KTM 390 Duke 2015 Owner's manual

Category
Motorcycles
Type
Owner's manual
OWNER'S MANUAL 2015
390 Duke US
Art. no. 3213283en
DEAR KTM CUSTOMER 1
DEAR KTM CUSTOMER
Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will
give you enormous pleasure if you service and maintain it accordingly.
We hope you enjoy your new vehicle!
Enter the serial numbers of your vehicle below.
Chassis number ( p. 26) Dealer's stamp
Engine number ( p. 27)
Key number ( p. 28)
The Owner's Manual contained the latest information for this model series at the time of going to print. Minor differences due to develop-
ments 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, devi-
ations from illustrations and descriptions, misprints, and other errors. The models portrayed partly contain special equipment that does not
belong to the regular scope of supply.
© 2015 KTM Sportmotorcycle GmbH, Mattighofen Austria
All rights reserved
Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright owner.
DEAR KTM CUSTOMER 2
ISO 9001(12 100 6061)
According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead to
the maximum possible quality of the products.
Issued by: TÃœV Management Service
KTM Sportmotorcycle GmbH
5230 Mattighofen, Austria
TABLE OF CONTENTS 3
TABLE OF CONTENTS
1 MEANS OF REPRESENTATION ........................................ 7
1.1 Symbols used ...................................................... 7
1.2 Formats used....................................................... 8
2 SAFETY ADVICE.............................................................. 9
2.1 Use definition...................................................... 9
2.2 Safety advice....................................................... 9
2.3 Degrees of risk and symbols................................ 10
2.4 Overview of labels .............................................. 12
2.5 Reporting safety defects ..................................... 15
2.6 Noise emission warranty ..................................... 15
2.7 Operating noise warning ..................................... 16
2.8 Consumer rights................................................. 16
2.9 Tampering warning............................................. 16
2.10 Safe operation ................................................... 17
2.11 Protective clothing ............................................. 18
2.12 Work rules......................................................... 18
2.13 Environment...................................................... 18
2.14 Owner's Manual ................................................. 19
3 IMPORTANT NOTES...................................................... 20
3.1 Guarantee, warranty ........................................... 20
3.2 Operating and auxiliary substances ...................... 20
3.3 Spare parts, accessories ..................................... 20
3.4 Service ............................................................. 20
3.5 Figures ............................................................. 21
3.6 Customer service................................................ 21
4 VIEW OF VEHICLE ........................................................ 22
4.1 View of vehicle, front left (example) ..................... 22
4.2 View of vehicle, rear right (example) .................... 24
5 SERIAL NUMBERS ....................................................... 26
5.1 Chassis number ................................................. 26
5.2 Type label ......................................................... 26
5.3 Engine number .................................................. 27
5.4 Key number....................................................... 28
6 CONTROLS................................................................... 29
6.1 Clutch lever....................................................... 29
6.2 Hand brake lever................................................ 29
6.3 Throttle grip ...................................................... 30
6.4 Horn button....................................................... 30
6.5 Light switch ...................................................... 31
6.6 High beam flasher button ................................... 31
6.7 Turn signal switch.............................................. 32
6.8 Emergency OFF switch ....................................... 32
6.9 Electric starter button......................................... 33
6.10 Ignition/steering lock.......................................... 33
6.11 Locking the steering........................................... 34
6.12 Unlocking the steering........................................ 34
6.13 Combination instrument ..................................... 35
6.13.1 Overview ....................................................... 35
6.13.2 Activation and test......................................... 36
6.13.3 Warning notes ............................................... 37
6.13.4 Function buttons ........................................... 40
6.13.5 Indicator lamps ............................................. 41
6.13.6 Display ......................................................... 42
6.13.7 Filling level display in fuel tank....................... 43
6.13.8 TRIP F display............................................... 44
6.13.9 Coolant temperature indicator ......................... 45
6.13.10 Info display ................................................... 46
TABLE OF CONTENTS 4
6.13.11 Riding time/average speed menu..................... 47
6.13.12 Average speed/average fuel consumption 1
menu............................................................ 47
6.13.13 Average fuel consumption 1/average fuel
consumption 2 menu ..................................... 48
6.13.14 Average fuel consumption 2/service menu ........ 49
6.13.15 Service/range menu........................................ 50
6.13.16 Range/riding time menu ................................. 51
6.13.17 Total distance menu ODO ............................... 52
6.13.18 Distance menu 1 TRIP 1 ................................ 52
6.13.19 Distance menu 2 TRIP 2 ................................ 53
6.13.20 Setting kilometers or miles ............................. 53
6.13.21 Setting the time............................................. 54
6.13.22 Adjusting the shift speed RPM 1 ..................... 55
6.13.23 Adjusting the shift speed RPM 2 ..................... 55
6.14 Opening the filler cap......................................... 56
6.15 Closing the filler cap .......................................... 58
6.16 Seat lock........................................................... 58
6.17 Tool set............................................................. 59
6.18 Grab handles ..................................................... 59
6.19 Passenger footrests ............................................ 60
6.20 Shift lever ......................................................... 60
6.21 Foot brake lever ................................................. 61
6.22 Side stand......................................................... 62
7 PREPARING FOR USE................................................... 63
7.1 Advice on first use ............................................. 63
7.2 Running in the engine ........................................ 64
7.3 Loading the vehicle............................................ 65
8 RIDING INSTRUCTIONS................................................ 67
8.1 Checks and maintenance when preparing for
use................................................................... 67
8.2 Starting............................................................. 68
8.3 Starting off........................................................ 70
8.4 Shifting, riding .................................................. 70
8.5 Applying the brakes............................................ 73
8.6 Stopping, parking............................................... 75
8.7 Transport .......................................................... 76
8.8 Refueling .......................................................... 77
9 SERVICE SCHEDULE .................................................... 79
9.1 Service schedule................................................ 79
10 TUNING THE CHASSIS ................................................. 81
10.1 Adjusting the spring preload of the shock
absorber ........................................................ 81
10.2 Adjusting the shift lever...................................... 82
11 SERVICE WORK ON THE CHASSIS................................. 83
11.1 Raising the motorcycle with the rear wheel
stand ................................................................ 83
11.2 Taking the motorcycle off of the rear wheel
stand ................................................................ 83
11.3 Raising the motorcycle with the front wheel
stand ................................................................ 84
11.4 Taking the motorcycle off of the front wheel
stand ................................................................ 85
11.5 Removing the passenger seat .............................. 86
11.6 Mounting the passenger seat............................... 87
11.7 Removing the seat ............................................. 87
11.8 Mounting the seat .............................................. 88
11.9 Checking for chain dirt accumulation................... 89
TABLE OF CONTENTS 5
11.10 Cleaning the chain ............................................. 89
11.11 Checking the chain tension ................................. 90
11.12 Adjusting the chain tension................................. 91
11.13 Checking the chain, rear sprocket, and engine
sprocket............................................................ 93
11.14 Removing the front spoiler .................................. 97
11.15 Fitting front spoiler ............................................ 98
12 BRAKE SYSTEM ........................................................... 99
12.1 ABS/antilock brake system.................................. 99
12.2 Checking the brake discs .................................. 100
12.3 Checking the brake fluid level of the front
brake .............................................................. 101
12.4 Adding front brake fluid ................................ 102
12.5 Checking the front brake linings ........................ 103
12.6 Checking the free travel of foot brake lever ......... 104
12.7 Adjusting the free travel of the foot brake
lever ............................................................ 105
12.8 Checking the rear brake fluid level..................... 106
12.9 Adding rear brake fluid ................................. 107
12.10 Checking the rear brake linings ......................... 109
13 WHEELS, TIRES ......................................................... 110
13.1 Removing the front wheel .............................. 110
13.2 Installing the front wheel .............................. 111
13.3 Removing the rear wheel ............................... 113
13.4 Installing the rear wheel ................................ 114
13.5 Checking the rear hub rubber dampers ........... 115
13.6 Checking the tire condition ............................... 117
13.7 Checking the tire air pressure............................ 118
14 ELECTRICAL SYSTEM ................................................. 120
14.1 Removing the battery .................................... 120
14.2 Installing the battery ..................................... 121
14.3 Recharging the battery .................................. 122
14.4 Changing the ABS fuses ................................... 125
14.5 Changing the fuses of individual power
consumers....................................................... 126
14.6 Changing the headlight bulb ............................. 128
14.7 Changing the parking light bulb......................... 131
14.8 Changing the turn signal bulb ........................... 134
14.9 Checking the headlight setting .......................... 136
14.10 Adjusting the headlight range............................ 137
15 COOLING SYSTEM ...................................................... 140
15.1 Cooling system ................................................ 140
15.2 Checking the antifreeze and coolant level........... 141
15.3 Checking the coolant level ................................ 143
15.4 Draining the coolant ..................................... 145
15.5 Filling/bleeding the cooling system ................. 146
16 TUNING THE ENGINE................................................. 148
16.1 Checking the play in the throttle cable ............... 148
16.2 Adjusting the play in the throttle cable ........... 149
16.3 Checking the clutch lever play........................... 149
16.4 Adjusting the clutch cable play ...................... 150
17 SERVICE WORK ON THE ENGINE ................................ 151
17.1 Checking the engine oil level............................. 151
17.2 Changing the engine oil and oil filter, cleaning
the oil screens ............................................. 151
17.3 Adding engine oil............................................. 154
18 CLEANING, CARE ....................................................... 156
18.1 Cleaning the motorcycle ................................... 156
18.2 Checks and maintenance steps for winter
operation......................................................... 158
TABLE OF CONTENTS 6
19 STORAGE................................................................... 160
19.1 Storage ........................................................... 160
19.2 Preparing for use after storage........................... 161
20 TROUBLESHOOTING .................................................. 162
21 TECHNICAL DATA....................................................... 165
21.1 Engine............................................................ 165
21.2 Engine tightening torques ................................. 166
21.3 Capacities ....................................................... 169
21.3.1 Engine oil ................................................... 169
21.3.2 Coolant....................................................... 169
21.3.3 Fuel ........................................................... 169
21.4 Chassis ........................................................... 169
21.5 Electrical system.............................................. 171
21.6 Tires............................................................... 172
21.7 Fork................................................................ 172
21.8 Shock absorber................................................ 172
21.9 Chassis tightening torques ................................ 173
22 SUBSTANCES ............................................................ 178
23 AUXILIARY SUBSTANCES ........................................... 180
24 STANDARDS .............................................................. 182
INDEX ............................................................................... 183
1 MEANS OF REPRESENTATION 7
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. There, your motorcycle will be optimally
cared for by specially trained experts using the specialist 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 8
1.2 Formats used
The typographical formats used in this document are explained below.
Specific name Identifies a proprietary name.
Name
®
Identifies a protected name.
Brandâ„¢ Identifies a brand available on the open market.
Underlined terms Refer to technical details of the vehicle or indicate technical terms that are explained in the
glossary.
2 SAFETY ADVICE 9
2.1 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.
2.2 Safety advice
A number of safety instructions need to be followed to operate the vehicle safely. Therefore, read this manual carefully. The safety instruc-
tions are highlighted in the text and are referred to at the relevant passages.
Info
The vehicle has various information and warning labels at prominent locations. Do not remove information/warning labels. If they
are missing, you or others may not recognize dangers and may therefore be injured.
2 SAFETY ADVICE 10
2.3 Degrees of risk and symbols
Danger
Indicates a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not
taken.
Warning
Indicates a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.
Caution
Indicates a danger that may lead to minor injuries if the appropriate measures are not taken.
Note
Indicates a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.
Warning
Indicates a danger that will lead to environmental damage if the appropriate measures are not taken.
11
2 SAFETY ADVICE 12
2.4 Overview of labels
K00027-10
2 SAFETY ADVICE 13
1 Type label for Canada
2 Information on emissions control
3 Information on preparations for use
4 Type label for USA
5 Information on noise emissions
K00011-01
Type label for Canada
K00013-01
Information on emissions control
2 SAFETY ADVICE 14
S00725-01
Information on preparations for use
K00012-01
Type label for USA
2 SAFETY ADVICE 15
K00015-01
Information on noise emissions
2.5 Reporting safety defects
If you believe that your vehicle has a defect which could cause an accident resulting in injury or death, you should immediately inform the
National Highway Traffic Safety Administration (NHTSA) in addition to notifying KTM North America, Inc.
If NHTSA receives multiple similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of
vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in individual problems between you, your
dealer, or KTM North America, Inc.
To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1–888–327–4236 or visit the website www.nhtsa.dot.gov, or
write to: NHTSA Headquarters, 1200 New Jersey Avenue, SE, West Building, Washington, DC 20590. You can also obtain other informa-
tion about motor vehicle safety from the Hotline.
2.6 Noise emission warranty
KTM Sportmotorcycle AG warrants that this exhaust system, at the time of sale, meets all applicable U.S. EPA Federal noise standards.
This warranty extends to the first person who buys this exhaust system for purposes other than resale, and to all subsequent buyers.
Warranty claims should be directed to:
KTM North America, Inc., Customer Support, 1119 Milan Ave., Amherst, OH 44001, USA
Phone: (440) 985–3553
www.ktmusa.com
KTM Canada, Inc., Customer Support, 1375-1 Marie-Victorin, Saint-Bruno, QC J3V 6B7
2 SAFETY ADVICE 16
Phone: (450) 441–4451 x 4250
www.ktmcanada.com
2.7 Operating noise warning
This product should be checked for necessary repair or replacement parts if the motorcycle noise has increased significantly through use.
Otherwise, the owner may become subject to penalties under the applicable ordinances.
2.8 Consumer rights
Warranty claims should be submitted to a KTM workshop. If you are not satisfied, please contact:
KTM North America, Inc., Customer Support, 1119 Milan Ave., Amherst, OH 44001, USA
Phone: (440) 985–3553
www.ktmusa.com
KTM Canada, Inc., Customer Support, 1375-1 Marie-Victorin, Saint-Bruno, QC J3V 6B7
Phone: (450) 441–4451 x 4250
www.ktmcanada.com
Different rights may apply, according to national or regional legislation.
2.9 Tampering warning
Tampering with the noise control system is prohibited. Federal law prohibits the following acts or the causing thereof:
1 The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or
element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate pur-
chaser or while it is in use, or
2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.
Among those acts presumed to constitute tampering are the acts listed below:
2 SAFETY ADVICE 17
1 Removal or puncturing of the main silencer, baffles, header pipes or any other components which conduct exhaust gases.
2 Removal or puncturing of parts of the intake system.
3 Lack of proper maintenance.
4 Replacing moving part of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by the manufac-
turer.
2.10 Safe operation
Danger
Danger of accidents Danger arising from the rider's judgement being impaired.
– Do not operate the vehicle while under the influence of alcohol, drugs and certain medications or physically or mentally
impaired.
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death.
– When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed
space without an effective exhaust extraction system.
Warning
Danger of burns Some vehicle components become very hot when the vehicle is operated.
– Do not touch hot components such as exhaust system, radiator, engine, shock absorber, and the brake system. Allow these
components to cool down before starting work on them.
Only operate the vehicle when it is in perfect technical condition, in accordance with its intended use, and in a safe and environmentally
compatible manner.
An appropriate driver's license is needed to ride the vehicle on public roads.
Have malfunctions that impair safety promptly eliminated by an authorized KTM workshop.
Adhere to the information and warning labels on the vehicle.
2 SAFETY ADVICE 18
2.11 Protective clothing
Warning
Risk of injury Missing or poor protective clothing presents an increased safety risk.
– Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle. Always wear
protective clothing that is in good condition and meets the legal requirements.
In the interest of your own safety, KTM recommends that you only operate the vehicle while wearing protective clothing.
2.12 Work rules
Special tools are necessary for certain tasks. The tools are not contained in the vehicle but can be ordered under the number in parenthe-
ses. E.g.: bearing puller (15112017000)
During assembly, non-reusable parts (e.g. self-locking screws and nuts, seals and seal rings, O-rings, pins, lock washers) must be replaced
by new parts.
In some instances, a thread locker (e.g. Loctite
®
) is required. The manufacturer instructions for use must be followed.
After disassembly, clean the parts that are to be reused and check them for damage and wear. Change damaged or worn parts.
After you complete the repair or service work, check the operating safety of the vehicle.
2.13 Environment
If you use your motorcycle responsibly, you can ensure that problems and conflicts do not occur. To protect the future of the motorcycle
sport, make sure that you use your motorcycle legally, display environmental consciousness, and respect the rights of others.
When disposing of used oil, other operating and auxiliary fluids, and used components, comply with the laws and regulations of the
respective country.
Because motorcycles are not subject to the EU regulations governing the disposal of used vehicles, there are no legal regulations that per-
tain to the disposal of an end-of-life motorcycle. Your authorized KTM dealer will be glad to advise you.
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KTM 390 Duke 2015 Owner's manual

Category
Motorcycles
Type
Owner's manual

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