2014 KTM 390 Duke Service & Repair Manual
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Art. no. 3206167en
390 Duke EU
390 Duke AUS
390 Duke MAL
390 Duke COL
REPAIR MANUAL 2014
TABLE OF CONTENTS 2
TABLE OF CONTENTS
1 MEANS OF REPRESENTATION ..................................... 5
1.1 Symbols used ................................................... 5
1.2 Formats used.................................................... 5
2 SAFETY ADVICE........................................................... 6
2.1 Repair Manual .................................................. 6
2.2 Safety advice .................................................... 6
2.3 Degrees of risk and symbols ............................... 6
2.4 Work rules ........................................................ 6
3 IMPORTANT INFORMATION ......................................... 7
3.1 Guarantee, warranty .......................................... 7
3.2 Operating and auxiliary substances ..................... 7
3.3 Spare parts, accessories .................................... 7
3.4 Figures ............................................................ 7
4 SERIAL NUMBERS ...................................................... 8
4.1 Chassis number/type label ................................. 8
4.2 Key number ...................................................... 8
4.3 Engine number ................................................. 8
5 MOTORCYCLE ............................................................. 9
5.1 Raising the motorcycle with the rear wheel
stand ............................................................... 9
5.2 Taking the motorcycle off of the rear wheel
stand ............................................................... 9
5.3 Raising the motorcycle with the front wheel
stand ............................................................... 9
5.4 Taking the motorcycle off of the front wheel
stand ............................................................. 10
5.5 Raising the motorcycle with the work stand ....... 10
5.6 Removing the motorcycle from the work stand ... 11
5.7 Starting.......................................................... 12
5.8 Starting the motorcycle to make checks ............ 13
6 FORK, TRIPLE CLAMP ............................................... 14
6.1 Cleaning the dust boots of the fork legs............. 14
6.2 Removing fork legs .......................................... 14
6.3 Installing the fork legs ..................................... 15
6.4 Disassembling the fork legs.............................. 16
6.5 Checking the fork legs ..................................... 18
6.6 Assembling the fork legs .................................. 19
6.7 Removing the lower triple clamp....................... 21
6.8 Installing the lower triple clamp ....................... 23
6.9 Checking the steering head bearing play............ 26
6.10 Adjusting the steering head bearing play ........... 26
7 HANDLEBAR, CONTROLS........................................... 28
7.1 Checking the play in the throttle cable .............. 28
7.2 Adjusting the play in the throttle cable.............. 28
7.3 Checking the clutch lever play .......................... 28
7.4 Adjusting the clutch cable play ........................ 29
8 SHOCK ABSORBER, SWINGARM ................................ 30
8.1 Adjusting the spring preload of the shock
absorber ......................................................... 30
8.2 Removing the shock absorber ........................... 30
8.3 Installing the shock absorber............................ 30
8.4 Removing the spring........................................ 31
8.5 Installing the spring ........................................ 31
9 EXHAUST .................................................................. 33
9.1 Removing the exhaust manifold ........................ 33
9.2 Installing the exhaust manifold ........................ 34
9.3 Removing the main silencer ............................. 35
9.4 Installing the main silencer .............................. 36
10 AIR FILTER ............................................................... 37
10.1 Removing the air filter ..................................... 37
10.2 Installing the air filter...................................... 37
11 FUEL TANK, SEAT, TRIM ........................................... 38
11.1 Opening the filler cap ...................................... 38
11.2 Closing the filler cap ....................................... 38
11.3 Removing the seat .......................................... 38
11.4 Mounting the seat ........................................... 39
11.5 Removing the passenger seat ........................... 39
11.6 Mounting the passenger seat ............................ 39
11.7 Removing the fuel tank cover ........................... 39
11.8 Installing the fuel tank cover ............................ 42
11.9 Removing the fuel tank.................................... 44
11.10 Installing the fuel tank .................................... 45
11.11 Removing the front spoiler ............................... 47
11.12 Fitting front spoiler ......................................... 47
11.13 Dismounting the front fender ........................... 48
11.14 Installing the front fender ................................ 48
11.15 Checking the fuel pressure............................... 48
11.16 Changing the fuel filter .................................... 49
11.17 Replacing the fuel pump ................................. 51
12 WHEELS ................................................................... 52
12.1 Checking the tire air pressure ........................... 52
12.2 Checking the tire condition .............................. 52
12.3 Checking the brake discs ................................. 53
12.4 Front wheel .................................................... 53
12.4.1 Removing the front wheel ............................ 53
12.4.2 Installing the front wheel ............................. 53
12.4.3 Removing the brake disc of the front brake.... 54
12.4.4 Installing the brake disc of the front brake .... 54
12.5 Rear wheel ..................................................... 55
12.5.1 Removing the rear wheel ............................. 55
12.5.2 Installing the rear wheel .............................. 55
12.5.3 Removing the brake disc of the rear brake ..... 56
12.5.4 Installing the brake disc of the rear brake...... 56
12.5.5 Checking the chain tension .......................... 57
12.5.6 Adjusting the chain tension ......................... 57
12.5.7 Checking the chain, rear sprocket, and
engine sprocket .......................................... 58
12.5.8 Cleaning the chain ...................................... 59
12.5.9 Checking the rear hub rubber dampers.......... 60
13 WIRING HARNESS, BATTERY ..................................... 61
13.1 Removing the battery ...................................... 61
13.2 Installing the battery ....................................... 61
13.3 Disconnecting the negative cable of the
battery ........................................................... 62
13.4 Reconnecting the negative cable of the
battery ........................................................... 62
13.5 Recharging the battery .................................... 62
13.6 Checking the charging voltage .......................... 63
13.7 Changing the fuses of individual power
consumers...................................................... 64
14 BRAKE SYSTEM ........................................................ 65
14.1 Checking the front brake linings ....................... 65
14.2 Changing the front brake linings ....................... 65
14.3 Checking the brake fluid level of the front
brake ............................................................. 67
14.4 Adding front brake fluid................................... 67
14.5 Changing the front brake fluid .......................... 68
14.6 Checking the rear brake linings ........................ 69
14.7 Changing the rear brake linings ........................ 70
14.8 Checking the free travel of foot brake lever ........ 71
14.9 Adjusting the free travel of the foot brake
lever .............................................................. 72
14.10 Checking the rear brake fluid level .................... 72
TABLE OF CONTENTS 3
14.11 Adding rear brake fluid .................................... 73
14.12 Changing the rear brake fluid ........................... 73
15 LIGHTING SYSTEM, INSTRUMENTS ........................... 75
15.1 Setting kilometers or miles............................... 75
15.2 Adjusting the shift speed RPM 1 ...................... 75
15.3 Adjusting the shift speed RPM 2 ...................... 75
15.4 Setting the time .............................................. 76
15.5 Resetting the service interval display ................ 76
15.6 Checking the headlight setting ......................... 76
15.7 Adjusting the headlight range........................... 77
15.8 Changing the parking light bulb........................ 78
15.9 Changing the headlight bulb ............................ 79
16 ENGINE .................................................................... 81
16.1 Removing the engine ....................................... 81
16.2 Installing the engine........................................ 85
16.3 Disassembling the engine ................................ 90
16.3.1 Preparations ............................................... 90
16.3.2 Draining the engine oil ................................ 90
16.3.3 Removing the chain securing guide .............. 90
16.3.4 Removing the valve cover............................. 91
16.3.5 Removing the spark plug ............................. 91
16.3.6 Removing the clutch cover ........................... 91
16.3.7 Setting the engine to ignition top dead
center ........................................................ 92
16.3.8 Removing the timing chain tensioner ............ 93
16.3.9 Removing the camshaft ............................... 93
16.3.10 Removing the cylinder head ......................... 94
16.3.11 Removing the piston ................................... 95
16.3.12 Removing the starter motor .......................... 95
16.3.13 Removing the timing chain .......................... 95
16.3.14 Removing the water pump wheel .................. 96
16.3.15 Removing the alternator cover ...................... 96
16.3.16 Removing the rotor...................................... 97
16.3.17 Removing the starter drive ........................... 97
16.3.18 Removing the balancer shaft drive wheel ....... 98
16.3.19 Removing the gear position sensor ................ 98
16.3.20 Removing the suction pump......................... 99
16.3.21 Removing the spacer ................................. 100
16.3.22 Removing the clutch cage.......................... 100
16.3.23 Removing the primary gear ........................ 101
16.3.24 Removing the force pump .......................... 102
16.3.25 Removing the shift shaft ............................ 103
16.3.26 Removing the shift drum locating ............... 103
16.3.27 Removing the locking lever ........................ 103
16.3.28 Removing the oil filter ............................... 103
16.3.29 Removing the left engine case.................... 104
16.3.30 Removing the shift rails ............................. 105
16.3.31 Removing the shift drum ........................... 105
16.3.32 Removing the shift forks ............................ 106
16.3.33 Removing the transmission shafts............... 106
16.3.34 Removing the balancer shaft ...................... 106
16.3.35 Removing the crankshaft ........................... 106
16.4 Work on individual parts ................................ 107
16.4.1 Work on the left section of the engine
case ........................................................ 107
16.4.2 Work on the right section of the engine
case ........................................................ 108
16.4.3 Changing the shaft seal ring of the water
pump ...................................................... 108
16.4.4 Checking the radial play of the lower
conrod bearing ......................................... 109
16.4.5 Changing the conrod bearing...................... 110
16.4.6 Changing the balancer shaft bearing ........... 111
16.4.7 Work on the cylinder head ......................... 112
16.4.8 Checking the cylinder head ........................ 113
16.4.9 Checking the pivot point of the
camshafts ................................................ 113
16.4.10 Checking/measuring the cylinder ................ 114
16.4.11 Checking the piston ring end gap ............... 114
16.4.12 Checking/measuring the piston................... 115
16.4.13 Checking the piston/cylinder mounting
clearance ................................................. 115
16.4.14 Checking the oil pump .............................. 115
16.4.15 Checking the oil pressure regulator valve ..... 116
16.4.16 Checking the clutch .................................. 117
16.4.17 Checking the shift mechanism ................... 118
16.4.18 Preassembling the shift shaft ..................... 119
16.4.19 Disassembling the main shaft .................... 119
16.4.20 Dismantling the countershaft ..................... 120
16.4.21 Checking the transmission ......................... 120
16.4.22 Assembling the main shaft......................... 121
16.4.23 Assembling the countershaft ...................... 122
16.4.24 Checking the timing assembly .................... 124
16.4.25 Changing the stator ................................... 124
16.4.26 Checking the electric starter drive .............. 125
16.4.27 Checking the freewheel ............................. 126
16.5 Assembling the engine .................................. 126
16.5.1 Installing the crankshaft ............................ 126
16.5.2 Installing the balancer shaft....................... 126
16.5.3 Installing the transmission shafts ............... 127
16.5.4 Installing the shift forks............................. 127
16.5.5 Installing the shift drum ............................ 127
16.5.6 Installing the shift rails ............................. 127
16.5.7 Installing the left engine case .................... 128
16.5.8 Installing the oil filter ................................ 129
16.5.9 Installing the locking lever ......................... 129
16.5.10 Installing the shift drum locating ................ 130
16.5.11 Installing the shift shaft ............................ 130
16.5.12 Installing the oil pump .............................. 130
16.5.13 Installing the primary gear ......................... 131
16.5.14 Installing the clutch cage .......................... 132
16.5.15 Installing the spacer.................................. 133
16.5.16 Installing the suction pump ....................... 134
16.5.17 Installing the gear position sensor .............. 135
16.5.18 Installing the balancer shaft drive wheel ..... 135
16.5.19 Installing the starter drive .......................... 136
16.5.20 Installing the rotor .................................... 137
16.5.21 Installing the alternator cover ..................... 137
16.5.22 Installing the water pump cover.................. 137
16.5.23 Installing the timing chain ......................... 138
16.5.24 Installing the starter motor......................... 138
16.5.25 Installing the piston .................................. 138
16.5.26 Installing the cylinder head........................ 140
16.5.27 Installing the camshafts ............................ 141
16.5.28 Installing the timing chain tensioner ........... 141
16.5.29 Checking the valve clearance ..................... 142
16.5.30 Adjusting the valve clearance ..................... 143
16.5.31 Installing the clutch cover ......................... 143
16.5.32 Installing the spark plug ............................ 144
16.5.33 Installing the valve cover ........................... 144
16.5.34 Installing the chain securing guide ............. 145
16.5.35 Installing the oil screen ............................. 145
16.5.36 Removing the engine from the engine
assembly stand ......................................... 146
TABLE OF CONTENTS 4
17 SHIFT MECHANISM ................................................. 147
17.1 Adjusting the shift lever ................................. 147
18 WATER PUMP, COOLING SYSTEM ............................ 148
18.1 Draining the coolant ...................................... 148
18.2 Filling/bleeding the cooling system ................. 148
18.3 Checking the antifreeze and coolant level ........ 149
18.4 Checking the coolant level ............................. 150
19 LUBRICATION SYSTEM............................................ 152
19.1 Oil circuit ..................................................... 152
19.2 Checking the engine oil level .......................... 152
19.3 Checking the engine oil pressure .................... 152
19.4 Changing the engine oil and oil filter,
cleaning the oil screen................................... 154
19.5 Adding engine oil .......................................... 155
20 IGNITION SYSTEM................................................... 156
20.1 Alternator - checking the stator winding .......... 156
21 TECHNICAL DATA .................................................... 157
21.1 Engine ......................................................... 157
21.2 Engine tolerance, wear limits ......................... 157
21.3 Engine tightening torques .............................. 158
21.4 Capacities .................................................... 159
21.4.1 Engine oil ................................................ 159
21.4.2 Coolant .................................................... 159
21.4.3 Fuel ........................................................ 159
21.5 Chassis ........................................................ 159
21.6 Electrical system........................................... 160
21.7 Tires ............................................................ 160
21.8 Fork............................................................. 160
21.9 Shock absorber ............................................. 160
21.10 Chassis tightening torques ............................. 161
22 CLEANING/PROTECTIVE TREATMENT ....................... 163
22.1 Cleaning the motorcycle ................................ 163
22.2 Checks and maintenance steps for winter
operation...................................................... 164
23 STORAGE ................................................................ 165
23.1 Storage ........................................................ 165
23.2 Preparing for use after storage........................ 165
24 SERVICE SCHEDULE ............................................... 166
24.1 Service schedule ........................................... 166
25 WIRING DIAGRAM ................................................... 168
25.1 Page 1 of 9 .................................................. 168
25.2 Page 2 of 9 .................................................. 170
25.3 Page 3 of 9 .................................................. 172
25.4 Page 4 of 9 .................................................. 174
25.5 Page 5 of 9 .................................................. 176
25.6 Page 6 of 9 .................................................. 178
25.7 Page 7 of 9 .................................................. 180
25.8 Page 8 of 9 .................................................. 182
25.9 Page 9 of 9 .................................................. 184
26 SUBSTANCES ......................................................... 186
27 AUXILIARY SUBSTANCES ........................................ 187
28 SPECIAL TOOLS ...................................................... 189
29 STANDARDS ........................................................... 198
INDEX ............................................................................ 199
1 MEANS OF REPRESENTATION 5
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).
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.
Denotes a voltage measurement.
Denotes a current measurement.
Denotes a resistance measurement.
1.2 Formats used
The typographical formats used in this document are explained below.
Proprietary name Identifies a proprietary name.
Name
®
Identifies a protected name.
Brand™ Identifies a trademark.
2 SAFETY ADVICE 6
2.1 Repair Manual
Read this Repair Manual carefully and thoroughly before beginning work. It contains useful information and tips that will help you
repair and maintain your vehicle.
This manual assumes that the necessary special KTM tools and KTM workplace and workshop equipment are available.
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
instructions 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.
2.3 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.
Warning
Identifies a danger that will lead to environmental damage if the appropriate measures are not taken.
2.4 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 paren-
theses. 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.
3 IMPORTANT INFORMATION 7
3.1 Guarantee, warranty
The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's
Service & Warranty Booklet and in the KTM dealer.net; otherwise, all warranty claims will be void. No warranty claims can be consid-
ered for damage resulting from manipulations and/or alterations to the vehicle.
Additional information on the guarantee or warranty and the procedures involved can be found in the Service & Warranty Booklet.
3.2 Operating and auxiliary substances
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to get into the ground water, the ground, or the sewage system.
Use the operating and auxiliary substances (such as fuel and lubricants) as specified in the manual.
3.3 Spare parts, accessories
Only use spare parts and accessories approved and/or recommended by KTM. KTM accepts no liability for other products and any
resulting damage or loss.
The current KTM PowerParts for your vehicle can be found on the KTM website.
International KTM Website: http://www.ktm.com
3.4 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 dis-
assemble the component to perform the activity in question. Please follow the instructions in the text.
4 SERIAL NUMBERS 8
4.1 Chassis number/type label
101877-10
The chassis number 1 is stamped on the right of the steering head.
The type label 2 is on the right of the frame behind the steering head.
4.2 Key number
B00755-10
The key number 1 can be found on the KEYCODECARD.
Info
You need the key number to order a spare key. Keep the KEYCODECARD in a safe
place.
4.3 Engine number
101876-10
The engine number 1 is stamped on the left side of the engine under the engine
sprocket.
5 MOTORCYCLE 9
5.1 Raising the motorcycle with the rear wheel stand
Note
Danger of damage The parked vehicle may roll away or fall over.
– Always place the vehicle on a firm and even surface.
B01387-01
– Mount the support of the wheel stand.
– Insert the adapter in the rear wheel stand.
Adapter (61029055130) ( p. 190)
Rear wheel stand (61029055400) ( p. 191)
– Stand the motorcycle upright, align the lifting gear with the swingarm and the
adapters, and lift the motorcycle.
5.2 Taking the motorcycle off of the rear wheel stand
Note
Danger of damage The parked vehicle may roll away or fall over.
– Always place the vehicle on a firm and even surface.
101884-10
– Secure the motorcycle against falling over.
– Remove the rear wheel stand and lean the vehicle on the side stand 1.
– Remove the support of the wheel stand.
5.3 Raising the motorcycle with the front wheel stand
Note
Danger of damage The parked vehicle may roll away or fall over.
– Always place the vehicle on a firm and even surface.
Preparatory work
– Raise the motorcycle with the rear wheel stand. ( p. 9)
101887-10
Condition
– Remove cap 1.
5 MOTORCYCLE 10
101888-01
– Move the handlebar to the straight-ahead position. Attach the lifting gear to the
steering stem.
Adapter (61029955620) ( p. 191)
Front wheel stand (61029055500) ( p. 191)
Info
Always raise the rear of the motorcycle first.
– Raise the front of the motorcycle.
5.4 Taking the motorcycle off of the front wheel stand
Note
Danger of damage The parked vehicle may roll away or fall over.
– Always place the vehicle on a firm and even surface.
101889-01
– Secure the motorcycle against falling over.
– Remove the front wheel stand.
101887-10
– Mount cap 1.
5.5 Raising the motorcycle with the work stand
Note
Danger of damage The parked vehicle may roll away or fall over.
– Always place the vehicle on a firm and even surface.
308227-10
– Remove screw 1.
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This workshop service manual for the KTM 390 Duke 2014 is designed for mechanical technicians familiar with service procedures for BRP products. It covers repair and overhaul procedures, assuming the technician's familiarity with general automobile practices. The manual includes instructions on components manufactured for the KTM 390 Duke 2014, as well as repairs of proprietary components. It provides reliable information and emphasizes particular information denoted by the wording and symbols: WARNING, CAUTION, NOTE.
It offers diagnostic and repair procedures, making it useful for both professional mechanics and DIY enthusiasts. The manual also emphasizes the importance of safety equipment and precautions when working on the KTM 390 Duke 2014, including the use of a torque wrench and special tools for adjustments or repairs.
Owning and referring to this manual will enable the KTM 390 Duke 2014 owner to be better informed and perform repairs like a professional automotive technician. It contains all necessary instructions for tune-ups, maintenance, removal & install procedures, assemblies & disassemblies, fuel system, ignition, lubrication system, exhaust, electrical system, body, and more extensive repairs involving engine and transmission disassembly.
This is an electronic delivery via email, and the content depicts parts and/or procedures applicable to the particular product at the time of writing. The manual also includes general maintenance tags for the KTM 390 Duke 2014, covering various checks and renewals for different components and systems.
