KTM RC 390 2016 Manual

SETUP INSTRUCTIONS 2016

RC 390

Art. no. 3213463en

INTRODUCTION

*3213463en*

3213463en

07/2017

INTRODUCTION

The work described in these setup instructions must be performed 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 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.

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:

RC 390 EU (F5303P1)

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.

2 SETUP

2.1 Unpacking and setting up the vehicle

S00827-01

–Remove the straps and box.

S00823-01

–Remove the adhesive tape in the upper area of the motorcycle.

S00824-01

–Roll down the film at the sides.

Info

To avoid damaging the motorcycle during the setup,

leave the protective film on the vehicle until you have

finished.

–Unpack the separate enclosure and check its contents on the

basis of the enclosure list.

–Check the vehicle for transport damage.

S00825-10

–Position damping rubber 1on both sides.

–Connect the plug-in connector 2of the mirrors on both

sides.

–Position mirrors on both sides. Mount and tighten the screws.

–Position all controls in their exact positions on the handlebar.

Tighten all screws.

S00826-01

–Mount the reflector.

–Remove the protective plastic.

–Carefully loosen and remove the tensioning belt over the

swingarm.

Info

An assistant prevents the motorcycle from falling over.

–Carefully loosen and remove the tensioning belts around the

lower triple clamp.

The vehicle is released at the front.

–Take the vehicle off the pallet.

2 SETUP

Warning

Risk of injury Battery acid and battery gases cause

serious chemical burns.

–Keep 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 battery.

–Only charge 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 battery.

Info

Read the notes in the battery package.

–Recharge the battery. ( p. 8)

–Install the battery. ( p. 9)

–Refuel. ( p. 11)

–Prepare the vehicle according to the specifications in the

KTM Dealer.net for handover to the customer.

–Set kilometers or miles. ( p. 12)

–Set the clock. ( p. 12)

3 WORK

3.1 Removing the front rider's seat

M00454-10

–Insert the ignition key in seat lock 1and turn it clockwise.

–Raise the rear of the front rider's seat, pull it toward the rear,

and remove it upward.

–Remove the ignition key from the seat lock.

3.2 Mounting the front rider's seat

H01084-10

–Attach recesses 1on the front rider's seat to the fuel tank,

push the front rider's seat forward, and lower at the rear.

The pin 2locks audibly in place.

–Check that the front rider's seat is correctly mounted.

3.3 Removing the passenger seat

Preparatory work

–Remove the front rider's seat. ( p. 5)

L02191-10

Main work

–Remove screw 1with the washer.

–Lift and take off the passenger seat.

3.4 Mounting the passenger seat

K00021-10

Main work

–Attach hook 1into bracket 2.

–Lower the passenger seat and push back.

3 WORK

L02191-11

–Mount and tighten screw 3with the washer.

Guideline

Screw, passenger

seat

M6 7 Nm (5.2 lbf ft)

Warning

Danger of accidents The passenger seat can come

loose from the anchoring if it is not mounted correctly.

–After mounting the passenger seat, check that it is

locked correctly by pulling up.

–Check that the passenger seat is correctly mounted.

Finishing work

–Mount the front rider's seat. ( p. 5)

3.5 Removing the battery cover

Preparatory work

–Remove the front rider's seat. ( p. 5)

V00150-10

Main work

–Pull loop 1toward the rear.

–Pull battery cover 2forward and remove toward the top.

3.6 Mounting the battery cover

M00451-10

Main work

–Position battery cover 1and pull toward the rear.

The battery cover engages with an audible click.

–Check the battery cover is seated correctly.

3 WORK

Finishing work

–Mount the front rider's seat. ( p. 5)

3.7 Removing the battery

Warning

Risk of injury Battery acid and battery gases cause serious chemical burns.

–Keep 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 battery.

–Only charge 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.

Preparatory work

–Switch off the ignition by turning the ignition key to the posi-

tion .

–Remove the front rider's seat. ( p. 5)

–Remove the battery cover. ( p. 6)

L02156-10

Main work

–Pull back negative terminal cover 1.

–Disconnect negative cable 2from the battery.

L02157-11

–Pull back positive terminal cover 3.

–Disconnect positive cable 4from the battery.

–Detach rubber band 5.

–Pull the battery up and out of the battery holder.

Info

Never operate the motorcycle with a discharged battery

or without a battery. In both cases, electrical compo-

nents and safety devices can be damaged. In this case

the vehicle is no longer roadworthy.

3 WORK

3.8 Disconnecting the negative cable of the battery

Preparatory work

–Remove the front rider's seat. ( p. 5)

–Remove the battery cover. ( p. 6)

L02156-10

Main work

–Pull back the negative terminal cover 1.

–Disconnect the negative cable 2of the battery.

3.9 Recharging the battery

Warning

Risk of injury Battery acid and battery gases cause serious chemical burns.

–Keep 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 battery.

–Only charge 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.

Warning

Environmental hazard Batteries contain environmentally-hazardous materials.

–Do not dispose of batteries as household waste.

–Dispose of batteries at a collection point for used batteries.

Warning

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 battery, it discharges steadily.

The charging level and the method of charging are very important for the service life of the battery.

Rapid recharging with a high charging current shortens the service life of the battery.

If the charging current, charging voltage, and charging time are exceeded, the battery will be destroyed.

If the battery is depleted from starting the vehicle repeatedly, the battery must be charged immediately.

If the battery is left in a discharged state for an extended period, it will become over-discharged and sul-

fated, destroying the battery.

The battery is maintenance-free, i.e., the acid level does not have to be checked.

Preparatory work

–Remove the front rider's seat. ( p. 5)

–Remove the battery cover. ( p. 6)

–Disconnect the negative cable of the battery. ( p. 8)

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