Perun moto KTM 790/890/1X90 Top Luggage rack - Installation Instructions

Installation instructions are same for all bikes (790/890/1090/1190/1290 Adventure R/S). 

For video instructions (790 Adventure) scroll to the bottom.

A. Installation of Top Luggage rack (with stock grab handles)

1. Unbolt 4 bolts and remove OEM luggage rack plate. 

2. Place two longer spacers in front and two shorter spacer in the back, as in the picture below. 

3. For all bikes (790/890/1X90) - position the rack and inserts longest bolts (M8x75) in front holes.

3A. KTM 1X90 - position M8x55 bolts in back holes.

3B. KTM 790/890 - position M8x50 bolts in back holes, use Loctite 243 or similar thread locker (if M8x50 bolts bottom out, use M8x45).

4. Make sure everything is properly aligned. Tighten the bolts, in alternating pattern. Torque to 20 Nm. (for 790/890 - check if rear M8x50 bolts bottom out - if they do, use M8x45)

5. After first few hundred kilometers with rack installed, check the bolts and re-tighten if needed. 

B. Installation of Top Luggage rack (without stock grab handles)

 1. Unbolt 4 bolts and remove OEM luggage rack plate and stock grab handles.

2. Place four spacers (H=23mm) above threaded holes. 

3. Place two larger spacers in the front and two shorter spacers in the back, above already placed spacers. 

4. For all bikes (790/890/1X90) - position the rack and inserts longest bolts (M8x75) in front holes.

4A. KTM 1X90 - position M8x55 bolts in back holes.

4B. KTM 790/890 - position M8x50 bolts in back holes, use Loctite 243 or similar thread locker (if M8x50 bolts bottom out, use M8x45).

5. Tighten the bolts, in alternating pattern. Torque to 20 Nm.

6. After first few hundred kilometers with rack installed, check the bolts and re-tighten if needed.

C. Installation of Top Luggage rack and Givi/Kappa Monokey Top case

Important - some plastic Givi/Kappa top cases (only Trekker line) can't be fitted with stock grab handles installed. Aluminum top cases fit perfectly.

1. Givi E115F Monokey Junction Hardware Kit and Givi Rubber grommets kit Z2710 needed (purchased separately).

Note: rubber grommets supplied with E115F kit are too high (7 mm) and made for thinner plate, so separate grommet kit is needed - Z2710 (5 mm high)!

But, in rare cases, depending on the Givi batch, higher grommets are indeed needed (7 mm) - in those kits higher grommets are included.

Grommets are there so top case don't rattle, check that out when you mount the case.

Bolts for pyramid shaped Givi parts supplied with E115F kit are countersunk (or too long) and won't fit so two additional M6X16 hex or button head bolts are needed. 

2. Make sure rubber grommets are approx. 5 mm thick. Grommet from Givi Z2710 kit shown. 

3. Position all hardware as on the picture below.

4. Make sure rubber grommets are properly seated. Use drop of super glue to make sure grommets will stay in place. 

5. Make sure slot on the pyramid-shaped part is facing towards front of the bike. 

6. Don't forget to inserts washers provided with Givi kit, under front mounting parts. 

7. Tighten all bolts and nuts. 

8. Follow mounting procedure A. Installation of Top Luggage rack (with stock grab handles) or B. Installation of Top Luggage rack (without stock grab handles) (see above).

9. Install Givi or Kappa Monokey top case. Make sure everything clicks in place. Check if top box is firm and secure. 

D. Installation of Top Luggage rack and SW-Motech Top case

1. SW-Motech Adapter kit for Trax needed (purchased separately).

2. Position all hardware as on the picture below.

3. Tighten the bolts lightly. Attachments should stay in place, but movement under slight pressure should be possible. 

4. Turn top case upside down and place attachments on the rack into the open slots. Push and let all attachments align with base plate. 

5. When all attachments are aligned, tighten the bolts. Tighten the bolts on the metal tab, but lightly. Mount rack to the top case again and close the top box lock. Determine in what position flange should be secured and tighten those bolts too. 

6. Mount the Top luggage rack on the bike. Follow mounting procedure A. Installation of Top Luggage rack (with stock grab handles) or B. Installation of Top Luggage rack (without stock grab handles) (see above).

7. Install SW-Motech top case. Make sure everything clicks in place. Check if top box is firm and secure. If needed, readjust attachments or lock flange.

E. Installation of Rotopax fuel can

Rotopax mount is needed. Either Standard, DLX or Lox will work. 

1. Remove sheet metal part from the Rotopax mount. Only billet part of the mount is needed. 

2. Depending on the Rotopax size or personal preference, choose one of the two positions, as shown below. 

Position 1

Position 2

3. Use appropriate bolts to secure Rotopax mount from underside of the rack. If Rotopax mount is in the Position 2, use countersunk bolt for rear hole. 

4. Tighten up the bolts and install the rack. 

5. Mount Rotopax. 

And Installation video - KTM 790 Adventure, courtesy of Codger Biker

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