KTM 790 Duke 2020 Manual

SETUP INSTRUCTIONS 2020
790 Duke
Art. no. 3214167en

INTRODUCTION
*3214167en*
3214167en
03/2021
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 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
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: TÜV Management Service
KTM Sportmotorcycle GmbH
Stallhofnerstraße 3
5230 Mattighofen, Austria
This document is valid for the following models:
790 Duke EU (F9603T5, F9603T6)
790 Duke L EU (F9603T8, F9603T9)
790 Duke US (F9675T5, F9675T6)
790 Duke ASEAN (F9688TA, F9688TB)
790 Duke CN (F9687T5, F9687T6)
790 Duke CKD CN (F9687TD, F9687TE)
790 Duke PH (F9682T5)
790 Duke IN (F9691TD, F9691TE)

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 Transport mode
H02713-01
This vehicle was blocked for transport in the software.
To operate the vehicle, the vehicle electronics must be enabled.
This process is conducted during initial setup in KTM Dealer.net.
Enabling ensures that the initial setup in KTM Dealer.net is docu-
mented.
Enabling can be performed either temporarily, e.g. for a test ride,
or permanently for vehicle handover.
Info
Make sure that the vehicle is permanently enabled before
handing it over to the customer.
2.2 Diagnostics connector
H02681-10
Diagnostics connector 1is located under the passenger seat.
(CN)
A diagnosis adapter has been connected in the factory for con-
nection with diagnosis interface which applies to all manufac-
turers.
Info
Remove the diagnosis adapter to use the KTM diagno-
sis tool.
Following completion of the diagnostics, plug the diag-
nostics adapter back in.
2.3 Unpacking and setting up the vehicle
V01334-10
–Remove the straps and the box.
V01335-01
–Remove the adhesive tape in the upper area of the motorcycle.
–Roll down the film at the sides.
Guideline
To avoid damaging the vehicle while setting it up, do
not remove the protective film on each component until
installing the component, and leave it on the vehicle until
work has been completed.
–Remove the separate enclosure and unpack it. Check that the
scope of supply is complete using the enclosed packing list.
Info
The procedure for missing components is described in
the Customer Service Manual.
–Check the vehicle for transport damage.

2 SETUP
4
Info
The procedure in the event of transport damage is
described in the Customer Service Manual.
V01336-10
–Remove cable tie(s) 1. Place the handlebar at the front.
–Remove the clutch and the 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.
–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.
–Check the handlebar position.
» If the handlebar position is not adjusted as required by the
customer:
–Adjust the handlebar position. ( p. 9)

SETUP 2
5
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 the 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 the brake assembly on the handlebar.
–Position brake assembly clamp on the handlebar.
The holding lug of the clamp 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 straps supplied.
V01340-01
–Mount and tighten the rear mirror on both sides.

2 SETUP
6
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 the license plate bracket 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.

SETUP 2
7
V01344-10
–Position grab handle and mount and tighten screws bp.
Guideline
Screw, grab
handle
M8x50 25 Nm (18.4 lbf ft)
Loctite®243™
–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. 9)
–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 12 V 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 12 V
battery.
–Only charge 12 V 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 12 V battery.
Info
Read the notes in the 12 V battery accessory pack.
–Charge the 12-V battery. ( p. 10)
–Stow the tool set between the 12-V battery and the front rider's
seat.
–Mount the passenger seat. ( p. 10)
–Unpack and mount the KTM PowerParts included in the deliv-
ery (optional).
Info
Read the accompanying KTM PowerParts fitting instruc-
tions.
–Attach the stickers included in the scope of supply (optional).
–Set time and date.
–Set kilometers or miles.

2 SETUP
8
–Check the headlight setting. ( p. 14)
–Refuel. ( p. 12)
–Position all controls in their exact positions on the handlebar.
Tighten all screws.
–Remove the remaining film, padding, the corrugated card-
board, and the other packaging material.
–Prepare the vehicle according to the specifications in
KTM Dealer.net for handover to the customer.
Info
Transport mode must be deactivated to be able to start
the motorcycle.