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.