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KTM 390 Duke EU 2013 User Manual

KTM 390 Duke EU 2013
204 pages
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REPAIR MANUAL 2013
390 Duke EU
390 Duke AUS
390 Duke MAL
390 Duke 2014 COL
Art. no. 3206167en

Table of Contents

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KTM 390 Duke EU 2013 Specifications

General IconGeneral
Displacement373.2 cc
Transmission6-speed
Fuel SystemElectronic Fuel Injection
Rear SuspensionWP Monoshock
ABSYes
Seat Height800 mm
Dry Weight139 kg
Front Tire110/70 ZR17
Rear Tire150/60 ZR17
Bore x Stroke89 mm x 60 mm
Compression Ratio12.5:1
Engine TypeSingle-cylinder, 4-stroke
Torque35 Nm at 7, 250 rpm
Front SuspensionWP upside-down fork
Rear Brake230 mm disc
Wheelbase1367 mm
Power44 hp (32.5 kW) @ 9500 rpm
Front BrakeFour-piston radial fixed caliper, 300 mm disc
Fuel Capacity11 liters

Summary

Introduction

Means of Representation

Symbols Used

Explains the meaning of various symbols used in the manual.

Formats Used

Explains the typographical formats used in the document.

Safety Advice

Repair Manual

Instructions for reading and using the repair manual.

Safety Advice

General safety instructions for vehicle operation.

Degrees of Risk and Symbols

Defines risk levels and associated symbols for hazards.

Work Rules

General rules and guidelines for performing repair work.

Important Information

Guarantee, Warranty

Details regarding warranty claims and service requirements.

Operating and Auxiliary Substances

Information on using and handling operating fluids and substances.

Spare Parts, Accessories

Guidelines on using approved spare parts and accessories.

Figures

Notes on interpreting diagrams and illustrations in the manual.

Serial Numbers

Chassis Number/Type Label

Location and identification of the chassis number and type label.

Key Number

Information on finding and storing the key number.

Engine Number

Location for identifying the engine serial number.

Motorcycle

Raising the Motorcycle with the Rear Wheel Stand

Procedure for lifting the motorcycle using a rear stand.

Taking the Motorcycle off of the Rear Wheel Stand

Procedure for lowering the motorcycle from a rear stand.

Raising the Motorcycle with the Front Wheel Stand

Procedure for lifting the motorcycle using a front stand.

Taking the Motorcycle off of the Front Wheel Stand

Procedure for lowering the motorcycle from a front stand.

Raising the Motorcycle with the Work Stand

Procedure for lifting the motorcycle using a general work stand.

Removing the Motorcycle from the Work Stand

Procedure for removing the motorcycle from a work stand.

Starting

Step-by-step guide on how to start the motorcycle engine.

Starting the Motorcycle to Make Checks

Instructions for starting the engine for diagnostic checks.

Fork, Triple Clamp

Cleaning the Dust Boots of the Fork Legs

Process for cleaning fork leg dust boots to prevent seal damage.

Removing Fork Legs

Step-by-step guide for removing the front fork legs.

Installing the Fork Legs

Procedure for installing the front fork legs.

Disassembling the Fork Legs

Detailed steps for taking apart the fork legs.

Checking the Fork Legs

Inspection of fork legs for damage and wear.

Assembling the Fork Legs

Procedure for reassembling the fork legs.

Removing the Lower Triple Clamp

Steps to remove the lower triple clamp assembly.

Installing the Lower Triple Clamp

Procedure for installing the lower triple clamp assembly.

Checking the Steering Head Bearing Play

How to check for play in the steering head bearings.

Adjusting the Steering Head Bearing Play

Method for adjusting steering head bearing play.

Handlebar, Controls

Checking the Play in the Throttle Cable

Procedure to check throttle cable free play.

Adjusting the Play in the Throttle Cable

Steps to adjust throttle cable free play.

Checking the Clutch Lever Play

Method for checking clutch lever free play.

Adjusting the Clutch Cable Play

Procedure to adjust clutch cable free play.

Shock Absorber, Swingarm

Adjusting the Spring Preload of the Shock Absorber

How to adjust the rear shock absorber spring preload.

Removing the Shock Absorber

Step-by-step guide for removing the rear shock absorber.

Installing the Shock Absorber

Procedure for installing the rear shock absorber.

Removing the Spring

Steps to remove the spring from the shock absorber.

Installing the Spring

Procedure for installing the spring onto the shock absorber.

Exhaust

Removing the Exhaust Manifold

Procedure for removing the exhaust manifold.

Installing the Exhaust Manifold

Steps to install the exhaust manifold.

Removing the Main Silencer

Procedure for removing the main silencer.

Installing the Main Silencer

Steps to install the main silencer.

Air Filter

Removing the Air Filter

Procedure for removing the air filter element.

Installing the Air Filter

Steps for installing a new air filter element.

Fuel Tank, Seat, Trim

Opening the Filler Cap

Instructions for opening the fuel filler cap.

Closing the Filler Cap

Procedure for securely closing the fuel filler cap.

Removing the Seat

Steps to remove the rider's seat.

Mounting the Seat

Procedure for installing the rider's seat.

Removing the Passenger Seat

Steps to remove the passenger seat.

Mounting the Passenger Seat

Procedure for installing the passenger seat.

Removing the Fuel Tank Cover

Steps to remove the fuel tank cover.

Installing the Fuel Tank Cover

Procedure for installing the fuel tank cover.

Removing the Fuel Tank

Detailed steps for removing the fuel tank.

Installing the Fuel Tank

Procedure for installing the fuel tank.

Removing the Front Spoiler

Steps to remove the front spoiler.

Fitting Front Spoiler

Procedure for installing the front spoiler.

Dismounting the Front Fender

Steps to remove the front fender.

Installing the Front Fender

Procedure for installing the front fender.

Checking the Fuel Pressure

How to check the fuel system pressure.

Changing the Fuel Filter

Procedure for replacing the fuel filter.

Replacing the Fuel Pump

Steps to replace the fuel pump assembly.

Wheels

Checking the Tire Air Pressure

How to check and set tire air pressure.

Checking the Tire Condition

Inspection of tires for damage, wear, and age.

Checking the Brake Discs

Procedure to check front and rear brake disc wear.

Front Wheel

Procedures related to the front wheel assembly.

Removing the Front Wheel

Steps to remove the front wheel assembly.

Installing the Front Wheel

Procedure for installing the front wheel assembly.

Removing the Brake Disc of the Front Brake

Steps to remove the front brake disc.

Installing the Brake Disc of the Front Brake

Procedure for installing the front brake disc.

Rear Wheel

Procedures related to the rear wheel assembly.

Removing the Rear Wheel

Steps to remove the rear wheel assembly.

Installing the Rear Wheel

Procedure for installing the rear wheel assembly.

Removing the Brake Disc of the Rear Brake

Steps to remove the rear brake disc.

Installing the Brake Disc of the Rear Brake

Procedure for installing the rear brake disc.

Checking the Chain Tension

How to check the motorcycle's chain tension.

Adjusting the Chain Tension

Procedure for adjusting the drive chain tension.

Checking the Chain, Rear Sprocket, and Engine Sprocket

Inspection of chain, sprockets for wear and alignment.

Cleaning the Chain

Method for cleaning the drive chain.

Checking the Rear Hub Rubber Dampers

Inspection of rear hub rubber dampers for wear.

Wiring Harness, Battery

Removing the Battery

Steps to safely remove the motorcycle battery.

Installing the Battery

Procedure for installing the motorcycle battery.

Disconnecting the Negative Cable of the Battery

How to disconnect the battery's negative terminal.

Reconnecting the Negative Cable of the Battery

Procedure for reconnecting the battery's negative terminal.

Recharging the Battery

Instructions for charging the motorcycle battery.

Checking the Charging Voltage

How to measure the battery's charging voltage.

Changing the Fuses of Individual Power Consumers

Procedure for replacing blown fuses in the fuse box.

Brake System

Checking the Front Brake Linings

How to inspect front brake pads for wear.

Changing the Front Brake Linings

Procedure for replacing front brake pads.

Checking the Brake Fluid Level of the Front Brake

How to check the front brake fluid level.

Adding Front Brake Fluid

Procedure for adding front brake fluid.

Changing the Front Brake Fluid

Steps to flush and replace front brake fluid.

Checking the Rear Brake Linings

How to inspect rear brake pads for wear.

Changing the Rear Brake Linings

Procedure for replacing rear brake pads.

Checking the Free Travel of Foot Brake Lever

How to check the free play of the rear brake pedal.

Adjusting the Free Travel of Foot Brake Lever

Procedure for adjusting rear brake pedal free play.

Checking the Rear Brake Fluid Level

How to check the rear brake fluid level.

Adding Rear Brake Fluid

Procedure for adding rear brake fluid.

Changing the Rear Brake Fluid

Steps to flush and replace rear brake fluid.

Lighting System, Instruments

Setting Kilometers or Miles

How to change display units from km to miles or vice-versa.

Adjusting the Shift Speed RPM 1

Setting the first shift speed warning RPM indicator.

Adjusting the Shift Speed RPM 2

Setting the second shift speed warning RPM indicator.

Setting the Time

Procedure for setting the vehicle's clock.

Resetting the Service Interval Display

How to reset the service reminder display.

Checking the Headlight Setting

Procedure to check headlight beam alignment.

Adjusting the Headlight Range

How to adjust the headlight beam distance.

Changing the Parking Light Bulb

Steps to replace the parking light bulb.

Changing the Headlight Bulb

Procedure for replacing the main headlight bulb.

Engine

Removing the Engine

Detailed procedure for removing the engine from the frame.

Installing the Engine

Procedure for installing the engine back into the frame.

Disassembling the Engine

Detailed procedures for engine disassembly.

Work on Individual Parts

Procedures for working on specific engine components.

Assembling the Engine

Detailed procedures for engine assembly.

Shift Mechanism

Adjusting the Shift Lever

Procedure for adjusting the gear shift lever.

Water Pump, Cooling System

Draining the Coolant

Steps to drain the motorcycle's coolant.

Filling/Bleeding the Cooling System

Procedure for filling and bleeding the cooling system.

Checking the Antifreeze and Coolant Level

How to check coolant antifreeze and level.

Checking the Coolant Level

Procedure to check the coolant level in the radiator and tank.

Lubrication System

Oil Circuit

Diagram and explanation of the engine oil circuit.

Checking the Engine Oil Level

How to check the engine oil level.

Checking the Engine Oil Pressure

Procedure to check engine oil pressure.

Changing the Engine Oil and Oil Filter, Cleaning the Oil Screen

Steps to change engine oil, filter, and clean oil screen.

Adding Engine Oil

Procedure for adding engine oil.

Ignition System

Alternator - Checking the Stator Winding

How to check the alternator stator winding resistance.

Technical Data

Engine

Technical specifications for the engine.

Engine Tolerance, Wear Limits

Engine component tolerances and wear limits.

Engine Tightening Torques

Torque specifications for engine fasteners.

Capacities

Fluid and fuel capacities for the motorcycle.

Chassis

Specifications for chassis components.

Electrical System

Specifications for electrical components.

Tires

Specifications for front and rear tires.

Fork

Specifications and details about the front fork.

Shock Absorber

Specifications and details about the rear shock absorber.

Chassis Tightening Torques

Torque specifications for chassis fasteners.

Cleaning/Protective Treatment

Cleaning the Motorcycle

Detailed instructions for cleaning the motorcycle.

Checks and Maintenance Steps for Winter Operation

Essential checks and maintenance for winter storage.

Storage

Storage

Steps and recommendations for storing the motorcycle.

Preparing for Use After Storage

Procedures to get the motorcycle ready after storage.

Service Schedule

Service Schedule

Maintenance schedule based on mileage or time intervals.

Wiring Diagram

Page 1 of 9

Wiring diagram section covering specific components.

Page 2 of 9

Wiring diagram section covering specific components.

Page 3 of 9

Wiring diagram section covering specific components.

Page 4 of 9

Wiring diagram section covering specific components.

Page 5 of 9

Wiring diagram section covering specific components.

Page 6 of 9

Wiring diagram section covering specific components.

Page 7 of 9

Wiring diagram section covering specific components.

Page 8 of 9

Wiring diagram section covering specific components.

Page 9 of 9

Wiring diagram section covering specific components.

Substances

Brake Fluid DOT 4 / DOT 5.1

Specifications and recommendations for brake fluid.

Coolant

Information on suitable coolant and mixture ratios.

Coolant (Mixed Ready to Use)

Details on pre-mixed coolant.

Engine Oil (SAE 15W/50)

Specifications and recommendations for engine oil.

Fork Oil (SAE 4) (48601166S1)

Specifications for fork oil.

Super Unleaded (ROZ 95/RON 95/PON 91)

Fuel grade requirements and ethanol content limits.

Auxiliary Substances

Chain Cleaner

Recommended chain cleaner product.

Chain Lube for Road Use

Recommended chain lubricant.

Cleaning and Preserving Materials for Metal, Rubber and Plastic

Recommended products for cleaning and protecting parts.

Fuel Additive

Recommended fuel additive.

High Viscosity Grease

Recommended high viscosity grease.

High-Luster Polish for Paint

Recommended paint polish.

Long-Life Grease

Recommended long-life grease.

Lubricant (T511)

Recommended lubricant T511.

Lubricant (T152)

Recommended lubricant T152.

Motorcycle Cleaner

Recommended motorcycle cleaner.

Universal Oil Spray

Recommended universal oil spray.

Special Tools

Bleeder Cover

Special tool for brake bleeding covers.

Bleeding Device

Special tool for bleeding brake systems.

Bleed Syringe

Special tool for measuring and dispensing fluids.

Circlip Pliers Reverse

Special tool for circlip removal/installation.

Clutch Holder

Special tool for holding the clutch assembly.

Valve Spring Compressor

Special tool for compressing valve springs.

Feeler Gauge

Tool for measuring small gaps and clearances.

Plastigauge Measuring Strips

Tool for measuring bearing clearance.

Piston Ring Mounting Tool

Tool for installing piston rings.

Adapter

Special adapter tool.

Rear Wheel Stand

Tool for lifting the rear wheel.

Front Wheel Stand

Tool for lifting the front wheel.

Testing Hose

Special hose for testing procedures.

Pressure Testing Tool

Tool for measuring pressure in systems.

Adapter

Special adapter tool.

Engine Assembly Stand

Stand for assembling/disassembling the engine.

Engine Blocking Screw

Special screw for blocking engine components.

Work Stand

General stand for supporting the motorcycle.

Floor Jack Attachment

Attachment for floor jacks used with special tools.

Oil Pressure Adapter

Adapter for oil pressure testing.

Limit Plug Gauge

Gauge for checking limits on components.

Insert for Valve Spring Lever

Special insert for valve spring lever tool.

Spark Plug Wrench

Tool for removing/installing spark plugs.

Insert for Piston Pin Retainer

Special tool for piston pin retainer.

Engine Fixing Arm

Arm for securing the engine on a stand.

Engine Fixing Arm

Arm for securing the engine on a stand.

Mounting Sleeve

Special sleeve tool for mounting components.

Pressure Screw for Crankshaft

Special screw for crankshaft procedures.

Castle Nut Wrench; ½" Drive

Tool for castle nuts.

Castle Nut Wrench; ½" Drive

Tool for castle nuts.

Mounting Sleeve

Special sleeve tool for mounting components.

Case Separating Tool

Tool for separating engine cases.

Castle Nut Wrench; ½" Drive

Tool for castle nuts.

Castle Nut Wrench; ½" Drive

Tool for castle nuts.

Key for Steering Head Bearing

Special key for steering head bearing adjustment.

Disassembly Tool, Balancer Shaft Bearing

Tool for disassembling balancer shaft bearings.

Puller for Rotor

Tool for pulling the engine rotor.

Hook Wrench

Tool for adjusting spring preload.

Spring Compressor

Tool for compressing springs.

Mounting Tool

Special tool for mounting components.

Clamping Stand

Stand for clamping components during work.

Standards

JASO T903 MA

Explanation of the JASO T903 MA standard for engine oils.

SAE

Explanation of SAE viscosity classes for oils.

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