KTM 790 Duke 2019 Owner's manual

OWNER'S MANUAL 2019

790 Duke

Art. no. 3213926en

DEAR KTM CUSTOMER

*3213926en*

3213926en

09/2018

DEAR KTM CUSTOMER

Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art

sports vehicle that will continue giving you pleasure for a long time if you maintain it properly.

We wish you good and safe riding at all times!

Enter the serial numbers of your vehicle below.

Vehicle identification number ( p. 34) Dealer's stamp

Engine number ( p. 35)

Key number ( p. 35)

The Owner's Manual contained the latest information for this model series at the time of going to print. However,

minor differences due to further developments in design cannot be ruled out completely.

All specifications are non-binding. KTM Sportmotorcycle GmbH specifically reserves the right to modify or delete

technical specifications, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice

and without specifying reasons, to adapt these to local conditions, as well as to stop production of a particular

model without prior notice. KTM accepts no liability for delivery options, deviations from figures and descriptions,

misprints, and other errors. The models portrayed partly contain special equipment that does not belong to the

regular scope of supply.

DEAR KTM CUSTOMER

2

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

5230 Mattighofen, Austria

This document is valid for the following models:

790 Duke US (F9675S5, F9675S6)

TABLE OF CONTENTS

3

TABLE OF CONTENTS

1 MEANS OF REPRESENTATION ...................... 9

1.1 Symbols used .................................... 9

1.2 Formats used................................... 10

2 SAFETY ADVICE.......................................... 11

2.1 Use definition – intended use............ 11

2.2 Misuse............................................ 11

2.3 Safety advice................................... 11

2.4 Degrees of risk and symbols.............. 12

2.5 Overview of labels ............................ 14

2.6 Reporting safety defects ................... 19

2.7 Noise emission warranty ................... 19

2.8 Operating noise warning ................... 20

2.9 Manufacturer warranty for the

exhaust monitoring system................ 20

2.10 Consumer rights............................... 21

2.11 Tampering warning........................... 21

2.12 Safe operation ................................. 22

2.13 Protective clothing ........................... 23

2.14 Work rules....................................... 24

2.15 Environment.................................... 24

2.16 Owner's Manual ............................... 25

3 IMPORTANT NOTES.................................... 26

3.1 Manufacturer and implied warranty.... 26

3.2 Fuel, auxiliary substances ................. 26

3.3 Spare parts, accessories ................... 26

3.4 Service ........................................... 27

3.5 Figures ........................................... 27

3.6 Customer service.............................. 27

4 VIEW OF VEHICLE ...................................... 30

4.1 View of vehicle, front left (example) ... 30

4.2 View of vehicle, rear right

(example)........................................ 32

5 SERIAL NUMBERS ..................................... 34

5.1 Vehicle identification number............ 34

5.2 Type label ....................................... 34

5.3 Key number..................................... 35

5.4 Engine number ................................ 35

5.5 Fork part number ............................. 36

5.6 Shock absorber article number .......... 36

5.7 Steering damper article number ........ 37

6 CONTROLS................................................. 38

6.1 Clutch lever..................................... 38

6.2 Hand brake lever.............................. 38

6.3 Throttle grip .................................... 39

TABLE OF CONTENTS

4

6.4 Switches on the left side of the

handlebar........................................ 39

6.4.1 Combination switch...................... 39

6.4.2 Light switch ................................ 40

6.4.3 Menu switch................................ 41

6.4.4 Turn signal switch........................ 41

6.4.5 Horn button ................................ 42

6.5 Switches on the right side of the

handlebar........................................ 43

6.5.1 Emergency OFF switch/electric

starter button .............................. 43

6.6 Ignition and steering lock.................. 44

6.7 Opening fuel tank filler cap............... 45

6.8 Closing the fuel tank filler cap........... 47

6.9 Seat lock......................................... 48

6.10 Tool set........................................... 48

6.11 Grab handle .................................... 49

6.12 Passenger foot pegs ......................... 49

6.13 Shift lever ....................................... 50

6.14 Foot brake lever ............................... 51

6.15 Side stand....................................... 51

7 COMBINATION INSTRUMENT ..................... 53

7.1 Combination instrument ................... 53

7.2 Activation and test ........................... 53

7.3 Day-Night mode............................... 55

7.4 Warnings......................................... 56

7.5 Indicator lamps................................ 58

7.6 Display ........................................... 62

7.7 TRACK display................................. 64

7.8 Shift warning light ........................... 65

7.9 Fuel level display ............................. 66

7.10 Time............................................... 67

7.11 Coolant temperature indicator ........... 67

7.12 Trip distance counter ....................... 68

7.13 Menu.............................................. 69

7.13.1 Favorites..................................... 69

7.13.2 Trip 1 ......................................... 70

7.13.3 Trip 2 ......................................... 71

7.13.4 General Info ................................ 72

7.13.5 Settings ...................................... 73

7.13.6 Bluetooth

®

(optional).................... 73

7.13.7 Distance ..................................... 74

7.13.8 Temp.......................................... 75

7.13.9 Pressure ..................................... 76

7.13.10 Fuel Cons.................................... 77

7.13.11 Language .................................... 78

7.13.12 Clock/Date .................................. 78

7.13.13 DRL ........................................... 79

7.13.14 TPMS warning ............................. 81

7.13.15 Quick Selector 1.......................... 82

7.13.16 Quick Selector 2.......................... 83

TABLE OF CONTENTS

5

7.13.17 Set Favorites ............................... 84

7.13.18 Service ....................................... 85

7.13.19 Extra functions ............................ 85

7.13.20 Warnings..................................... 86

7.13.21 Ride Mode .................................. 87

7.13.22 Track.......................................... 88

7.13.23 Anti‑wheelie mode ....................... 89

7.13.24 Launch control ............................ 90

7.13.25 MTC + MSR ................................ 90

7.13.26 ABS............................................ 91

7.13.27 ABS Mode................................... 92

7.13.28 Quick Shift +............................... 93

7.13.29 Shift Light .................................. 93

7.13.30 KTM MY RIDE (optional) .............. 94

7.13.31 Pairing (optional) ......................... 95

7.13.32 Audio player (optional) ................. 97

7.13.33 Telephony (optional) .................... 99

8 ERGONOMICS .......................................... 100

8.1 Handlebar position......................... 100

8.2 Adjusting the handlebar

position ..................................... 100

8.3 Adjusting the basic position of the

clutch lever ................................... 102

8.4 Adjusting the basic position of the

hand brake lever ............................ 103

8.5 Adjusting the basic position of the

foot brake lever .......................... 104

8.6 Checking the basic position of the

shift lever...................................... 106

8.7 Adjusting the basic position of the

shift lever .................................. 107

9 PREPARING FOR USE............................... 109

9.1 Advice on preparing for first use ...... 109

9.2 Running in the engine .................... 111

9.3 Loading the vehicle........................ 111

10 RIDING INSTRUCTIONS............................ 114

10.1 Checks and maintenance measures

when preparing for use ................... 114

10.2 Starting the vehicle ........................ 115

10.3 Starting off.................................... 116

10.4 Launch‑Control .............................. 117

10.5 Starting off with launch control ....... 117

10.6 Quickshifter +................................ 119

10.7 Shifting, riding .............................. 120

10.8 Engine traction torque

control (MSR)................................. 126

10.9 Applying the brakes........................ 127

10.10 Stopping, parking........................... 129

10.11 Transporting.................................. 131

TABLE OF CONTENTS

6

10.12 Refueling ...................................... 132

11 SERVICE SCHEDULE ................................ 135

11.1 Additional information.................... 135

11.2 Required work ............................... 135

11.3 Recommended work ....................... 138

12 TUNING THE CHASSIS ............................. 139

12.1 Adjusting the spring preload of the

shock absorber ........................... 139

13 SERVICE WORK ON THE CHASSIS............. 140

13.1 Raising the motorcycle with the

rear lifting gear .............................. 140

13.2 Removing the rear of the

motorcycle from the lifting gear....... 140

13.3 Lifting the motorcycle with the

front lifting gear............................. 141

13.4 Taking the motorcycle off the front

lifting gear .................................... 142

13.5 Cleaning the dust boots of the fork

legs ........................................... 143

13.6 Removing the passenger seat .......... 145

13.7 Mounting the passenger seat........... 146

13.8 Removing the front rider's seat........ 147

13.9 Mounting the front rider's seat......... 148

13.10 Checking the chain for dirt.............. 149

13.11 Cleaning the chain ......................... 150

13.12 Checking the chain tension ............. 152

13.13 Adjusting the chain tension............. 154

13.14 Checking the chain, rear sprocket,

engine sprocket, and chain guide .... 156

14 BRAKE SYSTEM ....................................... 160

14.1 Anti-lock braking system (ABS) ....... 160

14.2 Checking the brake discs ................ 162

14.3 Checking the front brake fluid

level ............................................. 163

14.4 Adding front brake fluid .............. 164

14.5 Checking the front brake linings ...... 167

14.6 Checking the free travel of the foot

brake lever .................................... 168

14.7 Checking the rear brake fluid

level ............................................. 169

14.8 Adding rear brake fluid ............... 170

14.9 Checking the rear brake linings ....... 172

15 WHEELS, TIRES ....................................... 174

15.1 Removing the front wheel ............ 174

15.2 Installing the front wheel ............ 176

15.3 Removing the rear wheel ............. 180

15.4 Installing the rear wheel .............. 183

TABLE OF CONTENTS

7

15.5 Checking the rear hub damping

rubber pieces ............................. 186

15.6 Checking the tire condition ............. 188

15.7 Checking tire pressure .................... 190

15.8 Using tire repair spray .................... 192

16 ELECTRICAL SYSTEM ............................... 193

16.1 Daytime running light (DRL)............. 193

16.2 Removing the 12-V battery .......... 194

16.3 Installing the 12-V battery ........... 197

16.4 Charging the 12-V battery ........... 199

16.5 Changing the main fuse.................. 203

16.6 Changing ABS fuses....................... 205

16.7 Changing the fuses of individual

power consumers ........................... 207

16.8 Loosening the headlight mask with

the headlight ................................. 210

16.9 Mounting the headlight mask with

the headlight ................................. 211

16.10 Removing the cover of the

headlight mask rack ....................... 212

16.11 Installing the cover of the headlight

mask rack ..................................... 214

16.12 Changing the turn signal bulb ......... 216

16.13 Checking the headlight setting ........ 217

16.14 Adjusting the headlight range.......... 218

16.15 Diagnostics connector .................... 219

16.16 Front ACC1 and ACC2 .................... 220

16.17 ACC1 and ACC2 rear ...................... 220

17 COOLING SYSTEM .................................... 221

17.1 Cooling system .............................. 221

17.2 Checking the antifreeze and

coolant level.................................. 222

17.3 Checking the coolant level in the

compensating tank......................... 224

17.4 Draining the coolant ................... 226

17.5 Filling/bleeding the cooling

system ...................................... 228

17.6 Change the coolant ........................ 230

18 TUNING THE ENGINE............................... 234

18.1 Ride Mode .................................... 234

18.2 Motorcycle traction control (MTC).... 235

18.3 Slip adjustment ............................. 236

18.4 Throttle response ........................... 236

19 SERVICE WORK ON THE ENGINE .............. 238

19.1 Checking the engine oil level........... 238

19.2 Changing the engine oil and oil

filter, cleaning the oil screens ...... 239

19.3 Adding engine oil........................... 243

TABLE OF CONTENTS

8

19.4 Checking the free travel of the

clutch lever ................................... 245

19.5 Setting the free travel of the clutch

lever .......................................... 246

20 CLEANING, CARE ..................................... 247

20.1 Cleaning the motorcycle ................. 247

20.2 Checks and maintenance steps for

winter operation............................. 250

21 STORAGE................................................. 252

21.1 Storage ......................................... 252

21.2 Preparing for use after storage......... 254

22 TROUBLESHOOTING ................................ 255

23 TECHNICAL DATA..................................... 259

23.1 engine .......................................... 259

23.2 Engine tightening torques ............... 261

23.3 Capacities ..................................... 266

23.3.1 Engine oil ................................. 266

23.3.2 Coolant..................................... 266

23.3.3 Fuel ......................................... 267

23.4 Chassis ......................................... 267

23.5 Electrical system............................ 269

23.6 Tires............................................. 270

23.7 Fork.............................................. 270

23.8 Shock absorber.............................. 271

23.9 Chassis tightening torques .............. 271

24 DECLARATIONS OF CONFORMITY ............. 278

24.1 Declarations of conformity .............. 278

24.2 Country-specific declarations of

conformity..................................... 280

24.3 Country-specific declarations of

conformity Part 2 ........................... 282

25 SUBSTANCES .......................................... 283

26 AUXILIARY SUBSTANCES ......................... 286

27 STANDARDS ............................................ 288

28 INDEX OF SPECIAL TERMS ....................... 289

29 LIST OF ABBREVIATIONS.......................... 290

30 LIST OF SYMBOLS.................................... 291

30.1 Red symbols.................................. 291

30.2 Yellow and orange symbols.............. 291

30.3 Green and blue symbols.................. 292

INDEX ............................................................. 293

MEANS OF REPRESENTATION 1

9

1.1 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).

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.

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.

1 MEANS OF REPRESENTATION

10

Indicates a voltage measurement.

Indicates a current measurement.

Indicates the end of an activity, including potential rework.

1.2 Formats used

The typographical formats used in this document are explained below.

Proprietary name Indicates a proprietary name.

Name

®

Indicates a protected name.

Brand™ Indicates a brand available on the open market.

Underlined terms Refer to technical details of the vehicle or indicate technical terms, which

are explained in the glossary.

SAFETY ADVICE 2

11

2.1 Use definition – intended use

The vehicle is designed and constructed to withstand the usual demands of regular traffic and use on race

courses.

This vehicle is not suitable for offroad use.

Info

This vehicle is only authorized for operation on public roads in its homologated version.

2.2 Misuse

The vehicle must only be used as intended.

Dangers can arise for people, property and the environment through use not as intended.

Any use of the vehicle beyond the intended and defined use constitutes misuse.

Misuse also includes the use of operating and auxiliary fluids which do not meet the required specification for the

respective use.

2.3 Safety advice

A number of safety instructions need to be followed to operate the product described safely. Therefore read this

instruction and all further instructions included carefully. The safety instructions are highlighted in the text and

are referred to at the relevant passages.

2 SAFETY ADVICE

12

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.

2.4 Degrees of risk and symbols

Danger

Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the

appropriate measures are not taken.

Warning

Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not

taken.

Note

Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are

not taken.

Note

Indicates a danger that will lead to environmental damage if the appropriate measures are not taken.

SAFETY ADVICE 2

13

2 SAFETY ADVICE

14

2.5 Overview of labels

V01503-10

SAFETY ADVICE 2

15

1 Type label, USA

2 Type label, Canada

3 Technical Information

4 Information, putting into operation

5 Information, emission control

6 Information, chain tension

7 Information, noise emission

V01501-01

Type label, USA

2 SAFETY ADVICE

16

V01498-01

Type label, Canada

V01504-01

Technical Information

SAFETY ADVICE 2

17

700210-01

Information, putting into operation

V01499-01

Information, emission control

2 SAFETY ADVICE

18

V01497-01

Information, chain tension

V01500-01

Information, noise emission

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