Factory Workshop SpecificationsPlatform Gen: 2019–2024

2024 KTM 790 Adventure / R / Rally Specifications & Consumables

Official workshop technical reference: fluid capacities, spark plug codes, drive chain specs, and tire inflation pressures.

Gen 2019–2024

Factory Platform Compatibility: All workshop fluid capacities, maintenance milestones, torque specifications, and consumables on this specification sheet are factory-identical across model years 2019 through 2024.

Select Model Year:(Active: 2024)

2019 2020 2021 2022 2023 2024

Engine

799cc

Drive

520

Cooling

Not Available

Engineering Subsystem Workbenches & Calculators

Dedicated deep-dive diagnostic tools, torque matrices, wiring pinouts, and calculators tailored for 2024 KTM 790 Adventure / R / Rally.

10 Dedicated Engineering Spoke Pages

Subsystem Guide/torques

Fastener Torques

Engine drain plug, axle spindles, caliper mounts, triple clamp pinch bolts & thread lubrication derating guide.

Open Dedicated Workbench →

Subsystem Guide/fluids

Fluids & Capacities

Oil: 2.80 L (3.00 US qt) • Coolant: 2.10 L (2.22 US qt) • Brake: Motorex Brake Fluid DOT 5.1

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Subsystem Guide/fuses-relays

Fuses & Relays

Main: N/A • Location: N/A

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Subsystem Guide/compression

Compression & Leakdown

Ratio: N/A

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Subsystem Guide/valves

Valve Clearances

Intake: N/A mm • Exhaust: N/A mm

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Subsystem Guide/fuel-delivery

Fuel Delivery & TB Sync

Idle: N/A • Rail Pressure: N/A • Vacuum: N/A

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Subsystem Guide/electrical

Charging & Battery

Battery: YTZ10S (12V 8.6Ah AGM)

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Subsystem Guide/tires

Tires & Gearing

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

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Subsystem Guide/suspension

Suspension & Sag

Front Travel: N/A • Rear Travel: N/A

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Subsystem Guide/maintenance

Maintenance Schedule

Oil: N/A • Valves: N/A • Plugs: N/A

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Fluids & Service Capacities

Shop Fluids →

Engine Oil (Drain & Filter Change)2.80 L (3.00 US qt)

Engine Oil (Drain Only)2.50 L (2.64 US qt)

Recommended Oil ViscosityMotorex Top Speed 4T SAE 10W-50 (JASO MA2, API SN)

Coolant System Capacity2.10 L (2.22 US qt)

Brake Fluid StandardMotorex Brake Fluid DOT 5.1

Drivetrain, Chain & Gearing

Gearing Calculator →Shop Chains & Sprockets →

Drive Chain Pitch520

Chain Link CountN/A

Front Sprocket TeethN/A

Rear Sprocket TeethN/A

Final Drive Configuration520 Pitch Chain

Ignition & Electrical Specifications

Shop Plugs & Batteries →

OEM Spark Plug Part NumberNGK LMAR9AI-8 (Laser Iridium, 2 plugs)

Electrode Spark Plug Gap0.7 - 0.8 mm (0.028 - 0.031 in)

OEM Battery Reference CodeYTZ10S (12V 8.6Ah AGM)

Battery Output & RatingNot Available

Spark Plug Inspection IntervalN/A

Wheels, Tires & Inflation Pressures

Shop Tires →

Front Tire Dimensions90/90-21 M/C 54H TL

Cold Front Inflation PressureN/A

Rear Tire Dimensions150/70R18 M/C 70H TL

Cold Rear Inflation PressureN/A

OEM Wheel Rim Widths (F / R)3.50" / 5.50"

Official NHTSA Safety Recalls & Technical Bulletins

0 Open Campaigns (Clean)

U.S. Department of Transportation compliance database (Title 49 U.S.C. Chapter 301).

Verify VIN on NHTSA.gov

No Active Federal Safety Recalls Reported

The U.S. DOT National Highway Traffic Safety Administration (NHTSA) records zero open safety recall campaigns for the 2024 KTM 790 Adventure / R / Rally platform. Always check your individual 17-digit VIN at an authorized dealership or via NHTSA.gov for individual recall completions.

OEM Workshop Archives

Official Factory Service Bulletins & Field Updates

2 Documented Bulletins

Bulletin #KTM-20V198Safety Recall KTB2011: Rear Brake Line Thermal Radiation Rerouting & Heat Shielding

Source: KTM_Recall20V198_RCRIT-20V198-6480.pdf

Mandated Torques:Rear Brake Line Banjo Bolts (2x M10): 25 N·m (18.5 lb-ft)Rear Brake Pedal Screw ISR (M6×20 T30 Torx): 5 N·m (44 in-lb)Rear Brake Caliper Bleeder Screw: 10 N·m (7.4 lb-ft)Foot Brake Cylinder Pushrod Locknut: 6 N·m (53 in-lb)

Consumable Specs:Motorex Brake Fluid DOT 5.1

Genuine Part Numbers:Brake Line Rear Elongated & Shielded (63542004100)Copper Seal Ring DIN 7603-10×14×1 (4x) (0603100141)Round Head Screw ISR M6×20-A2-7 (0738060205S)Motorex Brake Fluid DOT 5.1 (GA06)

NHTSA Recall 20V-198Bulletin KTB2011 / Campaign 13_1667518_00

KTM 790 & 890 Adventure Rear Brake Line Thermal Radiation Countermeasure

Elongated stainless-braided rear brake hose routing, catalytic pre-muffler heat shield gap, and hydraulic banjo torque specifications.

Safety Recall RemedyBanjo 25 N·m / Pedal T30 5 N·m / Bleeder 10 N·m

Genuine Part Numbers:6354200410006031001410738060205SGA06

Click any component or torque callout above to inspect thermal defect details, rerouting diagrams, and workshop torque specifications.

Bulletin #KTM-21V304Safety Recall KTB2106: Front Brake Master Cylinder Piston Return Spring Upgrade

Source: KTM_Recall21V304_RCMN-21V304-9024.pdf

Mandated Torques:Front Brake Lever Pivot Bolt (M6): 5 N·m (44 in-lb)Front Brake Lever Locknut (M6): 10 N·m (88 in-lb)Brake Fluid Reservoir Cover Screws (2x M4): 3 N·m (27 in-lb)Handlebar Clamp Collar Screws (2x M6): 5 N·m (Upper Zero-Gap)Handguard Mounting Bolts (M8): 25 N·m (18.5 lb-ft)

Consumable Specs:Motorex Brake Fluid DOT 5.1 / DOT 4

Genuine Part Numbers:Front Master Cylinder Return Spring Repair Set (63513008000)Piston & Primary Seal Assembly (63513009000)Collar Screw M6×20 ISA (0025060206)

NHTSA Recall 21V-304Bulletin KTB2106 / Campaign KTM2106

KTM 790 Adventure / R / Rally Front Brake Master Cylinder Return Spring

Upgraded piston return spring countermeasure, lever pivot torques, and handlebar clamp tightening sequence.

Safety Recall RemedyLever Nut 10 N·m / Pivot 5 N·m / Res 3 N·m

Genuine Part Numbers:63513008000635130090000025060206GA06

Click any component or torque callout above to inspect repair instructions, spring kits, and tightening procedures.

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