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KTM 390 DUKE 2022 Owner's Manual

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OWNER'S MANUAL
2022
390 DUKE
Art. no. 3214572en

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Summary of Contents for KTM 390 DUKE 2022

  • Page 1 OWNER'S MANUAL 2022 390 DUKE Art. no. 3214572en...
  • 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: Table Of Contents

    Quick Selector 2 display ....27 View of vehicle, front left (example) ... 10 7.17 Menu..........27 View of vehicle, rear right 7.17.1 KTM MY RIDE (optional) ....27 (example)........11 7.17.2 Trips/Data ........28 SERIAL NUMBERS ........12 7.17.3 Motorcycle ........
  • Page 5 TABLE OF CONTENTS 7.17.27 Service ........38 12.16 Removing the front spoiler ....64 7.17.28 Extra Functions ......38 12.17 Fitting front spoiler ......65 PREPARING FOR USE......... 40 13 BRAKE SYSTEM ......... 66 Advice on preparing for first use ..40 13.1 Anti-lock braking system (ABS) ..
  • Page 6 TABLE OF CONTENTS 17 TUNING THE ENGINE......... 97 17.1 Checking the clutch lever play... 97 17.2 Adjusting play in the clutch lever ... 97 18 SERVICE WORK ON THE ENGINE ....98 18.1 Checking the engine oil level..... 98 18.2 Changing the engine oil and oil filter, cleaning the oil screens ..

  • Page 7: Means Of Representation 1

    Indicates work that requires expert knowledge and technical understanding. In the interest of your own safety, have these jobs performed by an authorized KTM workshop! Your motorcycle will be cared for there to the highest degree by specially trained experts using the special tools required.

  • Page 8: Safety Advice

    2 SAFETY ADVICE 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 9: Tampering Warning

    Wear appropriate protective clothing such as helmet, boots, gloves as well as trousers and a jacket with protectors on all rides. – Always wear protective clothing that is in good condition and meets the legal regulations. In the interest of your own safety, KTM recommends that you only operate the vehicle while wearing protective clothing.

  • Page 10: Work Rules

    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 11: 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 12: View Of Vehicle

    4 VIEW OF VEHICLE View of vehicle, front left (example) S04740-10 Combination instrument Clutch lever ( p. 13) Front rider’s seat Passenger seat Grab handles ( p. 18) Seat lock ( p. 17) Side stand ( p. 19) Shift lever ( p.

  • Page 13: View Of Vehicle, Rear Right (Example)

    VIEW OF VEHICLE 4 View of vehicle, rear right (example) S04741-10 Tool set ( p. 18) Light switch ( p. 14) Menu buttons ( p. 14) Turn signal switch ( p. 14) Horn button ( p. 14) Ignition and steering lock ( p.

  • Page 14: 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 The type label is on the right of the frame behind the steering head. 402174-10 Engine number The engine number is stamped on the left side of the engine under the engine sprocket.

  • Page 15: 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 Throttle grip The throttle grip...

  • Page 16: Light Switch

    6 CONTROLS 6.4.2 Light switch Light switch is fitted on the left side of the handlebar. Possible states Low beam on – Light switch in position . In this position, the low beam and the tail light are switched High beam on – Push the light switch to position In this position, the high beam and the tail light are switched on.

  • Page 17: Switches On The Right Side Of The Handlebar

    CONTROLS 6 Switches on the right side of the handlebar 6.5.1 Emergency OFF switch The emergency OFF switch is fitted on the right side of the handlebar. Possible states Emergency OFF switch off – In this position, the igni- tion circuit is interrupted, a running engine stops, and a non-running engine cannot be started.

  • Page 18: Unlocking The Steering

    6 CONTROLS – Park the vehicle. – Turn the handlebar all the way to the left. – Insert the ignition key into the ignition and steering lock, press in, and turn to the left. Remove the ignition key. Steering is no longer possible. 400732-01 Unlocking the steering –...

  • Page 19: Closing The Fuel Tank Filler Cap

    CONTROLS 6 – Lift cover of the fuel tank filler cap and insert the ignition key into the lock. Note Danger of damage The ignition key may break if overloaded. Damaged ignition keys must be replaced. – Push down on the fuel tank filler cap to take pressure off the ignition key.

  • Page 20: Tool Set

    6 CONTROLS 6.12 Tool set The tool set is located under the passenger seat. F00729-10 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.

  • Page 21: Foot Brake Lever

    CONTROLS 6 The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. 401950-11 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...

  • Page 22: Combination Instrument

    7 COMBINATION INSTRUMENT Combination instrument The combination instrument is attached in front of the handlebar. H04875-51 The combination instrument is divided into two function areas. indicator lamps ( p. 21) Display M01577-10 Activation and test Activation The combination instrument is activated when the ignition is switched on.

  • Page 23: Warnings

    COMBINATION INSTRUMENT 7 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 24 The malfunction indicator lamp lights up yellow – The OBD has detected a malfunction in the vehicle 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.

  • Page 25: Display

    COMBINATION INSTRUMENT 7 Display M01580-11 Speed ( p. 24) Shift warning light ( p. 24) The shift warning light is integrated in the tachometer display. Gear display Unit for the speed display Speed ( p. 24) Unit for the speedometer ODO display ( p.

  • Page 26: 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 27: Odo Display

    COMBINATION INSTRUMENT 7 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 28: 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 29: Quick Selector 2 Display

    (optional) activated. – Press the SET button when the menu is closed. – Press the UP or DOWN button until KTM MY RIDE is highlighted. Press the SET button to open the menu. Info S05079-01 This function is only available if the vehicle has Bluetooth ®...

  • Page 30: Trips/Data

    – Press the SET button when the menu is closed. – Press the UP or DOWN button until KTM MY RIDE is highlighted. Press the SET button to open the menu. – Press the UP or DOWN button until Pairing is highlighted. Press the SET button to open the menu.

  • Page 31: Phone (Optional)

    – Press the SET button when the menu is closed. – Press the UP or DOWN button until KTM MY RIDE is highlighted. Press the SET button to open the menu. F01959-01 – Press the UP or DOWN button until Pairing is highlighted. Press the SET button to open the menu.

  • Page 32: Headset (Optional)

    – Press the SET button when the menu is closed. – Press the UP or DOWN button until KTM MY RIDE is highlighted. Press the SET button to open the menu. F01960-01 – Press the UP or DOWN button until Pairing is highlighted. Press the SET button to open the menu.

  • Page 33: Audio (Optional)

    – Press the SET button when the menu is closed. – Press the UP or DOWN button until KTM MY RIDE is highlighted. Press the SET button to open the menu. S05091-01 Warning Danger of accidents Headphone volume which is too high distracts attention from traffic activity.

  • Page 34: Telephony (Optional)

    7 COMBINATION INSTRUMENT 7.17.9 Telephony (optional) Condition • Function KTM MY RIDE activated (optional). • Bluetooth ® function is activated. • The Bluetooth ® function should also be activated in the device to be paired. • Headset linked with appropriate cellphone.

  • Page 35: Trip 2

    COMBINATION INSTRUMENT 7 Fuel Range displays 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. 7.17.12 Trip 2 – Press the SET button when the menu is closed. –...

  • Page 36: Quick Shift+ (Optional)

    7 COMBINATION INSTRUMENT Info If ABS mode Road is enabled, ABS controls both wheels. If the ABS mode Super Moto is enabled, ABS only con- trols the front wheel. The rear wheel is not controlled by ABS and may lock during braking maneuvers. Press and Activation of the different ABS modes.

  • Page 37: Quick Selector 2

    This function is only available if the vehicle has Bluetooth ® hardware. 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 of the combination instrument.

  • Page 38: Shift Light

    7 COMBINATION INSTRUMENT 7.17.21 Shift Light Condition • The motorcycle is stationary. • ODO > 1,000 km (621 mi). – Press the SET button when the menu is closed. – Press the UP or DOWN button until Settings is highlighted. Press the SET button to open the menu.

  • Page 39: Distance

    COMBINATION INSTRUMENT 7 Setting the date – Press UP or DOWN button until the date is marked. – Press the SET button. The day flashes and is underlined. – Press UP or DOWN button until the current day is set. –...

  • Page 40: Consumption

    7 COMBINATION INSTRUMENT 7.17.25 Consumption Condition • The motorcycle is stationary. – Press the SET button when the menu is closed. – Press the UP or DOWN button until Settings is highlighted. Press the SET button to open the menu. –...
  • Page 41 COMBINATION INSTRUMENT 7 Info The current KTM PowerParts and the available software for your vehicle can be found on the KTM website.

  • Page 42: Preparing For Use

    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 43: 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 44 8 PREPARING FOR USE – 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 the maximum permissible weight and maximum permissible axle loads. Guideline Maximum permissible overall weight 355 kg (783 lb.)

  • Page 45: Riding Instructions 9

    RIDING INSTRUCTIONS 9 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 46: Starting Off

    9 RIDING INSTRUCTIONS – Unlock the steering. ( p. 16) – 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 47: Quickshifter + (Optional)

    RIDING INSTRUCTIONS 9 Quickshifter + (optional) If the quickshifter + is activated, you can shift up and down with- out actuating the clutch. Because there is no need to close the throttle grip, uninterrupted gear shifts are possible. The quickshifter + uses the shifter shaft position to check whether or not a shift should be initiated, and sends a corresponding signal to the engine control.
  • Page 48 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. – Shift into a higher gear when conditions allow (incline, road situation, etc.).
  • Page 49 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 50: Applying The Brakes

    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 51: 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 52: Towing In The Event Of A Breakdown

    9 RIDING INSTRUCTIONS – Switch off the engine and remove the ignition key. – Use tension belts or other suitable devices to secure the motorcycle against accidents or falling over. 401448-01 Towing in the event of a breakdown Note Danger of damage Towing away using a towing vehicle is not an appropriate vehicle recovery method. Damage to the drive train or transmission may occur during towing.
  • Page 53 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 54: Service Schedule

    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 55: Recommended Work

    SERVICE SCHEDULE 10 10.3 Recommended work 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 frame. ● Check the link fork. ● ● Checking the fork bearing for play. ●...

  • Page 56: Tuning The Chassis

    11 TUNING THE CHASSIS 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 57 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 58: 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 59: Taking The Motorcycle Off The Front Lifting Gear

    SERVICE WORK ON THE CHASSIS 12 – 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. – Lift the motorcycle at the front. 402345-01 12.4 Taking the motorcycle off the front lifting gear...

  • Page 60: Removing The Passenger Seat

    12 SERVICE WORK ON THE CHASSIS 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 61: Removing The Front Rider's Seat

    SERVICE WORK ON THE CHASSIS 12 – Finally, check that the passenger seat is correctly mounted. 12.8 Removing the front rider's seat Preparatory work – Remove the passenger seat. ( p. 58) Main work – Raise the rear of the front rider's seat, pull it towards the rear, and remove it upwards.

  • Page 62: Cleaning The Chain

    12 SERVICE WORK ON THE CHASSIS 12.11 Cleaning the chain Warning Danger of accidents Lubricants on the tires reduces the road grip. – Remove lubricants from the tires using a suitable cleaning agent. Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. –...

  • Page 63: Adjusting The Chain Tension

    SERVICE WORK ON THE CHASSIS 12 Main work – Shift the transmission into neutral. – In the area after the chain sliding guard, press the chain upward toward the link fork and measure chain tension Info Top chain section must be taut. Chain wear is not always even, so you should repeat this measurement at different chain positions.

  • Page 64: Checking The Chain, Rear Sprocket, And Engine Sprocket

    12 SERVICE WORK ON THE CHASSIS – Tighten nut Guideline Nut, rear wheel spin- M14x1.5 98 Nm (72.3 lbf ft) Finishing work – Remove the rear of the motorcycle from the lifting gear. p. 56) 12.14 Checking the chain, rear sprocket, and engine sprocket Preparatory work –...

  • Page 65: Adjusting The Basic Position Of The Clutch Lever

    SERVICE WORK ON THE CHASSIS 12 – 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 66: 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 – Remove screws – Remove lower part of front spoiler. S04746-10...

  • Page 67: Fitting Front Spoiler

    SERVICE WORK ON THE CHASSIS 12 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 – Position the front spoiler, mount and tighten screws Guideline Screw, front spoiler M6x12...

  • Page 68: 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 69: Adjusting The Basic Position Of The Hand Brake Lever

    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.) – Check the front and rear brake disc thickness at multiple...

  • Page 70: Adding The Front Brake Fluid

    – 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 71: 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 72: Checking The Free Travel Of Foot Brake Lever

    13 BRAKE SYSTEM 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 73: 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 74: Adding Rear Brake Fluid

    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 75: 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 76: Wheels, Tires

    14 WHEELS, TIRES 14.1 Removing the front wheel Preparatory work – Raise the motorcycle with the rear lifting gear. ( p. 56) – Lift the motorcycle with the front lifting gear. ( p. 56) Main work – Remove screws with washers and push the fender slightly to the side.

  • Page 77: Removing The Rear Wheel

    WHEELS, TIRES 14 – Clean the thread of the wheel spindle and screw – Clean and grease the wheel spindle. Long-life grease ( p. 119) – Position the front wheel and insert the wheel spindle. The brake linings are correctly positioned. –...

  • Page 78: Installing The Rear Wheel

    14 WHEELS, TIRES – 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 79 WHEELS, TIRES 14 – 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. – Push the rear wheel forward as far as possible and lay the chain on the rear sprocket.

  • Page 80: Checking The Rear Hub Damping Rubber Pieces

    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 81: Checking Tire Pressure

    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. Info The type, condition, and pressure of the tires all have a major impact on the handling characteristic of the motorcycle.
  • Page 82 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 83: Electrical System 15

    Make sure that the daytime running light is deacti- vated with the diagnostics tool when the menu item is not available, but the low beam is required. (Your authorized KTM workshop will be glad to help.) – Note the legal regulations regarding the daytime run- ning light.

  • Page 84: Installing The 12-V Battery

    15 ELECTRICAL SYSTEM 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 85: Charging The 12-V Battery

    ELECTRICAL SYSTEM 15 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. – Wear suitable protective clothing and safety glasses. – Avoid contact with battery acid and battery gases.

  • Page 86: Changing The Main Fuse

    15 ELECTRICAL SYSTEM – Switch off the battery charger after charging and disconnect from the 12-V battery. Guideline The charging current, charging voltage, and charging time must not be exceeded. Recharge the 12-V battery 3 months regularly when the motorcy- cle is not being used –...

  • Page 87: Changing The Abs Fuses

    ELECTRICAL SYSTEM 15 – Mount protection cap S04754-10 Finishing work – Mount the passenger seat. ( p. 58) – Set time and date. ( p. 36) 15.6 Changing the ABS fuses Warning Fire hazard Incorrect fuses overload the electrical system. – Only use fuses with the required ampere value.

  • Page 88: Changing The Fuses Of Individual Electrical Power Consumers

    15 ELECTRICAL SYSTEM 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 Fire hazard Incorrect fuses overload the electrical system. S04756-11 – Only use fuses with the required ampere value.
  • Page 89 ELECTRICAL SYSTEM 15 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 beam, position light, tail light, license plate lamp Fuse 7 - 10 A - engine control unit, ABS control unit...

  • Page 90: Checking The Headlight Setting

    15 ELECTRICAL SYSTEM 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 91: 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 15.12 ACC2 rear...

  • Page 92: Cooling System

    16 COOLING SYSTEM 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 93: Checking The Coolant Level

    COOLING SYSTEM 16 Condition The engine is cold. – 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 94: Draining The Coolant

    16 COOLING SYSTEM Warning Danger of poisoning Coolant is harmful to health. – Keep coolant out of the reach of children. – Do not allow coolant to come into contact with the skin, the eyes and clothing. – Consult a doctor immediately if coolant is swallowed. –...

  • Page 95: Filling/Bleeding The Cooling System

    COOLING SYSTEM 16 Warning Danger of poisoning Coolant is harmful to health. – Keep coolant out of the reach of children. – Do not allow coolant to come into contact with the skin, the eyes and clothing. – Consult a doctor immediately if coolant is swallowed. –...

  • Page 96: Changing The Coolant

    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 97 COOLING SYSTEM 16 Warning Danger of poisoning Coolant is harmful to health. – Keep coolant out of the reach of children. – Do not allow coolant to come into contact with the skin, the eyes and clothing. – Consult a doctor immediately if coolant is swallowed. –...
  • Page 98 16 COOLING SYSTEM 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 99: Tuning The Engine 17

    TUNING THE ENGINE 17 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 100: 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 101 SERVICE WORK ON THE ENGINE 18 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 102: Adding Engine Oil

    Engine oil (SAE 15W/50) ( p. 117) 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 103: 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 104: Checks And Maintenance Steps For Winter Operation

    19 CLEANING, CARE – Push back the sleeves of the handlebar controls to allow any water that has penetrated to evaporate. – After the motorcycle has cooled down, lubricate all moving parts and pivot points. – Clean the chain. ( p.

  • Page 105: Storage 20

    – 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. 56) – Lift the motorcycle with the front lifting gear. ( p.

  • Page 106: Preparing For Use After Storage

    20 STORAGE 20.2 Preparing for use after storage – Take the motorcycle off the front lifting gear. ( p. 57) – Remove the rear of the motorcycle from the lifting gear. p. 56) – Install the 12-V battery. p. 82) –...

  • Page 107: Troubleshooting 21

    Carry out start procedure. ( p. 43) – 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 108 21 TROUBLESHOOTING Faults Possible cause Action – 12 V battery discharged The 12-V battery is not being Check the charging voltage. charged by the alternator – Check the open-circuit current. – The combination instrument Fuse 2 is blown Change the fuses of individual electri- shows nothing on the display cal power consumers.

  • Page 109: Technical Data 22

    TECHNICAL DATA 22 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 12.6:1 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 110: 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 111 TECHNICAL DATA 22 Screw, retaining bracket, radial 12 Nm (8.9 lbf ft) shaft seal ring, clutch cover Loctite ® 243™ Screw, shift drum locating 12 Nm (8.9 lbf ft) Loctite ® 243™ Screw, starter motor 12 Nm (8.9 lbf ft) Screw, timing chain tensioner 12 Nm (8.9 lbf ft) Screw, timing chain tensioning rail...

  • Page 112: 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. 117) 22.3.2 Coolant Coolant 1.2 l (1.3 qt.) Coolant ( p. 117) 22.3.3 Fuel Please observe the labels on EU fuel pumps. A00420-10 Total fuel tank capacity, approx.

  • Page 113: Electrical System

    The tires specified represent one of the possible series production tires. For alternative manufacturers, if any, contact an authorized dealer or qualified tire dealership. If local road approval regulations apply, these and the respective technical specifications must be observed. Additional information is available in the Service section under: KTM.COM...

  • Page 114: Fork

    22 TECHNICAL DATA 22.7 Fork Fork article number 93301000144 WP Suspension Fork Fork length 744 mm (29.29 in) Fork oil 450 ml (15.21 fl. oz.) Fork oil (SAE 4) (48601166S1) p. 118) 22.8 Shock absorber Shock absorber article number 93304010000 Shock absorber WP Suspension Spring preload...
  • Page 115 TECHNICAL DATA 22 Screw, damper block 8 Nm (5.9 lbf ft) Screw, engine sprocket cover 8 Nm (5.9 lbf ft) Screw, foot brake cylinder 9 Nm (6.6 lbf ft) Loctite ® 243™ Screw, front fender 7 Nm (5.2 lbf ft) Screw, front seat fixing 6 Nm (4.4 lbf ft) Screw, front spoiler...
  • Page 116 22 TECHNICAL DATA Screw, front wheel spindle 25 Nm (18.4 lbf ft) Screw, fuel tank 20 Nm (14.8 lbf ft) Screw, grab handle 22 Nm (16.2 lbf ft) Screw, handlebar clamp 20 Nm (14.8 lbf ft) Loctite ® 243™ Screw, horn 12 Nm (8.9 lbf ft) Screw, main silencer 23 Nm (17 lbf ft)
  • Page 117 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 118: 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 119: 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 120 24 SUBSTANCES Fork oil (SAE 4) (48601166S1) Standard/classification – SAE ( p. 120) (SAE 4) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties. Super unleaded (ROZ 95) Standard/classification –...

  • Page 121: 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 122: Standards

    26 STANDARDS 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 123: Index Of Special Terms 27

    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 124: List Of Abbreviations

    28 LIST OF ABBREVIATIONS Art. no. Article number circa compare e.g. for example etc. et cetera i.a. inter alia number poss. possibly...

  • Page 125: List Of Symbols 29

    The malfunction indicator lamp lights up yellow – The OBD has detected a malfunction in the vehicle 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.

  • Page 126: Index

    ..... 21 KTM MY RIDE ..... . . 27 Language .
  • Page 127 INDEX Coolant level Fuse checking ......90-91 for individual electrical power consumers, changing ......86 Cooling system .
  • Page 128 INDEX Play in the clutch lever chassis tightening torques ... . . 112 adjusting ......97 electrical system .
  • Page 129 *3214572en* 3214572en 07/2022 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KISKA/KTM KTM.COM...

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