for workshop use.
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Type:
V-twin cylinder, 4-stroke, DOHC, eight valves per cylinder
Displacement:
1195 cc (1190cc)
Bore X Stroke:
105 mm x 69 mm
Compression Ratio:
12.5:1
Performance
Horsepower:
Approx. 150 hp (112 kW) @ 9,000 rpm
Torque:
Approx. 125 Nm (92 lb-ft) @ 6,750 rpm
Fuel System
Induction:
Electronic fuel injection with dual throttle bodies, Ride-by-Wire
Fuel Type:
Unleaded gasoline, minimum Octane Rating 95 (RON)
Lubrication
System:
Forced lubrication with oil cooler
Oil Capacity:
Approx. 3.4 liters (3.6 US qt)
Oil Specification:
SAE 10W-50, JASO MA / MA2 approved synthetic motorcycle oil
Cooling System
Type:
Liquid-cooled
Coolant Type:
Antifreeze coolant, 50% mixture of ethylene glycol and distilled water
Coolant Capacity:
Approx. 2.0 liters (2.1 US qt)
🔧 Transmission
Standard
Type:
6-speed, claw-shifted
Optional
Optional Features:
Slipper clutch
Features
Clutch:
Pankl, wet multi-disc clutch, hydraulically actuated
Final Drive:
XW-ring chain 5/8 x 5/16", 118 links
Gearbox Oil Type:
SAE 75W-90, API GL-4
Gearbox Oil Capacity:
Approx. 1.2 liters (1.3 US qt)
📐 Dimensions
Exterior
Length:
Approx. 2300 mm (90.6 in)
Width:
Approx. 960 mm (37.8 in)
Height:
Approx. 1445 mm (56.9 in) (adjustible windshield)
Seat Height:
Approx. 860-875 mm (33.9-34.4 in) (adjustable)
Ground Clearance:
Approx. 220 mm (8.7 in)
Wheelbase:
Approx. 1580 mm (62.2 in)
Weights
Dry Weight:
Approx. 212 kg (467 lbs)
Wet Weight:
Approx. 230 kg (507 lbs) (fully fueled)
Gross Vehicle Weight Rating:
Not specified, but generally around 450kg (992 lbs) total capacity.
Fuel Tank Capacity:
Approx. 23 liters (6.1 US gal)
🛡️ Safety Features
Ratings
ABS Standard:
Standard Bosch 9M ABS, switchable
Active Features
Traction Control:
Multi-level MTC (Motorcycle Traction Control), adjustable
Ride Modes:
Multiple ride modes affecting throttle response and MTC intervention (Rain, Street, Sport, Offroad).
Passive Features
Lighting:
Full LED lighting (optional on some models, check spec)
Brakes:
Dual front disc with Brembo radial 4-piston calipers, single rear disc with Brembo caliper.
Frame Material:
Chromium-molybdenum steel trellis frame
💡 Technology Features
Infotainment
Display:
Multi-function LCD display with detailed vehicle information and settings.
Driver Assistance
Traction Control Levels:
Multiple MTC modes for varying traction conditions.
ABS Modes:
Switchable ABS for front and rear wheels, including an off-road mode.
Ride By Wire:
Electronic throttle control for precise throttle response and integrated rider modes.
Suspension Tech:
WP electronic semi-active suspension (optional) adjusts damping automatically based on road conditions and rider inputs.
Connectivity
Charging Port:
12V socket for charging accessories.
🔧 Maintenance
Service Intervals
Oil Change:
Every 15,000 km (9,320 miles) or annually, whichever comes first.
Oil Filter Replacement:
Every 15,000 km (9,320 miles) or annually.
Air Filter Cleaning:
Every 7,500 km (4,660 miles) or every 2 years.
Valve Clearance Check:
Every 30,000 km (18,640 miles).
Chain Lubrication:
Every 1,000 km (620 miles) or after riding in rain/wet conditions.
Chain Adjustment:
Every 7,500 km (4,660 miles).
Fluid Specifications
Brake Fluid:
DOT 4
Coolant:
50% Ethylene Glycol Antifreeze
Engine Oil:
SAE 10W-50, JASO MA/MA2 Synthetic Motorcycle Oil
Gearbox Oil:
SAE 75W-90, API GL-4
Known Issues
Clutch Slave Cylinder:
Occasional reports of clutch slave cylinder leaks, potentially requiring replacement.
Fuel Pump Relay:
Some owners have reported issues with the fuel pump relay, leading to starting problems.
Heated Grips:
Intermittent functionality of heated grips on some units.
ABS System Faults:
Rare instances of ABS system warning lights or faults, often related to sensor issues.
Wp Suspension Leaks:
Potential for minor fork seal leaks under heavy use, especially off-road.
📚 Vehicle History
Brand Heritage
Brand:
KTM, known for its 'Ready to Race' philosophy and off-road expertise.
Model Evolution
Predecessor:
KTM 990 Adventure
Introduction Year:
The 1190 Adventure was introduced for the 2013 model year, succeeding the 990 Adventure.
Production
Manufacturing Location:
Austria (Mattighofen)
🏆 Awards & Recognition
Recognitions
Category Awards:
Consistently recognized in adventure touring categories for its performance and versatility.