KTM 3214453en Manual

SETUP INSTRUCTIONS 2021

890 DUKE R

Art. no. 3214453en

INTRODUCTION

*3214453en*

3214453en

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.

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 (F9703U3)

890 DUKE R US (F9775U3)

1 MEANS OF REPRESENTATION

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

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

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

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

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

–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

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 operation

with one person.

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

–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

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.

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