KTM 890 DUKE R 2022 Manual

SETUP INSTRUCTIONS 2022
890 DUKE R
Art. no. 3214571en

INTRODUCTION
*3214571en*
3214571en
10/2021
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:
890 DUKE R EU (F9703V3)
890 DUKE R US (F9775V3)
890 DUKE R ASEAN (F9788V4)
890 DUKE R CN (F9787V4)

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.
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.
F03432-10
–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.
F03433-10
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. 12)

SETUP 2
5
V02051-10
–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)
V02052-10
–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.
F03434-01
–Mount and tighten the rear mirror on both sides.

2 SETUP
6
V02053-10
–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)
V02054-10
(EU/ASEAN/CN)
–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 sup-
port.
–Mount and tighten screws bn.
Guideline
Screw, license plate
holder
M5 3 Nm (2.2 lbf ft)
F03435-10
Condition
Operation with a passenger
Info
The vehicle has been set up in the factory for one-
person operation.
The components for one-person operation and for oper-
ation with a passenger are included in the scope of
supply.
Assemble the vehicle according to the customer's
requirements and point out legal regulations, e.g., entry
in the vehicle documents, if necessary.

SETUP 2
7
–Insert the ignition key in seat lock bo and turn it clock-
wise.
–Raise the rear of the seat cover, push it toward the rear,
and lift it off.
V02056-10
–Hook holding lugs bp of the passenger seat onto the stor-
age compartment, lower the rear and push forward.
–Press the 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 cor-
rectly locked and cannot be pulled up.
–Finally, check that the passenger seat is correctly
mounted.
V02057-10
–Remove screws bq.
V02058-10
–Position grab handle and mount and tighten screws br.
Guideline
Screw, grab
handle
M8x50 25 Nm (18.4 lbf ft)
Loctite®243™

2 SETUP
8
V02060-10
–Remove screws with washers bs.
Info
Retain the washer for the handover.
–Position the left footrest bracket with the passenger
footrest.
–Mount screw bt, but do not tighten yet.
Guideline
Screw, footrest
bracket, rear
M8x25 25 Nm (18.4 lbf ft)
Loctite®243™
–Mount screw ck, but do not tighten yet.
Guideline
Screw, footrest
bracket, rear
M8x40 25 Nm (18.4 lbf ft)
Loctite®243™
–Tighten all screws of the left footrest bracket with the pas-
senger footrest.
Guideline
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™
V02061-10
–Remove screw cl with the special washer.
–Remove screws cm.

SETUP 2
9
V02063-10
–Loosen clamp screw cn by several rotations.
–Lower the main silencer.
–Remove the main silencer holder.
Info
Retain the screws for the handover.
V02064-10
–Remove bushings co from the main silencer holder and
mount them on the right footrest bracket.
Info
Retain main silencer holder for the handover.
V02066-10
–Position the right footrest bracket with the passenger
footrest.
–Mount screw cp, but do not tighten yet.
Guideline
Screw, footrest
bracket, rear
M8x40 25 Nm (18.4 lbf ft)
Loctite®243™
–Mount screw cq, but do not tighten yet.
Guideline
Screw, footrest
bracket, rear
M8x25 25 Nm (18.4 lbf ft)
Loctite®243™
–Mount screw cl with the special washer, but do not
tighten yet.
Guideline
Screw, main
silencer fastening
M8 15 Nm
(11.1 lbf ft)
–Shake the main silencer slightly to avoid strain.
–Position the main silencer clamp and tighten screw cn.
Guideline
Screw, main
silencer clamp
M6 8 Nm (5.9 lbf ft)

2 SETUP
10
–Tighten all the screws of the right footrest bracket with the
passenger footrest.
Guideline
Screw, footrest
bracket, rear
M8x40 25 Nm (18.4 lbf ft)
Loctite®243™
Screw, footrest
bracket, rear
M8x25 25 Nm (18.4 lbf ft)
Loctite®243™
Remaining
screws, chassis
M8 25 Nm (18.4 lbf ft)
–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. 12)
–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. 13)
Guideline
The 12-V battery must be fully charged before it is handed
over to the customer.

SETUP 2
11
Info
The first charging process may take longer with a new
12-V battery.
–Stow the tool set between the 12-V battery and the front rider's
seat.
–Mount the passenger seat. ( p. 13)
–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.
–Check the headlight setting. ( p. 17)
–Refuel. ( p. 15)
–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.

3 WORK
12
3.1 Adjusting the handlebar position
Warning
Danger of accidents A repaired handlebar poses a safety risk.
If the handlebar is bent or straightened, the material becomes fatigued. The handlebar may break as a
result.
–Change the handlebar if the handlebar is damaged or bent.
V01210-10
–Remove screws 1. Take off the handlebar clamps 2. Posi-
tion the handlebar so that screws 3are accessible.
Info
Cover the components to protect them against damage.
Do not kink the cables and lines.
–Remove screws 3. Take off handlebar supports 4.
–Move the handlebar supports into the desired position A
or B. Mount and tighten screws 3.
Guideline
Mount the left and right handlebar supports in the same
position.
Screw, handle-
bar support
M10 45 Nm (33.2 lbf ft)
Loctite®243™
–Position the handlebar.
Info
Make sure the cables and wiring are positioned cor-
rectly.
–Position the handlebar clamp. Mount screws 1and tighten
evenly.
Guideline
Screw, handlebar
clamp
M8 20 Nm (14.8 lbf ft)
3.2 Removing the passenger seat
K01359-10
–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.

WORK 3
13
Info
The vehicle has been set up in the factory for one-
person operation. Only an authorized KTM workshop
may carry out the conversion.
The components for one-person operation and for oper-
ation with a passenger are included in the scope of
supply.
Always ensure that the legal requirements are observed,
e.g., entry in the vehicle documents if applicable.
3.3 Mounting the passenger seat
K01360-10
–Hook holding lugs 1of the passenger seat onto the storage
compartment, lower the rear and push forward.
–Press the 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.
Info
The vehicle has been set up in the factory for one-
person operation. Only an authorized KTM workshop
may carry out the conversion.
The components for one-person operation and for oper-
ation with a passenger are included in the scope of
supply.
Always ensure that the legal requirements are observed,
e.g., entry in the vehicle documents if applicable.
3.4 Charging the 12-V battery
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.
Note
Danger of damage An incorrectly selected charging mode will damage the 12-V battery.
–Always select a charging mode that is compatible with the type of battery.

3 WORK
14
Note
Environmental hazard 12 V batteries contain environmentally hazardous materials.
–Do not dispose of 12 V batteries as household waste.
–Dispose of 12 V batteries at a collection point for used batteries.
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 12-V battery, it discharges steadily each day.
The charging level and the method of charging are very important for the service life of the 12-V battery.
Rapid recharging with a high charging current shortens the service life of the battery.
If the charging current, charging voltage, or charging time is exceeded, electrolyte escapes through the
safety valves. This reduces the capacity of the 12-V battery.
If the 12-V battery is depleted by repeated starting, the 12-V battery must be charged immediately.
If the 12-V battery is left in a discharged state for an extended period, it will become deeply discharged
and sulfating occurs, destroying the battery.
The 12-V battery is maintenance-free. The acid level does not have to be checked.
Preparatory work
–Remove the passenger seat. ( p. 12)
–Disconnect the negative cable of the 12-V battery. ( p. 15)
311910-10
Main work
–Connect a battery charger to the 12-V battery. Adjust the bat-
tery charger.
EU battery charger XCharge‑professional (00029095050)
Alternative 1
US battery charger XCharge‑professional
(00029095051)
Alternative 2
UK battery charger XCharge‑professional
(00029095052)
Info
Follow the instructions of the charger and the manual.
–Disconnect the battery charger after charging the 12-V battery.
Guideline
The charging current, charging voltage, and charging time
must not be exceeded.
Recharge the 12-V battery
regularly when the motorcy-
cle is not being used
3 months
Finishing work
–Connect the negative cable of the 12-V battery. ( p. 15)
–Mount the passenger seat. ( p. 13)
–Set the time and date.

WORK 3
15
3.5 Disconnecting the negative cable of the 12-V battery
Preparatory work
–Remove the passenger seat. ( p. 12)
D05236-10
Main work
–Disconnect negative cable 1of the 12-V battery.
3.6 Connecting the negative cable of the 12-V 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. 13)
–Set the time and date.
3.7 Refueling
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
–Do not fuel 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.
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.

3 WORK
16
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.
V01463-10
–Switch off the engine.
–Open fuel tank filler cap. ( p. 16)
–Fill the fuel tank with fuel up to the lower edge Aof the filler
neck.
Fuel tank capacity,
approx.
14 l
(3.7 US gal)
Super unleaded
(ROZ 95)
( p. 23)
–Close the fuel tank filler cap. ( p. 17)
3.8 Opening fuel tank 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 fuel 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.
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.

WORK 3
17
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 fuel tank filler cap and insert the ignition
key into the lock.
Note
Danger of damage The ignition key may break if overloaded.
Damaged ignition keys must be replaced.
–Push down on the fuel tank filler cap to take pressure off
the ignition key.
–Turn the ignition key 90° clockwise.
–Lift the fuel tank filler cap.
3.9 Closing the fuel tank filler cap
V01197-01
–Fold down the fuel tank filler cap.
–Turn the ignition key 90° clockwise.
–Push down the fuel tank filler cap and turn the ignition key
counterclockwise until the lock closes.
Warning
Fire hazard Fuel is highly flammable, toxic and a
health hazard.
–Check that the fuel tank filler cap is locked cor-
rectly after closing.
–Change your clothing if 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.
3.10 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.

3 WORK
18
The light-dark boundary must be exactly on the lower mark-
ing when the motorcycle is ready to be operated with the
rider mounted along with any luggage and a passenger if
applicable.
» If the boundary between light and dark does not meet
specifications:
–Adjust the headlight range. ( p. 18)
3.11 Adjusting the headlight range
Preparatory work
–Check the headlight setting. ( p. 17)
F02770-10
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 lower mark-
ing Bwhen the motorcycle is ready to operate with the
rider mounted along with any luggage and a passenger, if
applicable.