KTM 790 DUKE 2018 User manual

OWNER'S MANUAL 2018
790 Duke
Art. no. 3213749en

DEAR KTM CUSTOMER
*3213749en*
3213749en
03/2018
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 properly.
We hope you enjoy riding this motorcycle!
Enter the serial numbers of your vehicle below.
Chassis 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 going to print. However,
minor differences due to further developments 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, 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

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)
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)

TABLE OF CONTENTS
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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 and implied warranty.... 17
3.2 Operating and 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 Chassis number ............................... 24
5.2 Type label ....................................... 24
5.3 Key number..................................... 25
5.4 Engine number ................................ 25
5.5 Fork part number ............................. 26
5.6 Shock absorber article number .......... 26
5.7 Steering damper article number ........ 27
6 CONTROLS................................................. 28
6.1 Clutch lever..................................... 28
6.2 Hand brake lever.............................. 28
6.3 Throttle grip .................................... 29
6.4 Switches on the left side of the
handlebar........................................ 29
6.4.1 Combination switch...................... 29
6.4.2 Light switch ................................ 30
6.4.3 Menu switch................................ 31
6.4.4 Turn signal switch........................ 31
6.4.5 Horn button ................................ 32

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6.5 Switches on the right side of the
handlebar........................................ 33
6.5.1 Emergency OFF switch/electric
starter button .............................. 33
6.6 Ignition/steering lock........................ 34
6.7 Opening the filler cap....................... 35
6.8 Closing the filler cap ........................ 37
6.9 Seat lock......................................... 38
6.10 Tool set........................................... 38
6.11 Grab handle .................................... 39
6.12 Passenger foot pegs ......................... 39
6.13 Shift lever ....................................... 40
6.14 Foot brake lever ............................... 41
6.15 Side stand....................................... 41
7 COMBINATION INSTRUMENT ..................... 43
7.1 Combination instrument ................... 43
7.2 Activation and test ........................... 43
7.3 Day-Night mode............................... 45
7.4 Warning notes.................................. 46
7.5 Indicator lamps................................ 48
7.6 Display ........................................... 52
7.7 TRACK display................................. 54
7.8 Shift warning light ........................... 55
7.9 Fuel level display ............................. 56
7.10 Time............................................... 57
7.11 Coolant temperature indicator ........... 57
7.12 Trip distance counter ....................... 58
7.13 Menu.............................................. 59
7.13.1 Favorites ..................................... 59
7.13.2 Trip 1 ......................................... 60
7.13.3 Trip 2 ......................................... 61
7.13.4 General Info ................................ 62
7.13.5 Settings ...................................... 63
7.13.6 Bluetooth®(optional).................... 63
7.13.7 Distance ..................................... 64
7.13.8 Temp.......................................... 65
7.13.9 Pressure ..................................... 66
7.13.10 Fuel Cons.................................... 67
7.13.11 Language .................................... 68
7.13.12 Clock/Date .................................. 68
7.13.13 DRL ........................................... 69
7.13.14 TPMS warning ............................. 71
7.13.15 Quick Selector 1.......................... 72
7.13.16 Quick Selector 2.......................... 73
7.13.17 Set Favorites ............................... 74
7.13.18 Service ....................................... 75
7.13.19 Extra functions ............................ 75
7.13.20 Warnings..................................... 76
7.13.21 Ride Mode .................................. 77
7.13.22 Track.......................................... 78
7.13.23 Anti‑wheelie mode ....................... 79

TABLE OF CONTENTS
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7.13.24 Launch control ............................ 80
7.13.25 MTC + MSR ................................ 80
7.13.26 ABS............................................ 81
7.13.27 ABS Mode................................... 82
7.13.28 Quick Shift +............................... 83
7.13.29 Shift Light .................................. 84
7.13.30 KTM MY RIDE (optional) .............. 85
7.13.31 Pairing (optional) ......................... 86
7.13.32 Audio player (optional) ................. 88
7.13.33 Telephony (optional) .................... 90
8 ERGONOMICS ............................................ 91
8.1 Handlebar position........................... 91
8.2 Adjusting the handlebar position .... 91
8.3 Adjusting the basic position of the
clutch lever ..................................... 93
8.4 Adjusting the basic position of the
hand brake lever .............................. 94
8.5 Adjusting the basic position of the
foot brake lever ............................ 95
8.6 Checking the basic position of the
shift lever........................................ 97
8.7 Adjusting the basic position of the
shift lever .................................... 98
9 PREPARING FOR USE............................... 100
9.1 Advice on preparing for first use ...... 100
9.2 Running in the engine .................... 102
9.3 Loading the vehicle........................ 102
10 RIDING INSTRUCTIONS............................ 105
10.1 Checks and maintenance measures
when preparing for use ................... 105
10.2 Starting the vehicle ........................ 106
10.3 Starting off.................................... 107
10.4 Launch‑Control .............................. 108
10.5 Starting off with launch control ....... 108
10.6 Quickshifter +................................ 110
10.7 Shifting, riding .............................. 111
10.8 Engine traction torque
control (MSR)................................. 117
10.9 Applying the brakes........................ 118
10.10 Stopping, parking........................... 120
10.11 Transporting .................................. 122
10.12 Refueling ...................................... 123
11 SERVICE SCHEDULE ................................ 125
11.1 Additional information.................... 125
11.2 Required work ............................... 125
11.3 Recommended work ....................... 128

TABLE OF CONTENTS
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12 TUNING THE CHASSIS ............................. 129
12.1 Adjusting the spring preload of the
shock absorber ........................... 129
13 SERVICE WORK ON THE CHASSIS............. 130
13.1 Raising the motorcycle with the
rear lifting gear .............................. 130
13.2 Removing the rear of the
motorcycle from the lifting gear....... 130
13.3 Lifting the motorcycle with the
front lifting gear............................. 131
13.4 Taking the motorcycle off the front
lifting gear .................................... 132
13.5 Cleaning the dust boots of the fork
legs ........................................... 133
13.6 Removing the passenger seat .......... 135
13.7 Mounting the passenger seat........... 136
13.8 Removing the front rider's seat........ 137
13.9 Mounting the front rider's seat......... 138
13.10 Checking the chain for dirt.............. 139
13.11 Cleaning the chain ......................... 140
13.12 Checking the chain tension ............. 142
13.13 Adjusting the chain tension............. 143
13.14 Checking the chain, rear sprocket,
engine sprocket, and chain guide .... 145
14 BRAKE SYSTEM ....................................... 149
14.1 Antilock brake system (ABS) ........... 149
14.2 Checking the brake discs ................ 151
14.3 Checking the front brake fluid
level ............................................. 153
14.4 Adding front brake fluid .............. 154
14.5 Checking the front brake linings ...... 156
14.6 Checking the free travel of the foot
brake lever .................................... 158
14.7 Checking rear brake fluid level ........ 159
14.8 Adding rear brake fluid ............... 160
14.9 Checking the rear brake linings ....... 162
15 WHEELS, TIRES ....................................... 164
15.1 Removing the front wheel ............ 164
15.2 Installing the front wheel ............ 166
15.3 Removing the rear wheel ............. 171
15.4 Installing the rear wheel .............. 174
15.5 Checking the rear hub rubber
dampers .................................... 177
15.6 Checking the tire condition ............. 179
15.7 Checking the tire pressure .............. 181
16 ELECTRICAL SYSTEM ............................... 183
16.1 Daytime running light (DRL)............. 183

TABLE OF CONTENTS
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16.2 Removing the battery .................. 184
16.3 Installing the battery ................... 187
16.4 Recharging the battery ................ 189
16.5 Changing the main fuse.................. 192
16.6 Changing the ABS fuses ................. 195
16.7 Changing the fuses of individual
power consumers ........................... 197
16.8 Loosening the headlight mask with
the headlight ................................. 200
16.9 Mounting the headlight mask with
the headlight ................................. 201
16.10 Removing the cover of the
headlight mask rack ....................... 202
16.11 Installing the cover of the headlight
mask rack ..................................... 204
16.12 Checking the headlight setting ........ 206
16.13 Adjusting the headlight range.......... 207
16.14 Diagnostics connector .................... 208
16.15 Front ACC1 and ACC2 .................... 208
16.16 ACC1 and ACC2 rear ...................... 209
17 COOLING SYSTEM .................................... 210
17.1 Cooling system .............................. 210
17.2 Checking the antifreeze and
coolant level.................................. 211
17.3 Checking the coolant level in the
compensating tank......................... 213
17.4 Draining the coolant ................... 215
17.5 Filling/bleeding the cooling
system ...................................... 217
17.6 Changing the coolant...................... 219
18 TUNING THE ENGINE............................... 223
18.1 Ride Mode .................................... 223
18.2 Motorcycle traction control (MTC).... 224
18.3 Slip adjustment ............................. 225
18.4 Throttle response ........................... 225
19 SERVICE WORK ON THE ENGINE .............. 227
19.1 Checking the engine oil level........... 227
19.2 Changing the engine oil and oil
filter, cleaning the oil screens ...... 228
19.3 Adding engine oil........................... 232
19.4 Checking the free travel of the
clutch lever ................................... 234
19.5 Setting the free travel of the clutch
lever .......................................... 235
20 CLEANING, CARE ..................................... 236
20.1 Cleaning the motorcycle ................. 236

TABLE OF CONTENTS
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20.2 Checks and maintenance steps for
winter operation............................. 239
21 STORAGE................................................. 241
21.1 Storage ......................................... 241
21.2 Preparing for use after storage......... 243
22 TROUBLESHOOTING ................................ 244
23 TECHNICAL DATA..................................... 248
23.1 engine .......................................... 248
23.2 Engine tightening torques ............... 250
23.3 Capacities ..................................... 255
23.3.1 Engine oil ................................. 255
23.3.2 Coolant ..................................... 255
23.3.3 Fuel ......................................... 255
23.4 Chassis ......................................... 256
23.5 Electrical system............................ 257
23.6 Tires............................................. 258
23.7 Fork.............................................. 258
23.8 Shock absorber.............................. 259
23.9 Chassis tightening torques .............. 260
24 DECLARATIONS OF CONFORMITY ............. 267
24.1 Declarations of conformity .............. 267
25 SUBSTANCES .......................................... 271
26 AUXILIARY SUBSTANCES ......................... 274
27 STANDARDS ............................................ 276
28 INDEX OF SPECIAL TERMS ....................... 277
29 LIST OF ABBREVIATIONS.......................... 278
30 LIST OF SYMBOLS.................................... 279
30.1 Red symbols.................................. 279
30.2 Yellow and orange symbols.............. 279
30.3 Green and blue symbols.................. 280
INDEX ............................................................. 281

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
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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.
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.

SAFETY ADVICE 2
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2.1 Use definition –intended use
The vehicle is designed and constructed to withstand the usual demands of regular traffic and use on race
courses.
This vehicle is not suitable for offroad use.
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.
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 maintenance, 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 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 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 an effective exhaust extraction system 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
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In the interest of your own safety, KTM recommends that you only operate the vehicle while wearing protective
clothing.
2.8 Work rules
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, seals,
sealing rings, O-rings, pins, and lock washers).
In the case of certain screws, a thread locker (e.g. Loctite®) is required. Apply according to the manufacturer's
instructions.
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.
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 SAFETY ADVICE
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2.10 Owner's Manual
It is important that you read this Owner's Manual carefully and completely before making your first trip. The Own-
er's Manual contains useful information and many tips on how to operate, handle, and maintain your motorcycle.
Only then will you find out how to customize the vehicle ideally for your own use and how you can protect yourself
from injury.
Keep the Owner's Manual in an accessible place to enable you to refer to it as needed.
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 and must be handed over to the new owner if the
vehicle is sold.
The Owner's Manual is also available for download from your authorized KTM dealer and on the KTM website.
International KTM Website: http://www.ktm.com

IMPORTANT NOTES 3
17
3.1 Manufacturer and 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 KTM Dealer.net, otherwise any warranty coverage will
become void. Damage or secondary damage caused by tampering with and/or conversions on the vehicle are not
covered by the warranty.
Additional information on the manufacturer or implied warranty and the procedures involved can be found in the
Service & Warranty Booklet.
3.2 Operating and 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 operating 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.

3 IMPORTANT NOTES
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The current KTM PowerParts for your vehicle can be found on the KTM website.
International KTM Website: http://www.ktm.com
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. Incorrect adjustment and
tuning of the engine and chassis can lead to damage and breakage of components.
Use of the vehicle under difficult conditions, such in rain, high heat or with a heavy load, can lead to consider-
ably more rapid wear of components such as the drive train, brake system, or suspension components. For this
reason, it may be necessary to inspect or replace parts before the next scheduled 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.
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.