390 Duke EU 2013

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

Default Chapter4
- Table of Contents4
1 Means of Representation7
- Symbols Used7
- Formats Used7
2 Safety Advice8
- Repair Manual8
- Degrees of Risk and Symbols8
- Work Rules8
3 Important Information9
- Guarantee, Warranty9
- Operating and Auxiliary Substances9
- Spare Parts, Accessories9
- Figures9
4 Serial Numbers10
- Chassis Number/Type Label10
- Key Number10
- Engine Number10
5 Motorcycle11
- Raising the Motorcycle with the Rear Wheel Stand11
- Taking the Motorcycle off of the Rear Wheel Stand11
- Raising the Motorcycle with the Front Wheel Stand11
- Taking the Motorcycle off of the Front Wheel Stand12
- Raising the Motorcycle with the Work Stand12
- Removing the Motorcycle from the Work Stand13
- Starting14
- Starting the Motorcycle to Make Checks15
6 Fork, Triple Clamp16
- Cleaning the Dust Boots of the Fork Legs16
- Removing Fork Legs16
- Installing the Fork Legs17
- Disassembling the Fork Legs18
- Checking the Fork Legs20
- Assembling the Fork Legs21
- Removing the Lower Triple Clamp23
- Installing the Lower Triple Clamp25
- Checking the Steering Head Bearing Play28
- Adjusting the Steering Head Bearing Play28
7 Handlebar, Controls30
- Checking the Play in the Throttle Cable30
- Adjusting the Play in the Throttle Cable30
- Checking the Clutch Lever Play30
- Adjusting the Clutch Cable Play31
8 Shock Absorber, Swingarm32
- Adjusting the Spring Preload of the Shock Absorber32
- Removing the Shock Absorber32
- Installing the Shock Absorber32
- Removing the Spring33
- Installing the Spring33
9 Exhaust35
- Removing the Exhaust Manifold35
- Installing the Exhaust Manifold36
- Removing the Main Silencer37
- Installing the Main Silencer38
10 Air Filter39
- Removing the Air Filter39
- Installing the Air Filter39
11 Fuel Tank, Seat, Trim40
- Opening the Filler Cap40
- Closing the Filler Cap40
- Removing the Seat40
- Mounting the Seat41
- Removing the Passenger Seat41
- Mounting the Passenger Seat41
- Removing the Fuel Tank Cover41
- Installing the Fuel Tank Cover44
- Removing the Fuel Tank46
- Installing the Fuel Tank47
- Removing the Front Spoiler49
- Fitting Front Spoiler49
- Dismounting the Front Fender50
- Installing the Front Fender50
- Checking the Fuel Pressure50
- Changing the Fuel Filter51
- Replacing the Fuel Pump53
12 Wheels54
- Checking the Tire Air Pressure54
- Checking the Tire Condition54
- Checking the Brake Discs55
- Front Wheel55
- Removing the Front Wheel55
- Installing the Front Wheel55
- Removing the Brake Disc of the Front Brake56
- Installing the Brake Disc of the Front Brake56
- Rear Wheel57
- Removing the Rear Wheel57
- Installing the Rear Wheel57
- Removing the Brake Disc of the Rear Brake58
- Installing the Brake Disc of the Rear Brake58
- Checking the Chain Tension59
- Adjusting the Chain Tension59
- Checking the Chain, Rear Sprocket, and Engine Sprocket60
- Cleaning the Chain61
- Checking the Rear Hub Rubber Dampers62
13 Wiring Harness, Battery63
- Removing the Battery63
- Installing the Battery63
- Disconnecting the Negative Cable of the Battery64
- Reconnecting the Negative Cable of the Battery64
- Recharging the Battery64
- Checking the Charging Voltage65
- Changing the Fuses of Individual Power Consumers66
14 Brake System67
- Checking the Front Brake Linings67
- Changing the Front Brake Linings67
- Checking the Brake Fluid Level of the Front Brake69
- Adding Front Brake Fluid69
- Checkin Brake Fluid Level (Front Brake)69
- Changing the Front Brake Fluid70
- Checking the Rear Brake Linings71
- Changing the Rear Brake Linings72
- Checking the Free Travel of Foot Brake Lever73
- Adjusting the Free Travel of the Foot Brake Lever74
- Checking the Rear Brake Fluid Level74
- Adding Rear Brake Fluid75
- Changing the Rear Brake Fluid75
15 Lighting System, Instruments77
- Setting Kilometers or Miles77
- Adjusting the Shift Speed RPM 177
- Adjusting the Shift Speed RPM 277
- Setting the Time78
- Resetting the Service Interval Display78
- Checking the Headlight Setting78
- Adjusting the Headlight Range79
- Changing the Parking Light Bulb80
- Changing the Headlight Bulb81
16 Engine83
- Removing the Engine83
- Installing the Engine87
- Disassembling the Engine92
- Preparations92
- Draining the Engine Oil92
- Removing the Chain Securing Guide92
- Removing the Valve Cover93
- Removing the Spark Plug93
- Removing the Clutch Cover93
- Setting the Engine to Ignition Top Dead Center94
- Removing the Timing Chain Tensioner95
- Removing the Camshaft95
- Removing the Cylinder Head96
- Removing the Piston97
- Removing the Starter Motor97
- Removing the Timing Chain97
- Removing the Water Pump Wheel98
- Removing the Alternator Cover98
- Removing the Rotor99
- Removing the Starter Drive99
- Removing the Balancer Shaft Drive Wheel100
- Removing the Gear Position Sensor100
- Removing the Suction Pump101
- Removing the Spacer102
- Removing the Clutch Cage102
- Removing the Primary Gear103
- Removing the Force Pump104
- Removing the Shift Shaft105
- Removing the Shift Drum Locating105
- Removing the Locking Lever105
- Removing the Oil Filter105
- Removing the Left Engine Case106
- Removing the Shift Rails107
- Removing the Shift Drum107
- Removing the Shift Forks108
- Removing the Transmission Shafts108
- Removing the Balancer Shaft108
- Removing the Crankshaft108
- Work on Individual Parts109
- Work on the Left Section of the Engine Case109
- Work on the Right Section of the Engine Case110
- Changing the Shaft Seal Ring of the Water Pump110
- Checking the Radial Play of the Lower Conrod Bearing111
- Changing the Conrod Bearing112
- Changing the Balancer Shaft Bearing113
- Work on the Cylinder Head114
- Checking the Cylinder Head115
- Checking the Pivot Point of the Camshafts115
- Checking/Measuring the Cylinder116
- Checking the Piston Ring End Gap116
- Checking/Measuring the Piston117
- Checking the Piston/Cylinder Mounting Clearance117
- Checking the Oil Pump117
- Checking the Oil Pressure Regulator Valve118
- Checking the Clutch119
- Checking the Shift Mechanism120
- Preassembling the Shift Shaft121
- Disassembling the Main Shaft121
- Dismantling the Countershaft122
- Checking the Transmission122
- Assembling the Main Shaft123
- Assembling the Countershaft124
- Checking the Timing Assembly126
- Changing the Stator126
- Checking the Electric Starter Drive127
- Checking the Freewheel128
- Assembling the Engine128
- Installing the Crankshaft128
- Installing the Balancer Shaft128
- Installing the Transmission Shafts129
- Installing the Shift Forks129
- Installing the Shift Drum129
- Installing the Shift Rails129
- Installing the Left Engine Case130
- Installing the Oil Filter131
- Installing the Locking Lever131
- Installing the Shift Drum Locating132
- Installing the Shift Shaft132
- Installing the Oil Pump132
- Installing the Primary Gear133
- Installing the Clutch Cage134
- Installing the Spacer135
- Installing the Suction Pump136
- Installing the Gear Position Sensor137
- Installing the Balancer Shaft Drive Wheel137
- Installing the Starter Drive138
- Installing the Rotor139
- Installing the Alternator Cover139
- Installing the Water Pump Cover139
- Installing the Timing Chain140
- Installing the Starter Motor140
- Installing the Piston140
- Installing the Cylinder Head142
- Installing the Camshafts143
- Installing the Timing Chain Tensioner143
- Checking the Valve Clearance144
- Adjusting the Valve Clearance145
- Installing the Clutch Cover145
- Installing the Spark Plug146
- Installing the Valve Cover146
- Installing the Chain Securing Guide147
- Installing the Oil Screen147
- Removing the Engine from the Engine Assembly Stand148
17 Shift Mechanism149
- Adjusting the Shift Lever149
18 Water Pump, Cooling System150
- Draining the Coolant150
- Filling/Bleeding the Cooling System150
- Checking the Antifreeze and Coolant Level151
- Checking the Coolant Level152
19 Lubrication System154
- Oil Circuit154
- Checking the Engine Oil Level154
- Checking the Engine Oil Pressure154
- Changing the Engine Oil and Oil Filter, Cleaning the Oil Screen156
- Adding Engine Oil157
20 Ignition System158
- Alternator - Checking the Stator Winding158
21 Technical Data159
- Engine159
- Engine Tolerance, Wear Limits159
- Engine Tightening Torques160
- Capacities161
- Engine Oil161
- Coolant161
- Fuel161
- Chassis161
- Electrical System162
- Tires162
- Fork162
- Shock Absorber162
- Chassis Tightening Torques163
22 Cleaning/Protective Treatment165
- Cleaning the Motorcycle165
- Checks and Maintenance Steps for Winter Operation166
23 Storage167
- Preparing for Use after Storage167
24 Service Schedule168
25 Wiring Diagram170
- Page 2 of172
- Page 3 of174
- Page 4 of176
- Page 5 of178
- Page 6 of180
- Page 7 of182
- Page 8 of184
- Page 9 of186
26 Substances188
27 Auxiliary Substances189
28 Special Tools191
29 Standards200
- Index201

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KTM 390 Duke EU 2013 Specifications

General

Brand	KTM
Model	390 Duke EU 2013
Category	Motorcycle
Language	English

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