KTM 390 Duke 2013–2014 Service & Repair Manual (P/N 3206167en)

KTM-Sportmotorcycle AG’s Repair Manual 2013, P/N 3206167en, covers the 2013 390 Duke EU, AUS, and MAL versions and the 390 Duke 2014 COL. This is the English-language 07/2013 edition.

Searchable Text, Bookmarks, and Wiring Detail

Search and diagram navigation: PDF text search is available throughout the manual, including the wiring diagrams. Embedded bookmarks provide access to chapters, individual procedures, and the index. Small wiring labels are best read with zoom; rotating the sideways diagrams also makes them easier to follow.

Supplied as one printable PDF with 204 pages, including the front and back covers and two blank or page-number-only pages.

Engine Overhaul, Chassis Service, and Electrical Tests

The following selected repair highlights outline the main workshop coverage. Other topics include headlight adjustment and resetting the service interval display.

• Engine repair: Step-by-step engine removal, disassembly, inspection, and reassembly procedures, with cylinder-head work, valve-clearance adjustment, and timing-chain installation.

• Clutch and transmission: Clutch inspection, shift-mechanism checks, and mainshaft and countershaft disassembly, component inspection, and reassembly.

• Suspension and steering: Fork overhaul, seal and bushing replacement, steering-head bearing adjustment, shock removal, spring replacement, and preload settings.

• Brakes and wheels: Brake-pad and disc replacement, pressure-assisted brake-fluid changes, wheel service, chain inspection and adjustment, and rear-hub damper checks.

• Fuel injection: Fuel-tank removal, filter and pump replacement, and fuel-pressure diagnosis using the KTM diagnostics tool and fuel-pump relay actuator test.

• Cooling and lubrication: Cooling-system filling and bleeding, water-pump seal replacement, oil-pump inspection, engine oil-pressure testing, and oil-filter and screen service.

• Electrical diagnosis: Charging-voltage checks, stator resistance and ground-fault tests, starter-drive inspection, and wiring diagrams with component legends and cable-color references.

The manual assumes a fully trained mechanic with access to the specified KTM special tools and workshop equipment; it does not teach general workshop methods.

Internal Engine, Clutch, and Transmission Work

The engine section covers the 375 cm³ water-cooled single-cylinder engine with its DOHC four-valve arrangement, mechanically operated wet clutch, and electronically controlled fuel injection.

Measurement and inspection: Piston and cylinder measurements, piston-ring end gaps, connecting-rod bearing radial clearance, crankpin classifications, and camshaft-bearing clearance support decisions about component reuse or replacement. Balancer-shaft bearing service, oil-pump clearances, and oil-pressure regulator inspection are also documented.

Mainshaft and countershaft procedures include individual gear, collar-bushing, lock-ring, sliding-gear, and shift-dog inspection rather than treating the gearbox as a sealed assembly. Clutch wear dimensions and shift-shaft play specifications accompany the relevant checks.

Timing and assembly: Camshaft alignment, timing-chain guides and tensioner installation, and shim-based valve-clearance adjustment are covered. Starter-drive inspection extends to the torque limiter, idler gear, and freewheel.

The crankcase instructions warn against wedging the case halves apart or drawing them together with the case screws, both of which risk case damage. The M16LHx1.5 inner clutch hub nut and the rotor puller are identified as left-hand threaded.

Forks, Steering, Brakes, and Final Drive

Fork procedures extend through teardown, tube inspection, seal and bushing assembly, and oil filling. Lower triple-clamp and steering-head bearing work distinguishes installation with a new bearing from reusing an existing bearing.

Rear suspension coverage includes shock removal, spring removal and installation, and preload adjustment. Wheel procedures address bearing condition, brake-disc mounting, and rear-hub rubber-damper inspection.

Front and rear brake-fluid replacement procedures use specified pressure-bleeding equipment. Chain checks cover wear, sprocket condition, sliding-guard wear, and wheel alignment as well as tension.

Fuel Delivery, Cooling, and Oil Circulation

Fuel-pressure diagnosis links the pump-relay actuator test to checks of tank ventilation and fuel-line flow before filter or pump replacement. This gives the mechanic a documented way to investigate low pressure rather than relying on the pressure specification alone.

The fuel-tank-cover section warns that unsupported fastener removal can distort the tank and prevent the screw holes from aligning. It includes a dimensioned drawing for temporary support screws.

Cooling coverage includes draining, filling, bleeding, antifreeze checks, and water-pump shaft-seal replacement. The labeled Oil circuit identifies the suction and force pumps, filter, pressure regulator, piston-cooling jet, and cam-follower lubrication feed.

Electrical References and Workshop Equipment

The nine wiring-diagram sheets are accompanied by component legends across an 18-page section. They identify the EFI and vehicle control units, diagnostics connector, fuel-pump and radiator-fan relays, engine-management sensors, lighting controls, ABS control unit, and front and rear wheel-speed sensors.

Further illustrated references include Checking the clutch, Checking the shift mechanism, Checking the timing assembly, and Checking the electric starter drive. Charging diagnosis includes regulator and wiring checks; stator testing separates winding resistance from a short to ground.

Tool references: Engine work identifies assembly stand 61229001000, fixing arms 90129002050 and 90129002060, case separator 90129048100, clutch holder 51129003000, and rotor puller 90229009000. Pressure testing specifies tool 61029094000 and oil-pressure adapter 75029094000, allowing equipment requirements to be checked before work begins.

Maintenance Schedule and Service Data

The factory schedule distinguishes the one-time 1,000 km service, 7,500 km or annual service, and 15,000 km or two-year service. It includes KTM diagnostics-tool fault-memory checks before and after the test ride.

Reference sections provide engine and chassis tightening torques, wear limits, fluid capacities, SAE 15W/50 engine-oil and SAE 4 fork-oil specifications, coolant requirements, and brake-disc inspection data.

Examples of Valve, Oil-Pressure, and Charging Specifications

Cold valve-clearance specifications are 0.08–0.12 mm for the intake valves and 0.13–0.17 mm for the exhaust valves, alongside the shim-adjustment procedures.

Engine oil-pressure testing specifies minimums of 0.7 bar at 1,500 rpm and 2.4 bar at 5,000 rpm, with coolant temperature at least 70 °C (158 °F).

With a fully functional, fully charged battery, the charging-voltage specification is 13.5–15.0 V at 5,000 rpm. Stator-winding resistance is specified at no more than 1 Ω at 20 °C (68 °F).

Working on fuel, brake, cooling, electrical, and supported engine assemblies carries real physical risk. Verify mechanical tolerances, use the specified workshop tools and support equipment, and follow the safety notices and torque requirements in the repair manual before returning the motorcycle to service.