KTM 790 DUKE 2018 Manual

SETUP INSTRUCTIONS 2018
790 Duke
Art. no. 3213835en

INTRODUCTION
*3213835en*
3213835en
03/2018
INTRODUCTION
Perform the work described in these setup instructions before the vehicle is delivered to the customer.
Read the setup instructions in their entirety before beginning work.
These setup instructions were written to correspond to the latest state of this series. We reserve the right to make
changes in the interest of technical advancement without at the same time updating this manual.
We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop
are not specified here. It is assumed that the work will be performed by a fully trained mechanic.
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.
© 2018 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.
ISO 9001(12 100 6061)
According to the international quality management standard ISO 9001, KTM uses quality assur-
ance processes that lead to the maximum possible quality of the products.
Issued by: TÜV Management Service
KTM Sportmotorcycle GmbH
Stallhofnerstraße 3
5230 Mattighofen, Austria
This document is valid for the following models:
790 Duke EU (F9603R5, F9603R6)
790 Duke L EU (F9603R8)

1 MEANS OF REPRESENTATION
2
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.
Indicates a voltage measurement.
Indicates a current measurement.
Indicates a resistance 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.

SETUP 2
3
2.1 Unpacking and setting up the vehicle
V01334-10
–Remove the straps and box.
V01335-01
–Remove the adhesive tape in the upper area of the motorcycle.
–Roll down the film at the sides.
Info
To avoid damaging the motorcycle during unpacking,
leave the other films on the vehicle until you have fin-
ished work on the vehicle.
–Remove the separate enclosure and unpack it. Check the sepa-
rate enclosure for completeness.
–Check the vehicle for transport damage.
V01336-10
–Remove cable tie(s) 1. Place handlebar at the front.
–Remove the clutch and brake assembly from the transport
holder.
–Remove screws 2from the handlebar clamps. Take off the
handlebar clamps and transport holder.
V01337-10
Warning
Danger of accidents A repaired handlebar poses a
safety risk.
If the handlebar is bent or straightened, the mate-
rial becomes fatigued. The handlebar may break as a
result.
–Change the handlebar if the handlebar is damaged
or bent.
–Unpack handlebar and position.
Info
Make sure the cables and wiring are positioned cor-
rectly.
The markings 3on the handlebar should be at the
height of the gap between the handlebar supports and
the handlebar clamps.

2 SETUP
4
–Position the handlebar clamps. Mount and tighten the screws
evenly.
Guideline
Screw, handlebar
clamp
M8 20 Nm (14.8 lbf ft)
Info
Keep the installed gap widths equal when tightening.
V01338-10
–Align the controls of the left handlebar half with the markings
on the handlebar. Tighten the screws.
Guideline
Screw, combination
switch, left
M5 2 Nm (1.5 lbf ft)
–Position clutch assembly on the handlebar.
–Position the clutch assembly clamp on the handlebar.
–Mount and tighten screws 4.
Guideline
Remaining screws,
chassis
M6 10 Nm (7.4 lbf ft)
V01339-10
–Align the control of the right handlebar half with the markings
on the handlebar. Tighten the screws.
Guideline
Screw, throttle grip M5 3.5 Nm
(2.58 lbf ft)
Screw, combination
switch, right
M5 5 Nm (3.7 lbf ft)
–Check the throttle grip for smooth operation.
–Position brake assembly on the handlebar.
–Position brake assembly clamp on the handlebar.
Clamp catch engages in the combination switch.
–Mount and tighten screws 5.
Guideline
Remaining screws,
chassis
M6 10 Nm (7.4 lbf ft)
–Tie the cables together with the rubber bands supplied.
V01340-01
–Mount and tighten the rear mirror on both sides.

SETUP 2
5
V01341-10
–Mount speed nuts 6on the license plate support.
–Position the splash protector.
–Mount and tighten screws 7.
Guideline
Remaining screws,
chassis
EJOTPT®
K50x18
2 Nm (1.5 lbf ft)
–Mount and tighten screws 8.
Guideline
Remaining screws,
chassis
M5 5 Nm (3.7 lbf ft)
V01342-10
–Mount reflector 9with rubber bushings bk and tension
washers bl on the license plate holder bm.
–Position license plate holder on the license plate support.
–Mount and tighten screws bn.
Guideline
Screw, license
plate holder
M6 10 Nm (7.4 lbf ft)
Loctite®243™
V01343-10
–Remove screws bo.

2 SETUP
6
V01344-10
–Position grab handle and mount and tighten screws bp.
Guideline
Screw, grab
handle
M8x50 25 Nm (18.4 lbf ft)
Loctite®243™
–Remove the protective film.
–Carefully loosen and remove the rear tension belt.
Info
An assistant prevents the motorcycle from falling over.
–Carefully loosen and remove the tension belts around the fork
legs.
The vehicle is released at the front.
–Together with an assistant, take the vehicle off the pallet.
–Remove the passenger seat. ( p. 7)
–Remove the spare key and KEYCODECARD keep in a safe place
for the handover.
Warning
Risk of injury Battery acid and battery gases cause
serious chemical burns.
–Keep batteries out of the reach of children.
–Wear suitable protective clothing and safety
glasses.
–Avoid contact with battery acid and battery gases.
–Keep sparks or open flames away from the battery.
–Only charge batteries in well-ventilated rooms.
–Rinse the affected area immediately with plenty of
water in the event of contact with the skin.
–Rinse eyes with water for at least 15 minutes and
consult a doctor immediately if battery acid and
battery gases get into the eyes.
–Fill the battery.
Info
Read the notes in the battery package.
–Recharge the battery. ( p. 7)
–Stow the tool set between the battery and the front rider's seat.
–Mount the passenger seat. ( p. 7)
–Refuel. ( p. 9)
–Check the headlight setting. ( p. 12)
–Adjust the time and date.
–Set kilometers or miles.
–Prepare the vehicle according to the specifications in the
KTM Dealer.net for handover to the customer.

WORK 3
7
3.1 Removing the passenger seat
V01232-10
–Insert the ignition key in seat lock 1and turn it clockwise.
–Raise the rear of the passenger seat cover, push it toward the
rear, and remove it upward.
–Remove the ignition key from the seat lock.
3.2 Mounting the passenger seat
V01233-10
–Hook catches 1of the passenger seat onto the storage com-
partment, lower the rear, and push forward.
–Press passenger seat downward until it clicks into place.
Warning
Danger of accidents The seat can come loose from the
anchoring if it is not mounted correctly.
–After assembly, check whether the seat is correctly
locked and cannot be pulled up.
–Finally, check that the passenger seat is correctly mounted.
3.3 Recharging the battery
Warning
Risk of injury Battery acid and battery gases cause serious chemical burns.
–Keep batteries out of the reach of children.
–Wear suitable protective clothing and safety glasses.
–Avoid contact with battery acid and battery gases.
–Keep sparks or open flames away from the battery.
–Only charge batteries in well-ventilated rooms.
–Rinse the affected area immediately with plenty of water in the event of contact with the skin.
–Rinse eyes with water for at least 15 minutes and consult a doctor immediately if battery acid and
battery gases get into the eyes.
Note
Environmental hazard Batteries contain environmentally-hazardous materials.
–Do not dispose of batteries as household waste.
–Dispose of batteries at a collection point for used batteries.

3 WORK
8
Note
Environmental hazard Hazardous substances cause environmental damage.
–Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.
Info
Even when there is no load on the battery, it discharges steadily.
The charging level and the method of charging are very important for the service life of the battery.
Rapid recharging with a high charging current shortens the service life of the battery.
If the charging current, charging voltage, and charging time are exceeded, the battery will be destroyed.
If the battery is depleted from starting the vehicle repeatedly, the battery must be charged immediately.
If the battery is left in a discharged state for an extended period, it will become over-discharged and sul-
fated, destroying the battery.
The battery is maintenance-free, i.e., the acid level does not have to be checked.
Preparatory work
–Switch off the ignition by turning the ignition key to the posi-
tion .
–Remove the passenger seat. ( p. 7)
–Disconnect the negative cable of the battery. ( p. 9)
311910-10
Main work
–Connect the battery charger to the battery. Adjust the battery
charger.
EU battery charger XCharge-professional (00029095050)
Alternative 1
US battery charger XCharge-professional
(00029095051)
Alternative 2
UK battery charger XCharge-professional
(00029095052)
Alternative 3
CH battery charger XCharge-professional
(00029095053)
Info
Follow the instructions of the charger and the manual.
–Disconnect the battery charger after charging the battery.
Guideline
The charging current, charging voltage, and charging time
must not be exceeded.
Charge the battery regularly
when the motorcycle is not
in use
3 months
Finishing work
–Connect the negative cable of the battery. ( p. 9)
–Mount the passenger seat. ( p. 7)
–Adjust the time and date.

WORK 3
9
3.4 Disconnecting the negative cable of the battery
Preparatory work
–Switch off the ignition by turning the ignition key to the posi-
tion .
–Remove the passenger seat. ( p. 7)
D05236-10
Main work
–Disconnect negative cable 1of the battery.
3.5 Connecting the negative cable of the battery
D05236-10
Main work
–Connect negative cable 1. Tighten the screw.
Guideline
Screw, battery termi-
nal
M6x12 4.5 Nm
(3.32 lbf ft)
Finishing work
–Mount the passenger seat. ( p. 7)
–Adjust the time and date.
3.6 Refueling
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
–Do not refuel the vehicle in the vicinity of open flames or lit cigarettes.
–Switch off the engine for refueling.
–Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
–If any fuel is spilled, wipe it off immediately.
–Observe the specifications for refueling.

3 WORK
10
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–Avoid skin, eye and clothing contact with fuel.
–Immediately consult a doctor if you swallow fuel.
–Do not inhale fuel vapors.
–In case of skin contact, rinse the affected area with plenty of water.
–Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
–Change your clothing in case of fuel spills on them.
Note
Material damage Inadequate fuel quality causes the fuel filter to quickly become clogged.
In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in
problems with the fuel system.
–Refuel only with clean fuel that meets the specified standards.
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.
V01211-10
–Switch off the engine.
–Open the filler cap. ( p. 10)
–Fill the fuel tank with fuel up to the lower edge Aof the filler
neck.
Total fuel tank
capacity, approx.
14 l
(3.7 US gal)
Super unleaded
(ROZ 95/RON
95/PON 91)
( p. 16)
–Close the filler cap. ( p. 11)
3.7 Opening the filler cap
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
–Do not refuel the vehicle in the vicinity of open flames or lit cigarettes.
–Switch off the engine for refueling.
–Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
–If any fuel is spilled, wipe it off immediately.
–Observe the specifications for refueling.

WORK 3
11
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–Avoid skin, eye and clothing contact with fuel.
–Immediately consult a doctor if you swallow fuel.
–Do not inhale fuel vapors.
–In case of skin contact, rinse the affected area with plenty of water.
–Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
–Change your clothing in case of fuel spills on them.
–Keep fuels correctly in a suitable canister, and out of the reach of children.
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.
V01196-10
–Lift cover 1of the filler cap and insert the ignition key in the
lock.
Note
Danger of damage The ignition key may break if overloaded.
Damaged ignition keys must be replaced.
–Push down on the filler cap to take pressure off the igni-
tion key.
–Turn the ignition key 90° clockwise.
–Open the filler cap.
3.8 Closing the filler cap
V01197-01
–Fold down the filler cap.
–Turn the ignition key 90° clockwise.
–Push down the filler cap and turn the ignition key counter-
clockwise until the lock closes.
Warning
Fire hazard Fuel is highly flammable, toxic and a
health hazard.
–Check the filler cap is locked correctly after clos-
ing.
–Change your clothing in case of fuel spills on them.
–Rinse the affected area immediately with plenty of
water in the event of contact with the skin.
–Remove the ignition key and close the cover.

3 WORK
12
3.9 Checking the headlight setting
400726-10
–Position the vehicle upright on a horizontal surface in front of
a light wall and make a marking at the height of the center of
the low beam headlight.
–Make another mark at a distance Bunder the first marking.
Guideline
Distance B5 cm (2 in)
–Position the vehicle perpendicular to the wall at a distance A
from the wall and switch on the low beam.
Guideline
Distance A5 m (16 ft)
–The rider now mounts the motorcycle with luggage and passen-
ger if applicable.
–Check the headlight setting.
The light-dark boundary must lie exactly on the lower mark-
ing when the motorcycle is ready to operate with the rider
mounted along with any luggage and a passenger if applica-
ble.
» If the light-dark border does not meet specifications:
–Adjust the headlight range. ( p. 12)
3.10 Adjusting the headlight range
Preparatory work
–Check the headlight setting. ( p. 12)
V01212-10
Main work
–Turn adjusting screw 1to adjust the headlight range.
Info
Turn clockwise to increase the headlight range; turn
counterclockwise to reduce the headlight range.
If you have a payload, you may have to correct the
headlight range.
Screw 1also secures the headlight. Ensure the screw
is always screwed in far enough.
400726-11
–Set the headlight to marking B.
Guideline
The light-dark boundary must lie exactly on the lower mark-
ing Bwhen the motorcycle is ready for use with the rider
mounted along with any luggage and a passenger if applica-
ble.

TECHNICAL DATA 4
13
4.1 Chassis tightening torques
Remaining screws, chassis EJOTPT®K45x12 1 Nm (0.7 lbf ft)
Remaining screws, chassis EJOTPT®K50x12 1 Nm (0.7 lbf ft)
Remaining screws, chassis EJOTPT®K50x14 1 Nm (0.7 lbf ft)
Remaining screws, chassis EJOTPT®K50x16 2 Nm (1.5 lbf ft)
Remaining screws, chassis EJOTPT®K50x18 2 Nm (1.5 lbf ft)
Screw, headlight EJOTPT®K50x14 2 Nm (1.5 lbf ft)
Remaining nuts, chassis M4 3 Nm (2.2 lbf ft)
Remaining screws, chassis M4 3 Nm (2.2 lbf ft)
Screw, fixed grip, left M4 2 Nm (1.5 lbf ft)
Clamp, front brake line M5 2 Nm (1.5 lbf ft)
Remaining nuts, chassis M5 5 Nm (3.7 lbf ft)
Remaining screws, chassis M5 5 Nm (3.7 lbf ft)
Screw, air filter box M5 3 Nm (2.2 lbf ft)
Screw, brake fluid reservoir of rear
brake
M5 5 Nm (3.7 lbf ft)
Screw, cable on starter motor M5 3 Nm (2.2 lbf ft)
Screw, combination instrument M5 4 Nm (3 lbf ft)
Screw, combination switch, left M5 2 Nm (1.5 lbf ft)
Screw, combination switch, right M5 5 Nm (3.7 lbf ft)
Screw, engine sprocket cover M5 5 Nm (3.7 lbf ft)
Loctite®243™
Screw, headlight mask M5 5 Nm (3.7 lbf ft)
Loctite®243™
Screw, heat guard M5 5 Nm (3.7 lbf ft)
Loctite®243™
Screw, side stand switch M5 2 Nm (1.5 lbf ft)
Loctite®243™
Screw, support roller M5 4 Nm (3 lbf ft)
Loctite®243™
Screw, throttle grip M5 3.5 Nm (2.58 lbf ft)
Screw, trim M5 3 Nm (2.2 lbf ft)
Nut, hand brake lever M6 Attach torque to nut.
10 Nm (7.4 lbf ft)
Nut, push rod, foot brake lever M6 6 Nm (4.4 lbf ft)
Nut, shift rod M6 6 Nm (4.4 lbf ft)
Nut, shift rod M6LH 6 Nm (4.4 lbf ft)
Remaining nuts, chassis M6 10 Nm (7.4 lbf ft)
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
Screw, angle sensor M6 5 Nm (3.7 lbf ft)
Screw, ball joint of push rod on
foot brake cylinder
M6 10 Nm (7.4 lbf ft)
Loctite®243™
Screw, battery terminal M6x12 4.5 Nm (3.32 lbf ft)
Screw, battery terminal M6x20 4.5 Nm (3.32 lbf ft)
Screw, brake assembly M6 5 Nm (3.7 lbf ft)
Screw, clutch assembly M6 5 Nm (3.7 lbf ft)

4 TECHNICAL DATA
14
Screw, exhaust pipe clamp M6 8 Nm (5.9 lbf ft)
Copper paste
Screw, foot brake cylinder M6 10 Nm (7.4 lbf ft)
Loctite®243™
Screw, foot brake lever stub M6 10 Nm (7.4 lbf ft)
Loctite®243™
Screw, fuel spoiler M6 3 Nm (2.2 lbf ft)
Screw, fuel tank bracket M6 10 Nm (7.4 lbf ft)
Loctite®243™
Screw, ground wire on frame M6 6 Nm (4.4 lbf ft)
Screw, ground wire to starter motor M6 10 Nm (7.4 lbf ft)
Screw, ignition lock (tamper-proof
screw)
M6 22 Nm (16.2 lbf ft)
Loctite®243™
Screw, license plate holder M6 10 Nm (7.4 lbf ft)
Loctite®243™
Screw, lower radiator bracket M6 5 Nm (3.7 lbf ft)
Screw, magnetic holder on side
stand
M6 2 Nm (1.5 lbf ft)
Loctite®243™
Screw, seat lock M6 10 Nm (7.4 lbf ft)
Loctite®222™
Screw, shift lever stub M6 10 Nm (7.4 lbf ft)
Loctite®243™
Screw, shift rod M6 10 Nm (7.4 lbf ft)
Loctite®243™
Screw, shift shaft deflector on shift
shaft
M6 10 Nm (7.4 lbf ft)
Loctite®243™
Screw, wheel speed sensor M6 6 Nm (4.4 lbf ft)
Nut, manifold on cylinder head M8 20 Nm (14.8 lbf ft)
Copper paste
Pin, rear brake caliper M8 22 Nm (16.2 lbf ft)
Remaining nuts, chassis M8 25 Nm (18.4 lbf ft)
Remaining screws, chassis M8 25 Nm (18.4 lbf ft)
Screw, bottom triple clamp M8 12 Nm (8.9 lbf ft)
Screw, cross member M8x18 25 Nm (18.4 lbf ft)
Loctite®243™
Screw, cross member in rear M8x35 25 Nm (18.4 lbf ft)
Loctite®243™
Screw, foot brake lever M8 25 Nm (18.4 lbf ft)
Loctite®2701™
Screw, footrest bracket, rear M8x25 25 Nm (18.4 lbf ft)
Loctite®243™
Screw, footrest bracket, rear M8x40 25 Nm (18.4 lbf ft)
Loctite®243™
Screw, fork stub M8 15 Nm (11.1 lbf ft)
Screw, front brake disc M8 30 Nm (22.1 lbf ft)
Loctite®2701™
Screw, grab handle M8x50 25 Nm (18.4 lbf ft)
Loctite®243™
Screw, handlebar clamp M8 20 Nm (14.8 lbf ft)

TECHNICAL DATA 4
15
Screw, linkage bracket, front
engine fixing arm
M8 25 Nm (18.4 lbf ft)
Loctite®243™
Screw, main silencer fastening M8 15 Nm (11.1 lbf ft)
Screw, passenger seat bracket M8 25 Nm (18.4 lbf ft)
Loctite®243™
Screw, presilencer on frame M8 25 Nm (18.4 lbf ft)
Loctite®243™
Screw, rear brake disc M8 30 Nm (22.1 lbf ft)
Loctite®2701™
Screw, shift lever M8 25 Nm (18.4 lbf ft)
Loctite®2701™
Screw, spring holder on side stand
bracket
M8 15 Nm (11.1 lbf ft)
Loctite®2701™
Screw, steering damper on holder M8 8 Nm (5.9 lbf ft)
Loctite®243™
Screw, steering damper on triple
clamp
M8 8 Nm (5.9 lbf ft)
Loctite®243™
Screw, steering stem M8 20 Nm (14.8 lbf ft)
Loctite®243™
Screw, top triple clamp M8 15 Nm (11.1 lbf ft)
Securing bolt for brake linings M8 10 Nm (7.4 lbf ft)
Engine carrying screw M10 45 Nm (33.2 lbf ft)
Loctite®243™
Remaining nuts, chassis M10 45 Nm (33.2 lbf ft)
Remaining screws, chassis M10 45 Nm (33.2 lbf ft)
Screw, front footrest bracket M10x30 45 Nm (33.2 lbf ft)
Loctite®243™
Screw, front footrest bracket M10x60 45 Nm (33.2 lbf ft)
Loctite®243™
Screw, front footrest bracket M10x80 45 Nm (33.2 lbf ft)
Loctite®243™
Screw, handlebar support M10 45 Nm (33.2 lbf ft)
Loctite®243™
Screw, side stand M10 35 Nm (25.8 lbf ft)
Loctite®243™
Screw, subframe M10 50 Nm (36.9 lbf ft)
Loctite®243™
Banjo bolt, brake line M10x1 25 Nm (18.4 lbf ft)
Screw, front brake caliper M10x1.25 45 Nm (33.2 lbf ft)
Loctite®243™
Screw, bottom shock absorber M12 80 Nm (59 lbf ft)
Loctite®2701™
Screw, swingarm pivot M12 100 Nm (73.8 lbf ft)
Screw, top shock absorber M12 80 Nm (59 lbf ft)
Loctite®2701™
Lambda sensor M18x1.5 50 Nm (36.9 lbf ft)
Swingarm adjusting screw M20LHx1.5 10 Nm (7.4 lbf ft)
Nut, rear wheel spindle M25x1.5 90 Nm (66.4 lbf ft)
Screw, front wheel spindle M25x1.5 45 Nm (33.2 lbf ft)
Screw, steering head M25x1.5 18 Nm (13.3 lbf ft)

5 SUBSTANCES
16
Super unleaded (ROZ 95/RON 95/PON 91)
Standard/classification
–DIN EN 228 (ROZ 95/RON 95/PON 91)
Guideline
–Only use unleaded super fuel that matches or is equivalent to the specified fuel grade.
–Fuel with an ethanol content of up to 10 % (E10 fuel) is safe to use.
Info
Do not use fuel containing methanol (e. g. M15, M85, M100) or more than 10 % ethanol (e. g. E15,
E25, E85, E100).

*3213835en*
3213835en
03/2018
KTM Sportmotorcycle GmbH
5230 Mattighofen/Austria
http://www.ktm.com
Photo: Mitterbauer/KTM