Page 1 OWNER'S MANUAL 2021 390 DUKE Art. no. 3214321en...
Page 3 KTM accepts no liability for delivery options, deviations from fig- ures and descriptions, misprints, and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of supply.
Page 4 Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright owner. ISO 9001(12 100 6061) KTM applies quality assurance processes that lead to the highest possible product quality as defined in the ISO 9001 international quality management standard. Issued by: TÜV Management Service KTM Sportmotorcycle GmbH Stallhofnerstraße 3...
Page 5: Table Of Contents
TABLE OF CONTENTS VIEW OF VEHICLE ........20 TABLE OF CONTENTS MEANS OF REPRESENTATION ...... 9 View of vehicle, front left (example) ... 20 Symbols used ........9 View of vehicle, rear right Formats used........10 (example)........22 SAFETY ADVICE.......... 11 SERIAL NUMBERS ........
Page 6 Quick Selector 2 display ....58 6.10 Closing the fuel tank filler cap... 36 7.17 Menu..........58 6.11 Seat lock......... 37 7.17.1 KTM MY RIDE (optional) ....59 6.12 Tool set........... 37 7.17.2 Info ..........60 6.13 Grab handles ........38 7.17.3 Motorcycle ........
Page 7 TABLE OF CONTENTS 7.17.21 Shift Light ........78 10 SERVICE SCHEDULE ........ 109 7.17.22 Setting the time and date ..... 78 10.1 Additional information ....109 7.17.23 DRL ........... 81 10.2 Required work ....... 109 7.17.24 Distance ........82 10.3 Recommended work .......
Page 8 TABLE OF CONTENTS 12.10 Checking for chain dirt 13.9 Checking the rear brake fluid accumulation......... 125 level ..........151 12.11 Cleaning the chain ......125 13.10 Adding rear brake fluid ....152 12.12 Checking the chain tension ..... 127 13.11 Checking the rear brake linings ..155 12.13 Adjusting the chain tension.....
Page 9 TABLE OF CONTENTS 15.10 Diagnostics connector ....189 19 CLEANING, CARE ........215 15.11 Front ACC1 and ACC2 ....189 19.1 Cleaning the motorcycle ....215 15.12 ACC2 rear ........190 19.2 Checks and maintenance steps for winter operation......218 16 COOLING SYSTEM ........
Page 10 TABLE OF CONTENTS 23 DECLARATIONS OF CONFORMITY ..... 244 23.1 Declarations of conformity ....244 24 SUBSTANCES .......... 245 25 AUXILIARY SUBSTANCES ......249 26 STANDARDS ..........251 27 INDEX OF SPECIAL TERMS ....... 252 28 LIST OF ABBREVIATIONS......253 29 LIST OF SYMBOLS........
Page 11: Means Of Representation 1
All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own safety, have these jobs performed by an authorized KTM workshop! Your motorcycle will be optimally cared for there by specially trained experts using the auxiliary tools required.
Page 12: Formats Used
1 MEANS OF REPRESENTATION Indicates a voltage measurement. Indicates a current measurement. Indicates the end of an activity, including potential rework. Formats used The typographical formats used in this document are explained below. Proprietary name Indicates a proprietary name. Name ®...
Page 13: Safety Advice 2
SAFETY ADVICE 2 Use definition KTM sport motorcycles are designed and constructed to meet the normal demands of regular road operation but not for use on race courses or offroad. Info The motorcycle is authorized for public road traffic in the homologous version only.
Page 14: Degrees Of Risk And Symbols
2 SAFETY ADVICE Info Various information and warning labels are attached in prominent locations on the product described. Do not remove any information or warning labels. If they are missing, you or others may not recognize dangers and may therefore be injured. Degrees of risk and symbols Danger Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the...
Page 15: Tampering Warning
SAFETY ADVICE 2 Tampering warning Tampering with the noise control system is prohibited. Federal law prohibits the following acts or the causing thereof: 1 The removal or rendering inoperative by any person other than for purposes of servicing, repair, or replace- ment, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any...
Page 16: Protective Clothing
An appropriate driver's license is needed to ride the vehicle on public roads. Have malfunctions that impair safety promptly eliminated by an authorized KTM workshop. Adhere to the information and warning labels on the vehicle.
Page 17: Work Rules
SAFETY ADVICE 2 In the interest of your own safety, KTM recommends that you only operate the vehicle while wearing protective clothing. Work rules Unless specified otherwise, the ignition must be turned off during all work (models with ignition lock, models with remote key) or the engine must be at a standstill (models without ignition lock or remote key).
Page 18: Owner's Manual
The Owner's Manual can be downloaded several times using the QR code or the link on the delivery certificate. The Owner's Manual is also available for download from your authorized KTM dealer and on the KTM website. A printed copy can also be ordered from your authorized KTM dealer.
Page 19: Important Notes 3
Manufacturer warranty, implied warranty The work prescribed in the service schedule must only be carried out in an authorized KTM workshop and con- firmed in the KTM Dealer.net, as otherwise all warranty claims will be void. Damage or secondary damage caused by tampering with and/or conversions on the vehicle are not covered by the manufacturer warranty.
Page 20: Service
Customer service Your authorized KTM dealer will be happy to answer any questions you may have on your vehicle and KTM. A list of authorized KTM dealers can be found on the KTM website. International KTM Website: KTM.com...
Page 21 IMPORTANT NOTES 3...
Page 22: View Of Vehicle
4 VIEW OF VEHICLE View of vehicle, front left (example) S04740-10...
Page 23 VIEW OF VEHICLE 4 Combination instrument Clutch lever ( p. 27) Front rider’s seat Passenger seat Grab handles ( p. 38) Seat lock ( p. 37) Side stand ( p. 40) Shift lever ( p. 39)
Page 24: View Of Vehicle, Rear Right (Example)
4 VIEW OF VEHICLE View of vehicle, rear right (example) S04741-10...
Page 25 VIEW OF VEHICLE 4 Tool set ( p. 37) Light switch ( p. 29) Menu buttons ( p. 30) Turn signal switch ( p. 30) Horn button ( p. 31) Ignition and steering lock ( p. 32) Emergency OFF switch ( p.
Page 26: Serial Numbers
5 SERIAL NUMBERS Vehicle identification number The vehicle identification number is stamped on the right side of the steering head. 402408-10 Type label (EU/JP/AR/BR/CN/CO/MY/PH/TH, 390 DUKE EU B.D.) The type label is on the right of the frame behind the steering head.
Page 27: Engine Number
SERIAL NUMBERS 5 (390 DUKE AU) The type label is on the left of the frame behind the steer- ing head. 402772-10 Engine number The engine number is stamped on the left side of the engine under the engine sprocket. 402486-10...
Page 28: Key Number
5 SERIAL NUMBERS Key number can be found on the KEYCODECARD. The key number Info The key number is needed to order a replacement key. Keep the KEYCODECARD in a safe place. If at least one ignition key is still available, a spare key can be produced.
Page 29: Controls 6
CONTROLS 6 Clutch lever The clutch lever is fitted on the left side of the handlebar. F00783-10 Hand brake lever The hand brake lever is fitted on the right side of the handle- bar. The front brake is engaged using the hand brake lever. F00784-10...
Page 30: Throttle Grip
6 CONTROLS Throttle grip The throttle grip is fitted on the right side of the handlebar. F00784-11 Switches on the left side of the handlebar 6.4.1 Combination switch The combination switch is fitted on the left side of the handlebar.
Page 31: Light Switch
CONTROLS 6 Overview of the left combination switch Light switch ( p. 29) Menu buttons ( p. 30) Turn signal switch ( p. 30) Horn button ( p. 31) F00785-10 6.4.2 Light switch Light switch is fitted on the left side of the handlebar. Possible states Low beam on –...
Page 32: Menu Buttons
6 CONTROLS 6.4.3 Menu buttons The menu buttons are fitted in the middle of the left combination switch. The menu buttons are used to control the display on the combina- tion instrument. Button is the UP button. Button is the DOWN button. Button is the SET button.
Page 33: Horn Button
CONTROLS 6 6.4.5 Horn button Horn button is fitted on the left side of the handlebar. Possible states • The horn button is in the basic position is pressed – The horn is operated in this • The horn button position.
Page 34: Start Button
6 CONTROLS 6.5.2 Start button Start button is fitted on the right side of the handlebar. Possible states • The start button is in the basic position is pressed – In this position, the starter • The start button motor is actuated. F00789-10 Ignition and steering lock The ignition and steering lock is located in front of the upper triple...
Page 35: Locking The Steering
CONTROLS 6 Steering locked LOCK – In this position, the ignition circuit is interrupted and the steering locked. The ignition key can be removed. Locking the steering Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface.
Page 36: Unlocking The Steering
6 CONTROLS Unlocking the steering – Insert the ignition key into the ignition and steering lock, press in, and turn to the right. Remove the ignition key. The handlebar can now be moved again. 400731-01 Opening fuel tank filler cap Danger Fire hazard Fuel is highly flammable.
Page 37 CONTROLS 6 Warning Danger of poisoning Fuel is poisonous and a health hazard. – Avoid skin, eye and clothing contact with fuel. – Immediately consult a doctor if you swallow fuel. – Do not inhale fuel vapors. – In case of skin contact, rinse the affected area with plenty of water. –...
Page 38: Closing The Fuel Tank Filler Cap
6 CONTROLS – Lift the fuel tank filler cap. 6.10 Closing the fuel tank filler cap Warning Fire hazard Fuel is highly flammable, toxic and a health hazard. – Check that the fuel tank filler cap is locked cor- rectly after closing. –...
Page 39: Seat Lock
CONTROLS 6 6.11 Seat lock The seat lock is located to the left of the seat. The seat lock can be unlocked using the ignition key. F00790-10 6.12 Tool set The tool set is located under the passenger seat. F00729-10...
Page 40: Grab Handles
6 CONTROLS 6.13 Grab handles The grab handles are used for moving the motorcycle around. If you carry a passenger, the passenger can hold onto the grab handles during the trip. F00791-10 6.14 Passenger foot pegs The passenger foot pegs can be folded up and down. Possible states Passenger foot pegs folded up –...
Page 41: Shift Lever
CONTROLS 6 6.15 Shift lever Shift lever is mounted on the left side of the engine. 401950-10 The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. 401950-11...
Page 42: Foot Brake Lever
6 CONTROLS 6.16 Foot brake lever Foot brake lever is located in front of the right footrest. The foot brake lever is used to activate the rear brake. 402177-10 6.17 Side stand The side stand is located on the left of the vehicle. The side stand is used for parking the motorcycle.
Page 43 CONTROLS 6 Side stand folded in – This position is mandatory when riding • the motorcycle. The safety starting system is inactive.
Page 44: Combination Instrument
7 COMBINATION INSTRUMENT Combination instrument The combination instrument is attached in front of the handlebar. The combination instrument is divided into two function areas. indicator lamps ( p. 46) Display M01577-10 Activation and test Activation The combination instrument is activated when the ignition is switched on.
Page 45: Day-Night Mode
COMBINATION INSTRUMENT 7 Day-Night mode Day mode is shown in a bright color. M01578-01 Night mode is shown in a dark color. Info The ambient light sensor in the combination instrument detects the brightness of the environment. Depending on the amount of light detected by the ambient light sensor, the display is brightened or dimmed, or switched to the other mode depending on the setting.
Page 46: Warnings
7 COMBINATION INSTRUMENT Warnings Warnings appear on the top and/or bottom edge of the display; these are marked yellow or red depending on their relevance. Yellow warnings indicate malfunctions or information which require prompt intervention or an adjustment to the riding style. Red warnings indicate malfunctions or information which require immediate intervention.
Page 47 COMBINATION INSTRUMENT 7...
Page 48: Indicator Lamps
7 COMBINATION INSTRUMENT Indicator lamps F00900-01...
Page 49 Malfunction indicator light lights up yellow – The OBD has detected a malfunction in the vehi- cle electronics. Come safely to a halt, and contact an authorized KTM workshop. The ABS warning lamp lights up yellow – Status or error messages relating to ABS. The ABS warning lamp flashes if the ABS mode Super Moto is enabled.
Page 50 7 COMBINATION INSTRUMENT The oil pressure warning lamp lights up red – The oil pressure is too low. Stop immediately, taking care not to endanger yourself or other road users in the process, and switch off the engine. Alarm system indicator lamp flashes red – Status message on the alarm system (optional). High beam indicator lamp lights up blue –...
Page 51 COMBINATION INSTRUMENT 7...
Page 52: Display
7 COMBINATION INSTRUMENT Display M01580-11...
Page 53 COMBINATION INSTRUMENT 7 Speed ( p. 52) Shift warning light ( p. 52) The shift warning light is integrated in the tachometer display. Gear display Unit for the speed display Speed ( p. 53) Unit for the speedometer ODO display ( p.
Page 54: Speed
7 COMBINATION INSTRUMENT Speed The speed is measured in revolutions per minute. M01581-10 Shift warning light The shift warning light is integrated in the tachometer display. In the Shift Light menu, the engine speed for the shift warning light can be set. The shift warning light is always active during the running-in phase (up to 1,000 km / 621 mi).
Page 55: Speed
COMBINATION INSTRUMENT 7 ≤ 35 °C (≤ 95 °F) Coolant temperature < 1,000 km (< 620 mi) The shift warning 6,500 rpm light always flashes Coolant temperature > 35 °C (> 95 °F) > 1,000 km (> 620 mi) RPM1 shift warning flashes light RPM2 shift warning...
Page 56: Odo Display
7 COMBINATION INSTRUMENT 7.10 ODO display The total distance covered ODO is shown in area of the display. Info This value is retained, even if the 12-V battery is discon- nected from the vehicle or the fuse blows. M01581-12 7.11 Coolant temperature indicator The coolant temperature indicator consists of bars.
Page 57: Fuel Level Display
COMBINATION INSTRUMENT 7 Info When all the bars light up, the warning ENGINE TEMP HIGH also appears. If the cooling system overheats, the maximum engine speed is limited. Possible states The engine is cold – Up to three bars light up. •...
Page 58: Time
7 COMBINATION INSTRUMENT Info If the fuel level is getting low, the last segment flashes red and the following warning also appears LOW FUEL. The fuel level is displayed with a slight delay to prevent the indicator from constantly moving while riding. The fuel level display is not updated while the side stand is folded out or the emergency off switch is switched off.
Page 59: Favourites Display
COMBINATION INSTRUMENT 7 7.14 Favourites display Up to eight items of information are shown in the Favourites dis- play. The Favourites display can be freely configured in the Favourites menu. Info One to four items of information selected are displayed on two lines.
Page 60: Quick Selector 2 Display
7 COMBINATION INSTRUMENT 7.16 Quick Selector 2 display When the menu is closed, the Quick Selector 2 menu is opened by pressing the DOWN button. Press the BACK button to close Quick Selector 2. Info The Quick Selector 2 can be configured in the Quick Selec- tor 2 menu.
Page 61: Ktm My Ride (Optional)
Press the SET button when the menu is closed. – Press the UP or DOWN button until KTM MY RIDE is marked. Press the SET button to open the menu. In the KTM MY RIDE menu, an appropriate cellphone or appropriate...
Page 62: Info
7 COMBINATION INSTRUMENT 7.17.2 Info – Press the SET button when the menu is closed. – Press the UP or DOWN button until Info is marked. Press the SET button to open the menu. General information can be accessed in Info. V01161-01 7.17.3 Motorcycle...
Page 63: Settings
COMBINATION INSTRUMENT 7 7.17.4 Settings Condition • The motorcycle is stationary. – Press the SET button when the menu is closed. – Press the UP or DOWN button until Settings is marked. Press the SET button to open the menu. Favorites and quick selection can be configured in Settings.
Page 64: Pairing (Optional)
– Press the SET button when the menu is closed. – Press the UP or DOWN button until KTM MY RIDE is marked. Press the SET button to open the menu. – Press the UP or DOWN button until Pairing is marked. Press the SET button to open the menu.
Page 65: Phone (Optional)
– Press the SET button when the menu is closed. – Press the UP or DOWN button until KTM MY RIDE is marked. Press the SET button to open the menu. F01959-01 – Press the UP or DOWN button until Pairing is marked. Press the SET button to open the menu.
Page 66 7 COMBINATION INSTRUMENT phone is displayed in the Pairing menu. Press the SET button to start the pairing. Info The cellphone must be visible via Bluetooth ® for the cellphone to be found by the combination instrument. – A message appears on the combination instrument indicat- ing that this is now ready for pairing.
Page 67: Headset (Optional)
– Press the SET button when the menu is closed. – Press the UP or DOWN button until KTM MY RIDE is marked. Press the SET button to open the menu. F01960-01 – Press the UP or DOWN button until Pairing is marked. Press the SET button to open the menu.
Page 68 7 COMBINATION INSTRUMENT – The combination instrument starts searching for a suitable headset. If the search was successful, the name of the head- set is displayed in the Pairing menu. Press the SET button to select the device. Press the SET button again to confirm the Confirm menu item.
Page 69: Audio (Optional)
– Press the SET button when the menu is closed. – Press the UP or DOWN button until KTM MY RIDE is marked. Press the SET button to open the menu. V01165-01 Warning Danger of accidents Headphone volume which is too high distracts attention from traffic activity.
Page 70 7 COMBINATION INSTRUMENT – Press the UP or DOWN button until Audio is marked. Press the SET button to open the menu. – Press and hold the UP button to increase the audio volume. – Press and hold the DOWN button to reduce the audio volume. –...
Page 71: Telephony (Optional)
COMBINATION INSTRUMENT 7 7.17.10 Telephony (optional) Condition • Function KTM MY RIDE activated (optional). • Function Bluetooth ® activated. • The Bluetooth ® function should also be activated in the device to be paired. • Headset linked with appropriate cellphone.
Page 72: General Info
7 COMBINATION INSTRUMENT 7.17.11 General Info – Press SET button when the menu is closed. – Press the UP or DOWN button until Info is marked. Press the SET button to open the menu. – Press the UP or DOWN button until General Info is marked. Press the SET button to open the menu.
Page 73: Trip 2
COMBINATION INSTRUMENT 7 Fuel Range indicates the possible distance you can cover with the fuel reserve. Press and All the entries in the Trip 1 menu are reset. hold the SET button for 3-5 seconds. 7.17.13 Trip 2 – Press SET button when the menu is closed. –...
Page 74: Warning
7 COMBINATION INSTRUMENT Press and All the entries in the Trip 2 menu are reset. hold the SET button for 3-5 seconds. 7.17.14 Warning Condition • Message or warning is present. – Press SET button when the menu is closed. –...
Page 75: Abs
COMBINATION INSTRUMENT 7 7.17.15 ABS Condition • The motorcycle is stationary. – Press SET button when the menu is closed. – Press the UP or DOWN button until Motorcycle is marked. Press the SET button to open the menu. – Press the UP or DOWN button until ABS is marked.
Page 76: Favourites
7 COMBINATION INSTRUMENT 7.17.16 Favourites Condition • The motorcycle is stationary. – Press the SET button when the menu is closed. – Press the UP or DOWN button until Settings is marked. Press the SET button to open the menu. –...
Page 77: Quick Selector 2
COMBINATION INSTRUMENT 7 When the menu is closed, the Quick Selector 1 menu is opened by pressing the UP button. 7.17.18 Quick Selector 2 Condition • The motorcycle is stationary. – Press the SET button when the menu is closed. –...
Page 78: Bluetooth (Optional)
V01171-01 off. Info The Bluetooth ® function can only be used in conjunction with KTM MY RIDE (optional). When the Bluetooth ® function is switched on and the device is connected, the Bluetooth ® symbol appears in the display...
Page 79: Display Theme
COMBINATION INSTRUMENT 7 7.17.20 Display Theme Condition • The motorcycle is stationary. – Press the SET button when the menu is closed. – Press the UP or DOWN button until Preferences is marked. Press the SET button to open the menu. –...
Page 80: Shift Light
7 COMBINATION INSTRUMENT 7.17.21 Shift Light Condition • The motorcycle is stationary. • ODO > 1000 km (621 miles). – Press the SET button when the menu is closed. – Press the UP or DOWN button until Preferences is marked. Press the SET button to open the menu.
Page 81 COMBINATION INSTRUMENT 7 – Press the SET button when the menu is closed. – Press the UP or DOWN button until Preferences appears. Press the SET button to open the menu. – Press the UP or DOWN button until Clock/Date is marked. Press the SET button to open the menu.
Page 82 7 COMBINATION INSTRUMENT Setting the date – Press the UP or DOWN button until the date is marked. – Press the SET button. The day flashes and is underlined. – Press the UP or DOWN button until the current day is set. –...
Page 83: Drl
COMBINATION INSTRUMENT 7 7.17.23 DRL Condition • The motorcycle is stationary. – Press the SET button when the menu is closed. – Press the UP or DOWN button until Preferences is marked. Press the SET button to open the menu. Warning Danger of accidents When visibility is poor, the day- time running light is not a substitute for the low beam.
Page 84: Distance
7 COMBINATION INSTRUMENT – Press the UP or DOWN button until DRL is marked. Press the SET button to open the menu. – Activate the menu item using the UP or DOWN button. – Press SET button to switch the daytime running light on or off. 7.17.24 Distance Condition •...
Page 85: Temperature
COMBINATION INSTRUMENT 7 7.17.25 Temperature Condition • The motorcycle is stationary. – Press the SET button when the menu is closed. – Press the UP or DOWN button until Preferences is marked. Press the SET button to open the menu. –...
Page 86: Language
7 COMBINATION INSTRUMENT – Activate the menu item using the UP or DOWN button. – Press the SET button to confirm the desired unit. 7.17.27 Language Condition • The motorcycle is stationary. – Press the SET button when the menu is closed. –...
Page 87: Service
COMBINATION INSTRUMENT 7 7.17.28 Service Condition • The motorcycle is stationary. – Press the SET button when the menu is closed. – Press the UP or DOWN button until Preferences is marked. Press the SET button to open the menu. –...
Page 88 7 COMBINATION INSTRUMENT Info The current KTM PowerParts and the available software for your vehicle can be found on the KTM website.
Page 89: Preparing For Use 8
Make sure that only tires with a similar tire tread pattern are fitted to the front and rear wheel. Warning Danger of accidents Non-approved or non-recommended tires and wheels impact the handling character- istic. – Only use tires/wheels approved by KTM with the corresponding speed index.
Page 90 Info When using the vehicle, remember that others may feel disturbed by excessive noise. – Ensure that the pre-sales inspection work has been carried out by an authorized KTM workshop. The delivery certificate is transferred upon vehicle handover. – Read the entire Owner's Manual before riding for the first time.
Page 91: Running In The Engine
PREPARING FOR USE 8 Running in the engine – During the running-in phase, do not exceed the specified engine speed. Guideline Maximum engine speed During the first: 1,000 km (620 mi) 7,500 rpm Info During the running-in phase, the shift warning light is set to a specified value and cannot be changed. –...
Page 92 8 PREPARING FOR USE Warning Danger of accidents Improper mounting of cases or the tank rucksack impairs the handling characteris- tic. – Mount and secure cases and tank rucksack according to the manufacturer's instructions. Warning Danger of accidents The luggage system will be damaged if it is overloaded. –...
Page 93 PREPARING FOR USE 8 – If luggage is carried, ensure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight distribution between the front and rear wheels. – Do not exceed maximum permissible weight and maximum permissible axle loads. Guideline Maximum permissible overall weight 355 kg (783 lb.)
Page 94: Riding Instructions
9 RIDING INSTRUCTIONS Checks and maintenance measures when preparing for use Info Before every trip, check the condition of the vehicle and ensure that it is roadworthy. The vehicle must be in perfect technical condition when it is being operated. –...
Page 95: Starting
RIDING INSTRUCTIONS 9 Starting Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death. – Always make sure there is sufficient ventilation when running the engine. – Use effective exhaust extraction when starting or running the engine in an enclosed space. Caution Danger of accidents Electronic components and safety devices will be damaged if the 12-V battery is dis- charged or missing.
Page 96 9 RIDING INSTRUCTIONS – Unlock the steering. ( p. 34) – Sit on the vehicle, take the weight off of the side stand, and move it all the way up with your foot. – Turn the emergency OFF switch to the position –...
Page 97: Starting Off
RIDING INSTRUCTIONS 9 Info Do not press the start button until the combination instrument function check has finished. Do not open the throttle to start. Press the starter for a maximum of five seconds. Wait for a least five seconds before trying again. This motorcycle is equipped with a safety starting sys- tem.
Page 98: Shifting, Riding
9 RIDING INSTRUCTIONS Shifting, riding Warning Danger of accidents Abrupt load alterations can cause the vehicle to get out of control. – Avoid abrupt load alterations and sudden braking actions. – Adapt your speed to the road conditions. Warning Danger of accidents If you change down at high engine speed, the rear wheel blocks and the engine races.
Page 99 RIDING INSTRUCTIONS 9 Warning Risk of injury The passenger may fall from the motorcycle if they conduct themselves incorrectly. – Ensure that the passenger sits correctly on the passenger seat, places his or her feet on the passenger foot pegs and holds on to the rider or the grab handles. –...
Page 100 Check and, if necessary, correct the coolant level on the cooling system while it is in a cooled state. Info If unusual noises occur while riding, stop immediately (taking care not to endanger yourself or other road users in the process), switch off the engine and contact an authorized KTM workshop.
Page 101 RIDING INSTRUCTIONS 9 – Shift into a higher gear when conditions allow (incline, road situation, etc.). – Release the throttle while simultaneously pulling the clutch lever, shift into the next gear, release the clutch lever, and open the throttle. Info The gear positions can be seen in the figure.
Page 102: Applying The Brakes
Contact an authorized KTM workshop. – If the malfunction indicator lamp lights up during a trip, please contact an authorized KTM workshop as soon as possi- ble. – If the general warning lamp lights up during a trip, an oper- ating safety (warning) message was detected.
Page 103 Danger of accidents A spongy pressure point on the front or rear brake reduces braking efficiency. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents The brake system fails in the event of overheating.
Page 104 9 RIDING INSTRUCTIONS Info When the ABS is enabled, maximum braking power can be achieved even with low road grip surfaces such as sandy, wet, or slippery terrain without locking the wheels. Warning Danger of accidents The rear wheel can lock due to the engine braking effect. –...
Page 105: Stopping, Parking
RIDING INSTRUCTIONS 9 Stopping, parking Warning Risk of injury People who act without authorization endanger themselves and others. – Do not leave the vehicle unattended if the engine is running. – Protect the vehicle against access by unauthorized persons. – Lock the steering and remove the ignition key if you leave the vehicle unattended. Warning Danger of burns Some vehicle components become very hot when the vehicle is operated.
Page 106: Transport
9 RIDING INSTRUCTIONS Note Fire hazard Hot vehicle components pose a fire hazard and explosion risk. – Do not park the vehicle near to materials which are highly flammable or explosive. – Allow the vehicle to cool down before covering it. –...
Page 107 RIDING INSTRUCTIONS 9 Note Fire hazard Hot vehicle components pose a fire hazard and explosion risk. – Do not park the vehicle near to materials which are highly flammable or explosive. – Allow the vehicle to cool down before covering it. –...
Page 108: Refueling
9 RIDING INSTRUCTIONS Refueling Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not fuel the vehicle in the vicinity of open flames or lit cigarettes. – Switch off the engine for refueling.
Page 109 In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the fuel system. – Refuel only with clean fuel that meets the specified standards. (Your authorized KTM workshop will be glad to help.) Note Environmental hazard Improper handling of fuel is a danger to the environment.
Page 110 9 RIDING INSTRUCTIONS – Switch off the engine. – Open fuel tank filler cap. ( p. 34) – Fill the fuel tank with fuel up to the lower edge of the fuel filler. Total fuel tank 13.5 l Super unleaded capacity, approx.
Page 111: Service Schedule 10
Different service intervals may apply in your country, depending on the local operating conditions. Individual service intervals and scopes may change in the course of technical developments. The most up-to-date service schedule can always be found on KTM Dealer.net. Your authorized KTM dealer will be happy to advise you.
Page 112 10 SERVICE SCHEDULE every 24 months every 12 months every 15,000 km (9,300 mi) every 7,500 km (4,650 mi) after 1,000 km (620 mi) ○ ● ● ● Check the front brake fluid level. ( p. 142) ○ ● ● ●...
Page 113: Recommended Work
Final check: Final check: Check the vehicle for safe operation and take a test ride. ○ ● ● ● ● Read out the error memory after the test ride using the KTM diagnostics tool. ○ ● ● ● ● Set the service interval display.
Page 114 10 SERVICE SCHEDULE every 48 months every 12 months every 30,000 km (18,600 mi) every 7,500 km (4,650 mi) after 1,000 km (620 mi) ● Check the link fork. ● ● Check the swingarm bearing for play. ● ● Check the wheel bearing for play. ○...
Page 115: Tuning The Chassis 11
TUNING THE CHASSIS 11 11.1 Adjusting the spring preload of the shock absorber Warning Danger of accidents Modifications to the suspension setting may seriously alter the handling characteris- tic. – Ride slowly to start with after making adjustments to get the feel of the new handling characteristic. Info The spring preload defines the initial status of the spring operation on the shock absorber.
Page 116: Adjusting The Shift Lever
11 TUNING THE CHASSIS 11.2 Adjusting the shift lever Info The adjustment range of the shift lever is limited. – Loosen nuts – Adjust the shift lever by turning shift rod Guideline Shift rod adjustment 90 … 102 mm (3.54 … range 4.02 in) Info...
Page 117 TUNING THE CHASSIS 11 Info After the nuts have been tightened, the bearings of the shift rod must be central and aligned identically to each other in order to ensure freedom of movement in the bearing shells. – Check the shift lever to ensure it is functioning properly and can move freely.
Page 118: Service Work On The Chassis
12 SERVICE WORK ON THE CHASSIS 12.1 Raising the motorcycle with rear lifting gear Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. – Mount the supports of the lifting gear. –...
Page 119: Lifting The Motorcycle With The Front Lifting Gear
SERVICE WORK ON THE CHASSIS 12 – Secure the motorcycle against falling over. – Remove the rear lifting gear and lean the vehicle on side stand – Remove bushings kit. 402029-10 12.3 Lifting the motorcycle with the front lifting gear Note Danger of damage The parked vehicle can roll away or fall over.
Page 120 12 SERVICE WORK ON THE CHASSIS Condition – Remove protection cap F00795-10 – Move the handlebar to the straight-ahead position. Position the lifting gear. Mounting pin (69329965030) Front wheel work stand, large (69329965100) Info Always raise the motorcycle at the rear first. –...
Page 121: Taking The Motorcycle Off The Front Lifting Gear
SERVICE WORK ON THE CHASSIS 12 12.4 Taking the motorcycle off the front lifting gear Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. Main work – Secure the motorcycle against falling over.
Page 122: Cleaning The Dust Boots Of The Fork Legs
12 SERVICE WORK ON THE CHASSIS – Mount protection cap F00795-10 Finishing work – Remove the rear of the motorcycle from the lifting gear. p. 116) 12.5 Cleaning the dust boots of the fork legs Preparatory work – Raise the motorcycle with the rear lifting gear. ( p.
Page 123 SERVICE WORK ON THE CHASSIS 12 Main work – Push dust boots of both fork legs downward. Info The dust boots remove dust and coarse dirt particles from the inside fork tubes. Over time, dirt can accumu- late behind the dust boots. If this dirt is not removed, the oil seals behind can start to leak.
Page 124: Removing The Passenger Seat
12 SERVICE WORK ON THE CHASSIS – Remove the rear of the motorcycle from the lifting gear. p. 116) 12.6 Removing the passenger seat – Insert the ignition key in seat lock and turn it clockwise. – Raise the rear of the seat, push it towards the rear, and lift it off.
Page 125: Mounting The Passenger Seat
SERVICE WORK ON THE CHASSIS 12 12.7 Mounting the passenger seat – Attach hooks on the passenger seat to seat mounting on the subframe, and lower it at the rear while pushing for- ward. – Press passenger seat downward until it clicks into place. Warning Danger of accidents The seat can come loose from the anchoring if it is not mounted correctly.
Page 126: Mounting The Front Rider's Seat
12 SERVICE WORK ON THE CHASSIS Main work – Raise the rear of the front rider's seat, pull it towards the rear, and remove it upwards. H01993-01 12.9 Mounting the front rider's seat Main work – Attach the front rider's seat in area and lower at the rear.
Page 127: Checking For Chain Dirt Accumulation
SERVICE WORK ON THE CHASSIS 12 12.10 Checking for chain dirt accumulation – Check the chain for coarse dirt accumulation. » If the chain is very dirty: – Clean the chain. ( p. 125) 400678-01 12.11 Cleaning the chain Warning Danger of accidents Lubricants on the tires reduces the road grip.
Page 128 12 SERVICE WORK ON THE CHASSIS Note Environmental hazard Hazardous substances cause environmental damage. – Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations. Info The service life of the chain depends largely on its maintenance. Preparatory work –...
Page 129: Checking The Chain Tension
SERVICE WORK ON THE CHASSIS 12 12.12 Checking the chain tension Warning Danger of accidents Incorrect chain tension damages components and results in accidents. If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel bearings wear more quickly. Some components may break if overloaded. If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket.
Page 130: Adjusting The Chain Tension
12 SERVICE WORK ON THE CHASSIS » If the chain tension does not meet the specification: – Adjust the chain tension. ( p. 128) – Remove the rear of the motorcycle from the lifting gear. p. 116) 12.13 Adjusting the chain tension Warning Danger of accidents Incorrect chain tension damages components and results in accidents.
Page 131 SERVICE WORK ON THE CHASSIS 12 Main work – Loosen nut – Loosen nuts – Adjust the chain tension by turning adjusting screws left and right. Guideline Chain tension 5 … 7 mm (0.2 … 0.28 in) Turn the adjusting screws on the left and right so that the markings on the left and right chain adjusters are in...
Page 132: Checking The Chain, Rear Sprocket, And Engine Sprocket
12 SERVICE WORK ON THE CHASSIS Finishing work – Remove the rear of the motorcycle from the lifting gear. p. 116) 12.14 Checking the chain, rear sprocket, and engine sprocket Preparatory work – Raise the motorcycle with the rear lifting gear. ( p.
Page 133 SERVICE WORK ON THE CHASSIS 12 – Shift the transmission into neutral. – Pull on the lower chain section with the specified weight Guideline Weight, chain wear measure- 15 kg (33 lb.) ment – Measure distance of 20 chain rollers in the lower chain section.
Page 134 12 SERVICE WORK ON THE CHASSIS – Check the chain sliding guard for wear. » If screw becomes visible in area of the chain slid- ing guard when viewed from above: – Change the chain sliding guard. – Check that the chain sliding guard is firmly seated. »...
Page 135: Adjusting The Basic Position Of The Clutch Lever
SERVICE WORK ON THE CHASSIS 12 12.15 Adjusting the basic position of the clutch lever – Adjust the basic position of the clutch lever to your hand size by turning adjusting wheel Info Push the clutch lever forward and turn the adjusting wheel.
Page 136: Removing The Front Spoiler
12 SERVICE WORK ON THE CHASSIS 12.16 Removing the front spoiler – Remove screws and remove the front spoiler. S04745-10...
Page 137 SERVICE WORK ON THE CHASSIS 12 – Remove screws – Remove lower part of front spoiler. S04746-10...
Page 138: Fitting Front Spoiler
12 SERVICE WORK ON THE CHASSIS 12.17 Fitting front spoiler – Position the lower part of front spoiler. Mount and tighten screws Guideline Screw, front spoiler M6x14 9 Nm (6.6 lbf ft) lower part S04746-11...
Page 139 SERVICE WORK ON THE CHASSIS 12 – Position the front spoiler, mount and tighten screws Guideline Screw, front spoiler M6x12 9 Nm (6.6 lbf ft) S04745-11...
Page 140: Brake System
Do not make any changes to the suspension travel. – Only use spare parts on the brake system which have been approved and recommended by KTM. – Only use tires/wheels approved by KTM with the corre- sponding speed index. – Maintain the specified tire pressure. –...
Page 141 BRAKE SYSTEM 13 Warning Danger of accidents Driving aids can reduce the probabil- ity of a fall only within physical limits. It is not always possible to compensate for extreme riding situations, for example with luggage loaded with a high center of gravity, varying road surfaces, steep descents or full braking without disengaging the gear.
Page 142: Adjusting The Basic Position Of The Hand Brake Lever
Do not make any adjustments while riding. F00784-13 13.3 Checking the brake discs Warning Danger of accidents Worn-out brake discs reduce the braking effect. – Make sure that worn-out brake discs are replaced immediately. (Your authorized KTM workshop will be glad to help.)
Page 143 BRAKE SYSTEM 13 – Check the front and rear brake disc thickness at multiple points for the dimension Info Wear will reduce the thickness of the brake disc at con- tact surface of the brake linings. Brake discs - wear limit front 4.5 mm (0.177 in) 400480-10...
Page 144: Checking The Front Brake Fluid Level
– Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) – Move the brake reservoir mounted on the handlebar into a hori- zontal position.
Page 145: Adding The Front Brake Fluid
If the brake fluid level drops below the MIN marking, the brake system is leaking or the brake linings are worn down. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.) Warning Skin irritation Brake fluid causes skin irritation. –...
Page 146 Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) Note Environmental hazard Hazardous substances cause environmental damage.
Page 147 BRAKE SYSTEM 13 Main work – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws – Take off cover with membrane – Add brake fluid to level Guideline 5 mm (0.2 in) Dimension F00862-10 Brake fluid DOT 4 / DOT 5.1 ( p.
Page 148: Checking The Front Brake Linings
Checking the front brake linings Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Damaged brake discs reduce the braking effect.
Page 149: Checking The Free Travel Of Foot Brake Lever
BRAKE SYSTEM 13 13.7 Checking the free travel of foot brake lever Warning Danger of accidents The brake system fails in the event of overheating. If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear brake.
Page 150 13 BRAKE SYSTEM – Disconnect spring – Move the foot brake lever back and forth between the end stop and the contact to the foot brake cylinder piston and check free travel Guideline Free travel at foot brake lever 3 … 5 mm (0.12 … 0.2 in) »...
Page 151: Adjusting The Free Travel Of The Foot Brake Lever
BRAKE SYSTEM 13 13.8 Adjusting the free travel of the foot brake lever Warning Danger of accidents The brake system fails in the event of overheating. If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear brake.
Page 152 13 BRAKE SYSTEM – Detach spring – Release nut and use screw to adjust the specified free travel Guideline Free travel at foot brake lever 3 … 5 mm (0.12 … 0.2 in) Info The range of adjustment is limited. –...
Page 153: Checking The Rear Brake Fluid Level
Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) – Stand the vehicle upright.
Page 154: Adding Rear Brake Fluid
If the brake fluid level drops below the MIN marking, the brake system is leaking or the brake linings are worn down. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.) Warning Skin irritation Brake fluid causes skin irritation. –...
Page 155 Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) Note Environmental hazard Hazardous substances cause environmental damage.
Page 156 13 BRAKE SYSTEM Main work Condition The screw cap is locked. – Remove screw and take off the screw cap lock. H01142-10 – Position the vehicle upright. – Remove screw cap with membrane – Add brake fluid up to the marking Brake fluid DOT 4 / DOT 5.1 ( p.
Page 157: Checking The Rear Brake Linings
Checking the rear brake linings Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Damaged brake discs reduce the braking effect.
Page 158 13 BRAKE SYSTEM – Check the brake linings for minimum thickness ≥ 1 mm (≥ 0.04 in) Minimum thickness » If the minimum thickness is less than specified: – Change the rear brake linings. – Check the brake linings for damage and cracking. »...
Page 159: Wheels, Tires 14
WHEELS, TIRES 14 14.1 Removing the front wheel Preparatory work – Raise the motorcycle with the rear lifting gear. ( p. 116) – Lift the motorcycle with the front lifting gear. ( p. 117) Main work – Remove screws with washers and push the fender slightly to the side.
Page 160: Installing The Front Wheel
14 WHEELS, TIRES Info Do not actuate the hand brake lever when the front wheel is removed. 14.2 Installing the front wheel Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. – Always keep the brake discs free of oil and grease. –...
Page 161 WHEELS, TIRES 14 – Clean the thread of the wheel spindle and screw – Clean and grease the wheel spindle. Long-life grease ( p. 249) – Position the front wheel and insert the wheel spindle. The brake linings are correctly positioned. –...
Page 162: Removing The Rear Wheel
14 WHEELS, TIRES – Remove the rear of the motorcycle from the lifting gear. p. 116) – Operate the front brake and compress the fork a few times firmly. The fork legs straighten. – Tighten screws Guideline Screw, fork stub 15 Nm (11.1 lbf ft) 14.3 Removing the rear wheel...
Page 163 WHEELS, TIRES 14 – Remove screw and pull wheel speed sensor out of the hole. – Remove nut and washer. – Take off chain adjuster – Holding the rear wheel, withdraw wheel spindle with the washer and chain adjuster – Push the rear wheel forward as far as possible and take the chain off the rear sprocket.
Page 164: Installing The Rear Wheel
14 WHEELS, TIRES 14.4 Installing the rear wheel Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. – Always keep the brake discs free of oil and grease. – Clean the brake discs with brake cleaner when necessary. Warning Danger of accidents There is no braking effect to start with at the rear brake after installing the rear wheel.
Page 165 WHEELS, TIRES 14 Long-life grease ( p. 249) – Clean the contact areas on the brake caliper bracket and link fork. – Mount the damping rubber and rear sprocket carrier on the rear wheel. – Insert the spacers. – Position the rear wheel. The brake linings are correctly positioned.
Page 166 14 WHEELS, TIRES – Pull the rear wheel back and mount wheel spindle with the washer and chain adjuster Guideline Mount left and right chain adjusters in the same posi- tion. – Mount nut and the washer. – Push the rear wheel forward so that the chain adjusters are in contact with the screws, and tighten nut Guideline In order for the rear wheel to be correctly aligned, the mark-...
Page 167: Checking The Rear Hub Damping Rubber Pieces
WHEELS, TIRES 14 – Mount and tighten screw Guideline Screw, chain guard EJOT PT ® 7 Nm (5.2 lbf ft) K60x30 F00865-11 Finishing work – Remove the rear of the motorcycle from the lifting gear. p. 116) – Check the chain tension. ( p.
Page 168 14 WHEELS, TIRES Main work – Check bearing » If the bearing is damaged or worn: – Change the bearing. – Check damping rubber pieces of the rear hub for damage and wear. » If the damping rubber pieces of the rear hub are damaged or worn: F00868-10 –...
Page 169: Checking The Tire Condition
Warning Danger of accidents If a tire bursts while riding, the vehicle becomes uncontrollable. – Ensure that damaged or worn tires are replaced immediately. (Your authorized KTM workshop will be glad to help.) Warning Danger of crashing Different tire tread patterns on the front and rear wheel impair the handling charac- teristic.
Page 170 14 WHEELS, TIRES Info The type, condition, and pressure of the tires all have a major impact on the handling characteristic of the motorcycle. Worn tires have a negative effect on handling characteristics, especially on wet surfaces. – Check the front and rear tires for cuts, run-in objects, and other damage.
Page 171: Checking Tire Pressure
DOT number. The first two digits indicate the week of manufacture and the last two digits the year of manu- facture. KTM recommends that the tires be changed after 5 H01144-10 years at the latest, regardless of the actual state of wear.
Page 172 14 WHEELS, TIRES – Remove the protection cap. – Check the tire pressure when the tires are cold. Tire pressure when solo front 2.0 bar (29 psi) rear 2.0 bar (29 psi) Tire pressure with passenger / full payload front 2.0 bar (29 psi) 400695-01 rear...
Page 173: Electrical System 15
ELECTRICAL SYSTEM 15 15.1 Daytime running light (DRL) Warning Danger of accidents When visibility is poor, the daytime running light is not a substitute for the low beam. Automatic switching between the daytime running light and low beam may only be partially available when visi- bility is significantly impaired due to fog, snow or rain.
Page 174: Removing The 12-V Battery
15 ELECTRICAL SYSTEM This is controlled by the ambient light sensor in the combination instrument. When visibility conditions are good, the low beam is switched off and the daytime running light is switched on. Info The position light lights up with all types of lighting. 15.2 Removing the 12-V battery Warning...
Page 175 ELECTRICAL SYSTEM 15 Main work – Disconnect negative cable from the 12-V battery. V01273-10 – Pull back positive terminal cover – Disconnect positive cable from the 12-V battery. – Detach rubber strap – Pull the 12-V battery upwards and out of the battery compart- ment.
Page 176: Installing The 12-V Battery
15 ELECTRICAL SYSTEM 15.3 Installing the 12-V battery Main work – Position the 12-V battery in the battery compartment. 12-V battery (ETZ‑9‑BS) ( p. 235) – Attach rubber strap – Position positive cable and mount and tighten the screw. – Position positive terminal cover V01274-11 –...
Page 177: Charging The 12-V Battery
ELECTRICAL SYSTEM 15 – Set the time and date. ( p. 78) 15.4 Charging the 12-V battery Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep 12 V batteries out of the reach of children. –...
Page 178 15 ELECTRICAL SYSTEM Info Even when there is no load on the 12-V battery, it discharges steadily each day. The charging level and the method of charging are very important for the service life of the 12-V battery. Rapid recharging with a high charging current shortens the service life of the battery. If the charging current, charging voltage, or charging time is exceeded, electrolyte escapes through the safety valves.
Page 179 ELECTRICAL SYSTEM 15 Main work – Connect a battery charger to the 12-V battery. Switch on the battery charger. Battery charger (58429074000) In addition, this battery charger can be used to test the open- circuit voltage, the starting ability of the 12-V battery, and the alternator.
Page 180: Changing The Main Fuse (Eu/Jp)
15 ELECTRICAL SYSTEM Finishing work – Mount the front rider's seat. ( p. 124) – Mount the passenger seat. ( p. 123) – Set the time and date. ( p. 78) 15.5 Changing the main fuse (EU/JP) Warning Fire hazard Incorrect fuses overload the electrical system. –...
Page 181 ELECTRICAL SYSTEM 15 Main work – Remove protection cap S04754-10 – Remove faulty main fuse Info A faulty fuse has a burned-out fuse wire A spare fuse is located in the fuse box. – Insert a new main fuse. Fuse (75011088030) ( p.
Page 182: Changing The Abs Fuses
15 ELECTRICAL SYSTEM – Mount protection cap S04754-10 Finishing work – Mount the passenger seat. ( p. 123) – Set the time and date. ( p. 78) 15.6 Changing the ABS fuses Warning Fire hazard Incorrect fuses overload the electrical system. –...
Page 183 ELECTRICAL SYSTEM 15 Info Two fuses for the ABS are located under the passenger seat. These fuses protect the return pump and the hydraulic unit of the ABS. The third fuse, which protects the ABS control unit, is located in the fuse box. Preparatory work –...
Page 184 15 ELECTRICAL SYSTEM Insert spare fuse in the fuse box so that it is available if needed. – Mount the protection cap. To change the fuse of the ABS return pump: – Take off the protection cap and remove fuse Info A faulty fuse has a burned-out fuse wire Warning...
Page 185: Changing The Fuses Of Individual Power Consumers
ELECTRICAL SYSTEM 15 Insert spare fuse in the fuse box so that it is available if needed. – Mount the protection cap. Finishing work – Mount the passenger seat. ( p. 123) 15.7 Changing the fuses of individual power consumers Info The fuse box with the main fuse and the fuses of the individual power consumers is located under the pas- senger seat.
Page 186 15 ELECTRICAL SYSTEM Main work – Open fuse box cover (EU B.D/AU/AR/BR/CN/CO/MY/PH/TH) – Remove the faulty fuse. Guideline Fuse 1 - 30 A - main fuse Fuse 2 - 10 A - combination instrument Fuse 3 - 10 A - power relay Fuse 4 - 15 A - ignition coil, fuel pump, start auxiliary relay, horn Fuse 5 - 15 A - radiator fan...
Page 187 ELECTRICAL SYSTEM 15 (EU/JP) – Remove the faulty fuse. Guideline Fuse 1 - not assigned Fuse 2 - 10 A - combination instrument Fuse 3 - 10 A - power relay Fuse 4 - 15 A - ignition coil, fuel pump, start auxiliary relay, horn Fuse 5 - 15 A - radiator fan Fuse 6 - 15 A - brake light, turn signal, high beam, low...
Page 188 15 ELECTRICAL SYSTEM Warning Fire hazard Incorrect fuses overload the electrical system. – Only use fuses with the required ampere value. – Do not bypass or repair fuses. – Insert the spare fuse with the correct rating. Fuse (75011088010) ( p. 235) Fuse (75011088015) ( p.
Page 189: Checking The Headlight Setting
ELECTRICAL SYSTEM 15 15.8 Checking the headlight setting – Park the vehicle on a horizontal surface in front of a light- colored wall and make a mark at the height of the center of the low beam headlight. – Make another mark at a distance under the first marking.
Page 190: Adjusting The Headlight Range
15 ELECTRICAL SYSTEM 15.9 Adjusting the headlight range Preparatory work – Check the headlight setting. ( p. 187) Main work – Turn adjusting screw to adjust the headlight range. Info Turn clockwise to increase the headlight range; turn counterclockwise to reduce the headlight range. If you have a payload, you may have to correct the headlight range.
Page 191: Diagnostics Connector
ELECTRICAL SYSTEM 15 15.10 Diagnostics connector Diagnostics connector is located under the passenger seat. H01906-10 15.11 Front ACC1 and ACC2 Installation location – Power supplies ACC1 and ACC2 front are located on the left of the vehicle, behind the cover under the fuel tank. E01189-10...
Page 192: Acc2 Rear
15 ELECTRICAL SYSTEM 15.12 ACC2 rear Installation location – Rear ACC2 power supplies are located under the passenger seat. S04730-10...
Page 193: Cooling System 16
COOLING SYSTEM 16 16.1 Cooling system Water pump in the engine ensures forced circulation of the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap . Heat expansion causes excess coolant to flow into compensating tank .
Page 194 16 COOLING SYSTEM The coolant is cooled by the air stream and a radiator fan which is activated at high temperature. The lower the speed, the less the cooling effect. Dirty cooling fins also reduce the cooling effect. Info If the cooling system overheats, the maximum engine speed is limited.
Page 195: Checking The Antifreeze And Coolant Level
COOLING SYSTEM 16 16.2 Checking the antifreeze and coolant level Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.
Page 196 16 COOLING SYSTEM – Stand the motorcycle upright on a horizontal surface. – Remove cap of the compensating tank. – Check the antifreeze in the coolant. −25 … −45 °C (−13 … −49 °F) » If the antifreeze in the coolant does not match the speci- fied value: –...
Page 197 COOLING SYSTEM 16 – Remove radiator cap – Check the antifreeze in the coolant. −25 … −45 °C (−13 … −49 °F) » If the antifreeze in the coolant does not match the speci- fied value: – Correct the antifreeze in the coolant. –...
Page 198: Checking The Coolant Level
16 COOLING SYSTEM 16.3 Checking the coolant level Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.
Page 199 COOLING SYSTEM 16 – Stand the motorcycle upright on a horizontal surface. – Check the coolant level in compensating tank The coolant level must be between the two markings. » If the coolant level does not match the specified value: –...
Page 200: Draining The Coolant
16 COOLING SYSTEM 16.4 Draining the coolant Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.
Page 201: Filling/Bleeding The Cooling System
COOLING SYSTEM 16 Main work – Position the motorcycle upright. – Position an appropriate container under the engine. – Remove screw with the seal ring. – Remove the radiator cap. – Completely drain the coolant. – Mount and tighten screw with a new seal ring.
Page 202 16 COOLING SYSTEM Main work – Remove radiator cap F00856-10 – Loosen bleeder screw Guideline 3 turns – Tilt the vehicle slightly to the right. – Pour in the coolant until it emerges without bubbles at the bleeder screw, and then mount and tighten the bleeder screw immediately.
Page 203 COOLING SYSTEM 16 Danger Danger of poisoning Exhaust gases are toxic and inhal- ing them may result in unconsciousness and death. – Always make sure there is sufficient ventilation when running the engine. – Use effective exhaust extraction when starting or running the engine in an enclosed space.
Page 204: Changing The Coolant
16 COOLING SYSTEM 16.6 Changing the coolant Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.
Page 205 COOLING SYSTEM 16 Main work – Position the motorcycle upright. – Position an appropriate container under the engine. – Remove screw with the seal ring. S04750-10 – Remove radiator cap – Completely drain the coolant. – Mount and tighten screw with a new seal ring.
Page 206 16 COOLING SYSTEM – Loosen bleeder screw Guideline 3 turns – Tilt the vehicle slightly to the right. – Pour in the coolant until it emerges without bubbles at the bleeder screw, and then mount and tighten the bleeder screw immediately.
Page 207 COOLING SYSTEM 16 – Stop the engine and allow it to cool down. – When the engine is cool, check the coolant level in the radiator and, if necessary, add coolant. – Remove cap of the compensating tank and top up the coolant level up to the MAX marking.
Page 208: Tuning The Engine
17 TUNING THE ENGINE 17.1 Checking the clutch lever play Note Clutch damage If there is no free travel by the clutch lever, the clutch will begin to slip. – Check the free travel of the clutch lever each time before using the motorcycle. –...
Page 209: Adjusting Play In The Clutch Lever
TUNING THE ENGINE 17 17.2 Adjusting play in the clutch lever – Move the handlebar to the straight-ahead position. – Push back sleeve – Loosen lock nut – Adjust the play in the clutch level by turning adjusting screw Guideline 1 …...
Page 210: Service Work On The Engine
18 SERVICE WORK ON THE ENGINE 18.1 Checking the engine oil level Condition The engine is at operating temperature. Preparatory work – Stand the motorcycle upright on a horizontal surface. Main work – Check the engine oil level. Info After switching off the engine, wait one minute before checking the level.
Page 211: Changing The Engine Oil And Oil Filter, Cleaning The Oil Screens
SERVICE WORK ON THE ENGINE 18 18.2 Changing the engine oil and oil filter, cleaning the oil screens Warning Danger of scalding Engine and gear oil get very hot when the motorcycle is ridden. – Wear suitable protective clothing and safety gloves. –...
Page 212 18 SERVICE WORK ON THE ENGINE Main work – Place an appropriate container under the engine. – Remove oil drain plug with the O-ring. – Remove oil screen with the O-ring. – Remove screw plug with oil screen – Allow the engine oil to drain completely. –...
Page 213 SERVICE WORK ON THE ENGINE 18 – Remove screws . Take off oil filter cover with the O- ring. – Pull oil filter out of the oil filter housing. – Allow the engine oil to drain completely. – Thoroughly clean the parts and the sealing surface. S04748-10 –...
Page 214 18 SERVICE WORK ON THE ENGINE – Remove filler plug with the O-ring, and fill up with engine oil. Engine oil 1.7 l (1.8 qt.) Engine oil (SAE 15W/50) p. 246) – Mount and tighten the filler plug together with the O-ring. Danger 401955-12 Danger of poisoning Exhaust gases are toxic and inhal-...
Page 215: Adding Engine Oil
Engine oil (SAE 15W/50) ( p. 246) Info In order to achieve optimal engine oil performance, it is not advisable to mix different engine oils. KTM recommends changing the engine oil. 401955-10 – Mount and tighten the filler plug together with the O-ring. Danger Danger of poisoning Exhaust gases are toxic and inhal-...
Page 216 18 SERVICE WORK ON THE ENGINE Finishing work – Check the engine oil level. ( p. 208)
Page 217: Cleaning, Care 19
CLEANING, CARE 19 19.1 Cleaning the motorcycle Note Material damage Components become damaged or destroyed if a pressure cleaner is used incorrectly. The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc. Pressure which is too high causes malfunctions and destroys components. –...
Page 218 19 CLEANING, CARE – Close off exhaust system to keep water from entering. – Remove loose dirt first with a soft jet of water. – Spray the heavily soiled parts with a normal commercial motor- cycle cleaner and clean using a brush. Motorcycle cleaner ( p.
Page 219 CLEANING, CARE 19 – After cleaning, ride the vehicle a short distance until the engine warms up. Info The heat produced causes water at inaccessible loca- tions in the engine and on the brake system to evapo- rate. – Push back the sleeves of the handlebar controls to allow any water that has penetrated to evaporate.
Page 220: Checks And Maintenance Steps For Winter Operation
19 CLEANING, CARE – Treat all plastic parts and powder-coated parts with a mild cleaning and care product. Special cleaner for glossy and matte paint finishes, metal and plastic surfaces ( p. 250) – Lubricate the ignition and steering lock. Universal oil spray ( p.
Page 221 CLEANING, CARE 19 – Clean the motorcycle. ( p. 215) – Clean the brakes. Info After EVERY trip on salted roads, thoroughly clean the motorcycle and, in particular, the brake calipers and brake linings, after they have cooled down and without removing them, with cold water and dry carefully.
Page 222: Storage
20 STORAGE 20.1 Storage Info If you plan to garage the motorcycle for a longer period, perform the following steps or have them per- formed. Before storing the motorcycle, check all parts for function and wear. If service, repairs, or replacements are necessary, you should do this during the storage period (less workshop overload).
Page 223 – Store vehicle in a dry location that is not subject to large fluc- tuations in temperature. Info KTM recommends jacking up the motorcycle. – Raise the motorcycle with the rear lifting gear. ( p. 116) – Lift the motorcycle with the front lifting gear. ( p.
Page 224: Preparing For Use After Storage
20 STORAGE 20.2 Preparing for use after storage – Take the motorcycle off the front lifting gear. ( p. 119) – Remove the rear of the motorcycle from the lifting gear. p. 116) – Install the 12-V battery. p. 174) –...
Page 225: Troubleshooting 21
Carry out start procedure. ( p. 93) – Malfunction in the electronic Read out the fault memory using the fuel injection KTM diagnostics tool. – Engine has too little power Air filter is very dirty Change the air filter. –...
Page 226 Check the radiator fan system. – Malfunction indicator lamp Malfunction in the electronic Read out the fault memory using the lights up yellow fuel injection KTM diagnostics tool. – Engine dies during the trip Lack of fuel Refuel. ( p. 106) –...
Page 227 TROUBLESHOOTING 21 Faults Possible cause Action – Turn signal, brake light, and Fuse 4 or 6 blown Change the fuses of individual power horn are not functional consumers. ( p. 183) – Time is not displayed or not Fuse 2 is blown Change the fuses of individual power correctly displayed consumers.
Page 228: Technical Data
22 TECHNICAL DATA 22.1 Engine Design 1-cylinder 4-stroke engine, water-cooled Displacement 373 cm³ (22.76 cu in) Stroke 60 mm (2.36 in) Bore 89 mm (3.5 in) Compression ratio 12.4:1 Control DOHC, four valves controlled via cam lever, chain drive Intake valve diameter 36 mm (1.42 in) Exhaust valve diameter 29 mm (1.14 in)
Page 229 TECHNICAL DATA 22 Transmission 6-gear transmission, claw shifted Transmission ratio 1st gear 12:32 2nd gear 14:26 3rd gear 19:27 4th gear 21:24 5th gear 23:22 6th gear 25:21 Mixture preparation Electronic fuel injection Ignition Contactless controlled fully electronic ignition with digital ignition adjustment Alternator 12 V, 230 W...
Page 230: Engine Tightening Torques
22 TECHNICAL DATA 22.2 Engine tightening torques Oil nozzle 6 Nm (4.4 lbf ft) Loctite ® 243™ Screw, crankshaft speed sensor 6 Nm (4.4 lbf ft) Loctite ® 243™ Screw, gear sensor 6 Nm (4.4 lbf ft) Loctite ® 243™ Screw, retaining bracket 6 Nm (4.4 lbf ft) Loctite...
Page 231 TECHNICAL DATA 22 Screw, camshaft, decompression 10 Nm (7.4 lbf ft) Loctite ® 243™ shaft Screw, chain securing guide 10 Nm (7.4 lbf ft) Loctite ® 243™ Screw, clutch cable retaining 6 Nm (4.4 lbf ft) Loctite ® 243™ bracket Screw, clutch cover 12 Nm (8.9 lbf ft) Screw, clutch spring...
Page 232 22 TECHNICAL DATA Screw, retaining bracket 12 Nm (8.9 lbf ft) Loctite ® 243™ Screw, retaining bracket, radial 12 Nm (8.9 lbf ft) Loctite ® 243™ shaft seal ring, clutch cover Screw, shift drum locating 12 Nm (8.9 lbf ft) Loctite ®...
Page 233 TECHNICAL DATA 22 Coolant temperature sensor 14 Nm (10.3 lbf ft) Oil pressure sensor 14 Nm (10.3 lbf ft) Screw, camshaft gear wheel 36 Nm (26.6 lbf ft) Loctite ® 243™ Screw, cylinder head 1st stage 30 Nm (22.1 lbf ft) 2nd stage 60 Nm (44.3 lbf ft) Thread is oiled, head flat is greased...
Page 234: Capacities
22 TECHNICAL DATA 22.3 Capacities 22.3.1 Engine oil Engine oil 1.7 l (1.8 qt.) Engine oil (SAE 15W/50) p. 246) 22.3.2 Coolant Coolant 1.2 l (1.3 qt.) Coolant ( p. 245) 22.3.3 Fuel Please observe the labels on EU fuel pumps. A00420-10 Total fuel tank capacity, approx.
Page 235: Chassis
TECHNICAL DATA 22 Total fuel tank capacity, approx. 13.5 l (3.57 US gal) Gasohol 95 E20 (RON 95) p. 247) (390 DUKE TH) Total fuel tank capacity, approx. Super unleaded, type C (ROZ 95/RON 95/PON 91) ( p. 248) (390 DUKE BR) Fuel reserve, approx.
Page 236 22 TECHNICAL DATA front 4.5 mm (0.177 in) rear 3.6 mm (0.142 in) Tire pressure when solo front 2.0 bar (29 psi) rear 2.0 bar (29 psi) Tire pressure with passenger / full payload front 2.0 bar (29 psi) rear 2.2 bar (32 psi) Secondary ratio 15:45...
Page 237: Electrical System
TECHNICAL DATA 22 22.5 Electrical system 12-V battery ETZ‑9‑BS Battery voltage: 12 V Nominal capacity: 8 Ah Maintenance-free Fuse 75011088010 10 A Fuse 75011088015 15 A Fuse 90111088025 25 A Fuse 75011088030 30 A Headlight Position light Combination instrument lighting and indicator lamps Turn signal Brake/tail light License plate lamp...
Page 238: Tires
110/70 R 17 M/C 54H TL 150/60 R 17 M/C 66H TL Continental ContiMotion Continental ContiMotion The tires specified represent one of the possible series production tires. Additional information is available in the Service section under: KTM.com 22.7 Fork Fork article number 93301000144 Fork...
Page 239: Chassis Tightening Torques
TECHNICAL DATA 22 Spring preload Standard 5 clicks Static sag 14 mm (0.55 in) Riding sag 47 mm (1.85 in) Fitted length 304 mm (11.97 in) 22.9 Chassis tightening torques Screw, chain guard EJOT PT ® K60x30 7 Nm (5.2 lbf ft) Remaining screws, chassis 4 Nm (3 lbf ft) Remaining nuts, chassis...
Page 240 22 TECHNICAL DATA Remaining nuts, chassis 10 Nm (7.4 lbf ft) Remaining screws, chassis 10 Nm (7.4 lbf ft) Screw, ABS hose clamp 7 Nm (5.2 lbf ft) Screw, ABS module 10 Nm (7.4 lbf ft) Screw, ABS module retaining 7 Nm (5.2 lbf ft) bracket on frame Screw, air filter box...
Page 241 TECHNICAL DATA 22 Screw, fuel tank trim 5 Nm (3.7 lbf ft) Screw, fuel tank trim 7 Nm (5.2 lbf ft) Screw, headlight 8 Nm (5.9 lbf ft) Screw, holder of fuel vapor valve 9 Nm (6.6 lbf ft) Screw, ignition coil 8 Nm (5.9 lbf ft) Screw, ignition lock (tamper-proof 13 Nm (9.6 lbf ft)
Page 242 22 TECHNICAL DATA Screw, side stand sensor cable 9 Nm (6.6 lbf ft) Loctite ® 243™ holder Screw, tilt sensor 8 Nm (5.9 lbf ft) Loctite ® 243™ Screw, wheel speed sensor holder 8 Nm (5.9 lbf ft) Nut, rear sprocket 27 Nm (19.9 lbf ft) Remaining nuts, chassis 25 Nm (18.4 lbf ft)
Page 243 TECHNICAL DATA 22 Screw, passenger footrest unit 22 Nm (16.2 lbf ft) Loctite ® 243™ Screw, rear brake disc 21 Nm (15.5 lbf ft) Loctite ® 243™ Screw, rear seat fixing 18 Nm (13.3 lbf ft) Screw, seat support plate 18 Nm (13.3 lbf ft) Screw, subframe 25 Nm (18.4 lbf ft)
Page 244 22 TECHNICAL DATA Nut, side stand bracket M10x1.25 35 Nm (25.8 lbf ft) Screw, combination instrument M10x1.25 21 Nm (15.5 lbf ft) bracket Screw, front footrest bracket M10x1.25 44 Nm (32.5 lbf ft) Loctite ® 243™ Screw, front footrest bracket / M10x1.25 49 Nm (36.1 lbf ft) engine bearer...
Page 245 TECHNICAL DATA 22 Nut, steering head M30x1 1st stage 45 Nm (33.2 lbf ft) 2nd stage (loosen, counterclock- wise) 2 turns 3rd stage 5 Nm (3.7 lbf ft)
Page 246: Declarations Of Conformity
COBO SpA hereby declares that the BT‑ROUTER wireless system conforms with the relevant guidelines. The full text of the Declaration of Conformity is available at the following Internet address. Certification website: http://www.ktm.com/btrouter JNS Instruments Ltd. hereby declares that the 210M1100 wireless system conforms with the relevant guidelines.
Page 247: Substances 24
SUBSTANCES 24 Brake fluid DOT 4 / DOT 5.1 Standard/classification – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that exhibits the corresponding properties. Recommended supplier Castrol – REACT PERFORMANCE DOT 4 MOTOREX ®...
Page 248 24 SUBSTANCES The mixture ratio must be adjusted to the necessary antifreeze protection. Use distilled water if the coolant needs to be diluted. The use of premixed coolant is recommended. Observe the coolant manufacturer specifications for antifreeze protection, dilution and miscibility (compatibility) with other coolants.
Page 249 SUBSTANCES 24 Fork oil (SAE 4) (48601166S1) Standard/classification – SAE ( p. 251) (SAE 4) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties. Gasohol 95 E20 (RON 95) Standard/classification –...
Page 250 24 SUBSTANCES – Fuel with an ethanol content of up to 10% (E10 fuel) is safe to use. Info Do not use fuel containing methanol (e.g., M15, M85, M100) or more than 10% ethanol (e.g., E15, E25, E85, E100). Super unleaded, type C (ROZ 95/RON 95/PON 91) Standard/classification –...
Page 251: Auxiliary Substances 25
AUXILIARY SUBSTANCES 25 Chain cleaner Recommended supplier MOTOREX ® – Chain Clean Fuel additive Recommended supplier MOTOREX ® – Fuel Stabilizer Long-life grease Recommended supplier MOTOREX ® – Bike Grease 2000 Motorcycle cleaner Recommended supplier MOTOREX ® – Moto Clean Perfect finish and high gloss polish for paints Recommended supplier MOTOREX...
Page 252 25 AUXILIARY SUBSTANCES Preserving materials for paints, metal and rubber Recommended supplier MOTOREX ® – Moto Protect Special cleaner for glossy and matte paint finishes, metal and plastic surfaces Recommended supplier MOTOREX ® – Quick Cleaner Street chain spray Guideline Recommended supplier MOTOREX ®...
Page 253: Standards 26
STANDARDS 26 JASO T903 MA2 Different technical development directions required a separate specification for motorcycles – the JASO T903 MA2 standard. Earlier, engine oils from the automobile industry were used for motorcycles because there was no separate motor- cycle specification. Whereas long service intervals are demanded for automobile engines, the focus for motorcycle engines is on high performance at high engine speeds.
Page 254: Index Of Special Terms
Light, which enhances the visibility of the vehicle dur- ing the day but is not focused, and in contrast to low beam does not illuminate the road surface KTM MY RIDE System for wireless communication with appropriate cellphones and headsets for telephony and audio...
Page 255: List Of Abbreviations 28
LIST OF ABBREVIATIONS 28 Art. no. Article number circa compare e.g. for example etc. et cetera i.a. inter alia number poss. possibly...
Page 256: List Of Symbols
Malfunction indicator light lights up yellow – The OBD has detected a malfunction in the vehi- cle electronics. Come safely to a halt, and contact an authorized KTM workshop. The ABS warning lamp lights up yellow – Status or error messages relating to ABS. The ABS warning lamp flashes if the ABS mode Super Moto is enabled.
Page 257 LIST OF SYMBOLS 29 The idle indicator lamp lights up green – The transmission is in neutral. High beam indicator lamp lights up blue – The high beam is switched on.
Page 258: Index
INDEX INDEX Brake discs 12-V battery checking ......140 charging ......175 Brake fluid installing .
Page 259 Info ......60 KTM MY RIDE ..... . . 59 checking .
Page 260 INDEX warnings ......44 Engine oil level checking ......208 Combination switch .
Page 261 INDEX removing ......157 Fuel tank filler cap Key number ......26 closing .
Page 262 INDEX Owner's Manual ......16 Riding ......96 starting off .
Page 263 INDEX Switch Troubleshooting ....223-225 on the left side of the handlebar ..28 Turn signal switch .
Page 264 *3214321en* 3214321en 02/2021 KTM Sportmotorcycle GmbH Photo: 5230 Mattighofen/Austria Mitterbauer/KISKA/KTM KTM.com...

KTM 390 DUKE 2021 Owner's Manual

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