KTM RC 390, RC 390 GP Manual

MEANS OF REPRESENTATION

Symbols used

The meaning of specific symbols is described below.

	Indicates an expected reaction (e.g. of a work step or a function).
	Indicates an unexpected reaction (e.g. of a work step or a function).
	Indicates a page reference (more information is provided on the specified page).
	Indicates information with more details or tips.
	Indicates the result of a testing step.
	Indicates a voltage measurement.
	Indicates a current measurement.
	Indicates a resistance measurement.
	Indicates the end of an activity including potential rework.

SETUP

Transport mode

This vehicle was blocked for transport in the software.
To operate the vehicle, the vehicle electronics must be enabled.
This process is conducted during initial setup in KTMDealer.net.
Enabling ensures that the initial setup in KTMDealer.net is documented.
Enabling can be performed either temporarily, e.g. for a test ride, or permanently for vehicle handover.

Make sure that the vehicle is permanently enabled before handing it over to the customer.

Diagnostics connector

Diagnostics connector is located under the front rider's seat.

Unpacking and setting up the vehicle

Preliminary work

• Remove the straps and the box.

Main work

• Remove the adhesive tape in the upper area of the motorcycle.
• Roll down the film at the sides.
  To avoid damaging the motorcycle during unpacking, leave the other films on the vehicle until you have finished work on the vehicle.
• Remove the separate enclosure and unpack it. Check the separate enclosure for completeness.
  The procedure for missing components is described in the Customer Service Manual.
• Check the vehicle for transport damage.
  The procedure in the event of transport damage is described in the Customer Service Manual.
• Turn the rear mirror to the correct position on both sides.
  
• Make sure that the clutch cable is attached to the clutch release lever and secured.
• Check the clutch lever play.
  
• Carefully remove the bracket from the link fork.
  An assistant prevents the motorcycle from falling over.
  
• Carefully loosen and remove the tension belts around the lower triple clamp.
  ✓ The vehicle is released at the front.
• Together with an assistant, take the vehicle off the pallet.
  
  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.
  • Keep sparks or open flames away from the 12 V battery.
  • Only charge 12 V batteries in well-ventilated rooms.
  • Rinse the affected area immediately with plenty of water in the event of contact with the skin.
  • Rinse eyes with water for at least 15 minutes and consult a doctor immediately if battery acid and battery gases get into the eyes.
• Fill the 12 V battery.
  Read the notes in the 12 V battery accessory pack.
• Charge the 12-V battery.
  Guideline
  The 12-V battery must be fully charged before it is handed over to the customer.
  The first charging process may take longer with a new 12-V battery.
• Remove the front rider's seat.
• Store the tool set below the seat.
• Remove spare key and KEYCODECARD and keep in a safe place for the handover.
• Remove the fuel tank cover.
• Install the 12-V battery.
• Remove the remaining film, padding, the corrugated cardboard, and the other packaging material.
• Mount the fuel tank cover.
• Mount the front rider's seat.
• Refuel.
• Prepare the vehicle according to the specifications in KTMDealer.net for handover to the customer.
  

WORK

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.
• Adjust the free travel of the clutch lever when necessary in accordance with the specification.

• Check the clutch lever for smooth operation.
• Move the handlebar to the straight-ahead position.
• Pull the clutch lever until resistance is perceptible, and determine the play in the clutch lever .
  

  Clutch lever play

  1... 3 mm (0.04... 0.12 in)

  If the clutch lever play does not meet the specified value:
  • Adjust play in the clutch lever.
• Move the handlebar to and fro over the entire steering range.
  The clutch lever play must not change.
  If the clutch lever play changes:
  • Check the routing of the clutch cable.
    

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

  Clutch lever play

  1... 3 mm (0.04... 0.12 in)

• Tighten lock nut .
• Position bellows .
  

Removing the passenger seat

Preparatory work

• Remove the front rider's seat.

Main work

• Loosen seat lock cover in area and pull to the front.
  
• Remove screw .
  
• Lift and take off the passenger seat.
  

Mounting the passenger seat

Main work

• Position the passenger seat and slide it forward.
  ✓ Hook engages in bracket .
  
• Mount and tighten screw with washer.
  
  Guideline

  Screw, passenger seat

  M6

  7 Nm (5.2 lbf ft)

  
  Danger of accidents
  The seat can come loose from the anchoring if it is not mounted correctly.
  • After assembly, check whether the seat is correctly locked and cannot be pulled up.
• Check that the passenger seat is mounted correctly.
• Position seat lock cover and press area into the bracket.
  
  Finishing work
• Mount the front rider's seat.
  

Removing the front rider's seat

• Insert the ignition key in seat lock and turn it clockwise.
  
• Raise the rear of the front rider's seat, pull it toward the rear, and remove it upward.
• Remove the ignition key from the seat lock.
  

Mounting the front rider's seat

• Attach recesses on the front rider's seat to the fuel tank, push the front rider's seat forward, and lower at the rear.
  ✓ The pin locks audibly in place.
  
• Check that the front rider's seat is mounted correctly.
  

Removing the fuel tank cover

Preparatory work

• Remove the front rider's seat.

Main work

• Remove screws .
  
• Pull the fuel tank cover from holding lugs .
  
• Pull holding lugs out of the brackets.
  
• Pull the fuel tank cover off towards the rear and take off upwards.
  

Mounting the fuel tank cover

Main work

• Position the fuel tank cover and slide it forward.
  ✓ Holding lugs engage in the brackets.
  
• Position brackets with rubber bushings on holding lugs and slide down.
• Mount and tighten screws .
  
  Guideline

  Remaining screws, trim

  M6

  6 Nm (4.4 lbf ft)

• Check that the fuel tank cover is mounted correctly.

Finishing work

• Mount the front rider's seat.
  

Charging the 12-V battery

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.
• Keep sparks or open flames away from the 12 V battery.
• Only charge 12 V batteries in well-ventilated rooms.
• Rinse the affected area immediately with plenty of water in the event of contact with the skin.
• Rinse eyes with water for at least 15 minutes and consult a doctor immediately if battery acid and battery gases get into the eyes.

Note
Danger of damage
An incorrectly selected charging mode will damage the 12-V battery.

• Always select a charging mode that is compatible with the type of battery.
  Note
  Environmental hazard
  12 V batteries contain environmentally hazardous materials.
  • Do not dispose of 12 V batteries as household waste.
  • Dispose of 12 V batteries at a collection point for used batteries.

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.

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. This reduces the capacity of the 12-V battery.
If the 12-V battery is discharged by repeated starting, charge the 12-V battery immediately.
If the 12-V battery is left in a discharged state for an extended period, it will become deeply discharged and sulfating occurs, thus destroying the battery.
The 12-V battery is maintenance-free. The acid level does not have to be checked.

Preparatory work

• Remove the front rider's seat.
• Remove the fuel tank cover.
• Disconnect the negative cable of the 12-V battery.

Main work

• Connect a battery charger to the 12-V battery. Adjust the battery charger.
  
  EU battery charger XCharge‑professional (00029095050)
  Alternative 1
  US battery charger XCharge‑professional (00029095051)
  Alternative 2
  UK battery charger XCharge‑professional (00029095052)
  Follow the instructions of the charger and the manual.
• Disconnect the battery charger after charging the 12-V battery.
  Guideline

  The charging current, charging voltage, and charging time must not be exceeded.
  Recharge the 12-V battery regularly when the motorcycle is not being used	6 months

Finishing work

• Connect the negative cable of the 12-V battery.
• Mount the fuel tank cover.
• Mount the front rider's seat.
• Set time and date.
  

Installing the 12-V battery

Main work

• Position the 12-V battery in the battery compartment.
  Guideline
  The terminals of the battery must face upwards.
  12-V battery (ETZ-9-BS)
• Attach rubber strap .
  
• Position positive cable and mount and tighten the screw.
• Position positive terminal cover .
• Position negative cable and mount and tighten the screw.
  

Finishing work

• Mount the fuel tank cover.
• Mount the front rider's seat.
• Set time and date.
  

Disconnecting the negative cable of the 12-V battery

Preparatory work

• Remove the front rider's seat.
• Remove the fuel tank cover.

Main work

• Disconnect negative cable of the 12-V battery.
  
  

Connecting the negative cable of the 12-V battery

Main work

• Connect negative cable of the 12-V battery.
  

Finishing work

• Mount the fuel tank cover.
• Mount the front rider's seat.
• Set time and date.
  

Setting the time and date

Condition
The motorcycle is stationary.

• Press the SET button when the menu is closed.
• Press UP or DOWN button until Settings appears. Press the SET button to open the menu.
• Press the UP or DOWN button until Time/Date is highlighted. Press the SET button to open the menu.

Setting the clock

• Press UP or DOWN button until the time is marked.
• Press the SET button.
  ✓ The hour flashes and is underlined.
• Press UP or DOWN button until the current hour is set.
• Press the SET button.
  ✓ The minutes flash and are underlined.
• Press UP or DOWN button until the current minute is set.
• Press the SET button.
  ✓ The time is stored.

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.
• Press the SET button.
  ✓ The month flashes and is underlined.
• Press UP or DOWN button until the current month is set.
• Press the SET button.
  ✓ The year flashes and is underlined.
• Press UP or DOWN button until the current year is set.
• Press the SET button.
  ✓ The date is stored.
  

Opening fuel tank filler cap

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.
• Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
• If any fuel is spilled, wipe it off immediately.
• Observe the specifications for refueling.

Danger of poisoning
Fuel is harmful to health.

• Avoid skin, eye and clothing contact with fuel.
• Immediately consult a doctor if you swallow fuel.
• Do not inhale fuel vapors.
• Rinse the affected area immediately with plenty of water in the event of contact with the skin.
• Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
• Change your clothing if fuel spills on them.
• Keep fuels correctly in a suitable canister, and out of the reach of children.

Note
Environmental hazard
Improper handling of fuel is a danger to the environment.

• Do not allow fuel to enter the groundwater, the soil, or the sewage system.

• 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.
• Turn the ignition key 90° clockwise.
• Lift the fuel tank filler cap.
• Remove the ignition key.
  

Closing the fuel tank filler cap

Fire hazard
Fuel is highly flammable and a health hazard.

• Check that the fuel tank filler cap is locked correctly after closing.
• Change your clothing if fuel spills on them.
• Rinse the affected area immediately with plenty of water in the event of contact with the skin.

• Close the fuel tank filler cap.
• Turn the ignition key 90° clockwise.
• Push down the fuel tank filler cap and turn the ignition key counterclockwise until the fuel tank filler cap lock engages.
• Remove the ignition key and close the cover.
  

Refueling

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.
• Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
• If any fuel is spilled, wipe it off immediately.
• Observe the specifications for refueling.

Danger of poisoning
Fuel is harmful to health.

• Avoid skin, eye and clothing contact with fuel.
• Immediately consult a doctor if you swallow fuel.
• Do not inhale fuel vapors.
• Rinse the affected area immediately with plenty of water in the event of contact with the skin.
• Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
• Change your clothing if fuel spills on them.

Note
Material damage
Inadequate fuel quality causes the fuel filter to quickly become clogged.
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.
  Note
  Environmental hazard
  Improper handling of fuel is a danger to the environment.
  • Do not allow fuel to enter the groundwater, the soil, or the sewage system.

• Switch off the engine.
• Open the fuel tank filler cap.
• Fill the fuel tank with fuel up to the lower edge of the fuel filler.
  

  Total fuel tank capacity, approx.

  14 l (3.7 US gal)

  Super unleaded (ROZ 95)

• Close the fuel tank filler cap.
  

TECHNICAL SPECIFICATIONS

Chassis tightening torques

SUBSTANCES

Super unleaded (ROZ 95)
Standard/classification

• DIN EN 228 (ROZ 95)

Guideline

• Only use super unleaded fuel that matches or is equivalent to the specified standard.
• Fuel with an ethanol content of up to 10% (E10 fuel) is safe to use.
  Do not use fuel containing methanol (e.g., M15, M85, M100) or more than 10% ethanol (e.g., E15, E25, E85, E100).