KTM RC 390 2021 Owner's manual

Category
Motorcycles
Type
Owner's manual
OWNER'S MANUAL 2021
RC 390
Art. no. 3214314en
DEAR KTM CUSTOMER
*3214314en*
3214314en
02/2021
DEAR KTM CUSTOMER
Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art,
sporty motorcycle that you will continue to enjoy 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. 24) Dealer's stamp
Engine number ( p. 25)
Key number ( p. 25)
The Owner's Manual contained the latest information for this model series at the time of publication. However,
minor differences due to further developments in design cannot be ruled out completely.
All specifications contained herein 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 produc-
tion of a particular model without prior notice. 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.
© 2021 KTM Sportmotorcycle GmbH, Mattighofen Austria
All rights reserved
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: TÃœV Management Service
KTM Sportmotorcycle GmbH
Stallhofnerstraße 3
5230 Mattighofen, Austria
This document is valid for the following models:
RC 390 B.D. EU (F5303U2, F5303U2L)
RC 390 AU (F5360U1)
RC 390 JP (F5386U1)
RC 390 CN (F5387U1)
RC 390 TH (F5383U1)
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 Tampering warning........................... 13
2.6 Safe operation ................................. 13
2.7 Protective clothing ........................... 14
2.8 Work rules....................................... 15
2.9 Environment.................................... 15
2.10 Owner's Manual ............................... 16
3 IMPORTANT NOTES.................................... 17
3.1 Manufacturer warranty, implied
warranty.......................................... 17
3.2 Fuel, auxiliary substances................. 17
3.3 Spare parts, accessories ................... 17
3.4 Service ........................................... 18
3.5 Figures ........................................... 18
3.6 Customer service.............................. 18
4 VIEW OF VEHICLE ...................................... 20
4.1 View of vehicle, front left (example) ... 20
4.2 View of vehicle, rear right
(example)........................................ 22
5 SERIAL NUMBERS ..................................... 24
5.1 Vehicle identification number............ 24
5.2 Type label ....................................... 24
5.3 Engine number ................................ 25
5.4 Key number..................................... 25
6 CONTROLS................................................. 26
6.1 Clutch lever..................................... 26
6.2 Hand brake lever.............................. 26
6.3 Throttle grip .................................... 27
6.4 Horn button..................................... 27
6.5 Light switch .................................... 28
6.6 High beam flasher button ................. 28
6.7 Turn signal switch............................ 29
6.8 Emergency OFF switch ..................... 30
6.9 Start button..................................... 30
6.10 Ignition and steering lock.................. 31
6.11 Locking the steering......................... 31
6.12 Unlocking the steering...................... 32
6.13 Opening fuel tank filler cap............... 33
TABLE OF CONTENTS
4
6.14 Closing the fuel tank filler cap........... 35
6.15 Seat lock......................................... 36
6.16 Tool set........................................... 36
6.17 Grab handles ................................... 37
6.18 Passenger foot pegs ......................... 37
6.19 Shift lever ....................................... 38
6.20 Foot brake lever ............................... 39
6.21 Side stand....................................... 39
7 ERGONOMICS ............................................ 41
7.1 Adjusting the basic position of the
hand brake lever .............................. 41
7.2 Adjusting the basic position of the
clutch lever ..................................... 41
7.3 Adjusting the shift lever.................... 42
8 COMBINATION INSTRUMENT ..................... 44
8.1 Combination instrument ................... 44
8.2 Activation and test ........................... 45
8.3 Warnings......................................... 46
8.4 Indicator lamps................................ 51
8.5 Shift warning light ........................... 53
8.6 Display ........................................... 55
8.7 Fuel level display ............................. 56
8.8 Coolant temperature indicator ........... 57
8.9 Function buttons.............................. 58
8.10 TRIP F display................................. 59
8.11 Info display ..................................... 60
8.12 ODO display .................................... 61
8.12.1 Fuel Range.................................. 61
8.12.2 Service ....................................... 62
8.12.3 Actual F.C................................... 63
8.13 TRIP 1 display................................. 64
8.13.1 Time Trip 1................................. 64
8.13.2 Average Speed Trip1 .................... 65
8.13.3 Avg F.C. Trip 1 ............................ 66
8.14 TRIP 2 display................................. 67
8.14.1 Time Trip 2................................. 67
8.14.2 Average Speed Trip2 .................... 68
8.14.3 Avg F.C. Trip 2 ............................ 69
8.15 Setting the units.............................. 69
8.16 Setting the clock.............................. 71
8.17 Adjusting the shift speed RPM1 ........ 72
8.18 Adjusting the shift speed RPM2 ........ 73
9 PREPARING FOR USE................................. 75
9.1 Advice on preparing for first use ........ 75
9.2 Running in the engine ...................... 77
9.3 Loading the vehicle .......................... 77
TABLE OF CONTENTS
5
10 RIDING INSTRUCTIONS.............................. 80
10.1 Checks and maintenance measures
when preparing for use ..................... 80
10.2 Starting........................................... 81
10.3 Starting off...................................... 83
10.4 Shifting, riding. ............................... 84
10.5 Applying the brakes.......................... 88
10.6 Stopping, parking............................. 90
10.7 Transport ........................................ 92
10.8 Refueling ........................................ 93
11 SERVICE SCHEDULE .................................. 96
11.1 Additional information...................... 96
11.2 Required work ................................. 96
11.3 Recommended work ......................... 99
12 TUNING THE CHASSIS ............................. 100
12.1 Adjusting the spring preload of the
shock absorber ........................... 100
13 SERVICE WORK ON THE CHASSIS............. 101
13.1 Raising the motorcycle with rear
lifting gear .................................... 101
13.2 Removing the rear of the
motorcycle from the lifting gear....... 101
13.3 Lifting the motorcycle with the
front lifting gear............................. 102
13.4 Taking the motorcycle off the front
lifting gear .................................... 104
13.5 Cleaning the dust boots of the fork
legs .............................................. 105
13.6 Removing the front rider's seat........ 107
13.7 Mounting the front rider's seat......... 108
13.8 Removing the passenger seat .......... 108
13.9 Mounting the passenger seat........... 109
13.10 Checking for chain dirt
accumulation................................. 111
13.11 Cleaning the chain ......................... 111
13.12 Checking the chain tension ............. 113
13.13 Adjusting the chain tension............. 115
13.14 Checking the chain, rear sprocket,
and engine sprocket ....................... 117
13.15 Removing the battery cover ............. 119
13.16 Mounting the battery cover.............. 121
13.17 Removing the front spoiler .............. 122
13.18 Fitting front spoiler ........................ 123
13.19 Removing the left side cover ........ 125
13.20 Installing the left side cover ........ 126
13.21 Removing the right side cover ...... 128
13.22 Installing the right side cover ....... 129
TABLE OF CONTENTS
6
14 BRAKE SYSTEM ....................................... 130
14.1 Anti-lock braking system (ABS) ....... 130
14.2 Checking the brake discs ................ 132
14.3 Checking the front brake fluid
level ............................................. 133
14.4 Adding the front brake fluid ......... 134
14.5 Checking the front brake linings ...... 137
14.6 Checking the rear brake fluid
level ............................................. 138
14.7 Adding rear brake fluid ............... 139
14.8 Checking the rear brake linings ....... 143
14.9 Checking the free travel of foot
brake lever .................................... 144
14.10 Adjusting the free travel of the foot
brake lever ................................. 146
15 WHEELS, TIRES ....................................... 148
15.1 Removing the front wheel ............ 148
15.2 Installing the front wheel ............ 149
15.3 Removing the rear wheel ............. 151
15.4 Installing the rear wheel .............. 153
15.5 Checking the rear hub damping
rubber pieces ............................. 155
15.6 Checking the tire condition ............. 157
15.7 Checking tire pressure .................... 159
16 ELECTRICAL SYSTEM ............................... 161
16.1 Removing the 12-V battery .......... 161
16.2 Installing the 12-V battery ........... 163
16.3 Charging the 12-V battery ........... 164
16.4 Changing the ABS fuses ................. 167
16.5 Changing the fuses of individual
electrical power consumers ............. 170
16.6 Changing the low beam bulb ........... 173
16.7 Changing the high beam bulb.......... 175
16.8 Checking the low beam headlight
adjustment.................................... 177
16.9 Checking the high beam headlight
adjustment.................................... 179
16.10 Adjusting the headlight range of
the low beam................................. 180
16.11 Adjusting the headlight range of
the high beam ............................... 181
16.12 Diagnostics connector .................... 182
16.13 Front ACC1 and ACC2 .................... 182
17 COOLING SYSTEM .................................... 183
17.1 Cooling system .............................. 183
17.2 Checking the coolant level in the
compensating tank......................... 185
TABLE OF CONTENTS
7
17.3 Checking the antifreeze and
coolant level.................................. 187
17.4 Correcting the coolant level in the
compensating tank......................... 190
17.5 Draining the coolant ................... 191
17.6 Filling/bleeding the cooling
system ...................................... 193
17.7 Changing the coolant...................... 196
18 TUNING THE ENGINE............................... 200
18.1 Checking the clutch lever play......... 200
18.2 Adjusting play in the clutch
lever .......................................... 201
19 SERVICE WORK ON THE ENGINE .............. 202
19.1 Checking the engine oil level........... 202
19.2 Changing the engine oil and oil
filter, cleaning the oil screens ...... 203
19.3 Adding engine oil........................... 207
20 CLEANING, CARE ..................................... 209
20.1 Cleaning the motorcycle ................. 209
20.2 Checks and maintenance steps for
winter operation............................. 212
21 STORAGE................................................. 214
21.1 Storage ......................................... 214
21.2 Preparing for use after storage......... 216
22 TROUBLESHOOTING ................................ 217
23 TECHNICAL DATA..................................... 220
23.1 Engine .......................................... 220
23.2 Engine tightening torques ............... 222
23.3 Capacities ..................................... 226
23.3.1 Engine oil ................................. 226
23.3.2 Coolant..................................... 226
23.3.3 Fuel ......................................... 226
23.4 Chassis ......................................... 227
23.5 Electrical system............................ 228
23.6 Tires............................................. 230
23.7 Fork.............................................. 230
23.8 Shock absorber.............................. 230
23.9 Chassis tightening torques .............. 231
24 SUBSTANCES .......................................... 237
25 AUXILIARY SUBSTANCES ......................... 241
26 STANDARDS ............................................ 243
27 INDEX OF SPECIAL TERMS ....................... 244
TABLE OF CONTENTS
8
28 LIST OF ABBREVIATIONS.......................... 245
29 LIST OF SYMBOLS.................................... 246
29.1 Yellow and orange symbols.............. 246
29.2 Green and blue symbols.................. 246
INDEX ............................................................. 247
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.
Brandâ„¢ 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
This vehicle has been designed and built to withstand the normal stresses and strains of road use. This vehicle is
not suitable for use on race tracks or offroad.
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.
Caution
Identifies a danger that may lead to minor injuries 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
2.5 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 servicing, repair, or replace-
ment, 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 purchaser 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:
1 Removal or puncturing of the main silencers, 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 parts of the vehicle, or parts of the exhaust system or intake system, with parts other than
those specified by the manufacturer.
2.6 Safe operation
Danger
Danger of accidents A rider who is not fit to ride poses a danger to him or herself and others.
– Do not operate the vehicle if you are not fit to ride due to alcohol, drugs or medication.
– Do not operate the vehicle if you are physically or mentally impaired.
2 SAFETY ADVICE
14
Danger
Danger of poisoning Exhaust gases are toxic and inhaling 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.
Warning
Danger of burns Some vehicle components become very hot when the vehicle is operated.
– Do not touch any parts such as the exhaust system, radiator, engine, shock absorber, or brake system
before the vehicle parts have cooled down.
– Let the vehicle parts cool down before you perform any work on the vehicle.
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.
2.7 Protective clothing
Warning
Risk of injury Missing or poor protective clothing presents an increased safety risk.
– 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.
SAFETY ADVICE 2
15
In the interest of your own safety, KTM recommends that you only operate the vehicle while wearing protective
clothing.
2.8 Work rules
Unless specified otherwise, the ignition must be turned off during all work (models with ignition lock, models
with remote key) or the engine must be at a standstill (models without ignition lock or remote key).
Special tools are necessary for certain tasks. The tools are not a component of the vehicle, but can be ordered
using the number in parentheses. Example: bearing puller (15112017000)
During assembly, use new parts to replace parts which cannot be reused (e.g. self-locking screws and nuts,
expansion screws, seals, sealing rings, O-rings, pins, and lock washers).
In the case of certain screws, a screw adhesive (e.g. Loctite
®
) is required. Observe the manufacturer's instruc-
tions.
If thread locker (e.g., Precote
®
) has already been applied to a new part, do not apply any additional thread locker.
After disassembly, clean the parts that are to be reused and check them for damage and wear. Change damaged
or worn parts.
After completing a repair or service work, check the operating safety of the vehicle.
2.9 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 conscious-
ness, 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.
2 SAFETY ADVICE
16
Because motorcycles are not subject to the EU regulations governing the disposal of used vehicles, there are no
legal regulations that pertain to the disposal of an end-of-life motorcycle. Your authorized KTM dealer will be glad
to advise you.
2.10 Owner's Manual
Read this owner's manual carefully and completely before making your first trip. The Owner's Manual contains
useful information and many tips on how to operate, handle, and service your motorcycle. This is the only way to
find out how best to customize the vehicle for your own use and how you can protect yourself from injury.
Tip
Store the Owner's Manual on your terminal device, for example, so that you can read it whenever you need
to.
If you would like to know more about the vehicle or have questions on the material you read, please contact an
authorized KTM dealer.
The Owner's Manual is an important component of the vehicle. If the vehicle is sold, the Owner's Manual must be
downloaded again by the new owner.
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.
International KTM Website: KTM.com
IMPORTANT NOTES 3
17
3.1 Manufacturer warranty, implied warranty
The work specified in the service schedule may only be performed in an authorized KTM workshop and must be
recorded in both the Service & Warranty Booklet and in the KTM Dealer.net, otherwise any warranty claim will be
void. Damage or secondary damage caused by tampering with and/or conversions on the vehicle are not covered
by the manufacturer warranty.
Additional information on the manufacturer warranty or implied warranty and the procedures involved can be
found in the Service & Warranty Booklet.
3.2 Fuel, auxiliary substances
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.
Use fuels and auxiliary substances in accordance with the Owner's Manual and specification.
3.3 Spare parts, accessories
For your own safety, only use spare parts and accessory products that are approved and/or recommended by KTM
and have them installed by an authorized KTM workshop. KTM accepts no liability for other products and any
resulting damage or loss.
Certain spare parts and accessory products are specified in parentheses in the descriptions. Your authorized KTM
dealer will be glad to advise you.
The current KTM PowerParts for your vehicle can be found on the KTM website.
International KTM Website: KTM.com
3 IMPORTANT NOTES
18
3.4 Service
A prerequisite for perfect operation and prevention of premature wear is that the service, care, and tuning work
on the engine and chassis is properly carried out as described in the Owner's Manual. An incorrect suspension
setting can lead to damage and breakage of chassis components.
Use of the vehicle under difficult conditions, such as dusty environments, heavy rain, high heat or with a heavy
load, can lead to considerably more rapid wear of components such as the air filter, drive train, brake system, or
suspension components. For this reason, it may be necessary to inspect or replace parts before the next sched-
uled service.
It is imperative that you adhere to the stipulated run-in times and service intervals. If you observe these exactly,
you will ensure a much longer service life for your motorcycle.
The relevant mileage or time interval is whichever occurs first.
3.5 Figures
The figures contained in the manual may depict special equipment.
In the interest of clarity, some components may be shown disassembled or may not be shown at all. It is not
always necessary to disassemble the component to perform the activity in question. Please follow the instructions
in the text.
3.6 Customer service
Your authorized KTM dealer will be happy to answer any questions you may have on your vehicle and KTM.
A list of authorized KTM dealers can be found on the KTM website.
International KTM Website: KTM.com
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KTM RC 390 2021 Owner's manual

Category
Motorcycles
Type
Owner's manual

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