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

• KTM-Sportmotorcycle AG Repair Manual 2013 for the 390 Duke EU, AUS, MAL, and 390 Duke 2014 COL; Art. no. 3206167en, 204-page PDF
• Factory service schedule covers the one-time 1,000 km (621 mi) service, 7,500 km (4,660 mi) / annual service, and 15,000 km (9,321 mi) / two-year service, including KTM diagnostics-tool fault-memory checks
• Key test values include 2.5–2.9 bar (36–42 psi) fuel pressure, 5–7 mm (0.20–0.28 in) chain tension, cold valve clearances of 0.08–0.12 mm intake and 0.13–0.17 mm exhaust, and charging voltage of 13.5–15.0 V at 5,000 rpm
• Fluid and chassis data include 1.6 L (1.7 qt) SAE 15W/50 engine oil, 1.1 L (1.2 qt) coolant, 450 ml (15.21 fl oz) SAE 4 fork oil, 11 L (2.9 US gal) fuel capacity, and front/rear brake-disc wear limits of 3.6 mm (0.142 in)
• Includes a nine-page wiring diagram, electrical component legends, torque tables, wear limits, special-tool references, and workshop procedures for engine, transmission, fuel, brake, suspension, cooling, lubrication, and electrical repair

Mechanical and Chassis Coverage

This factory manual goes well beyond routine maintenance. The engine section covers engine removal and installation, complete disassembly and reassembly, cylinder-head and valve work, piston and cylinder measurement, crankshaft and connecting-rod bearing checks, balancer-shaft service, timing-chain components, starter drive, oil pumps, clutch, shift mechanism, and the six-speed transmission. 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.

The chassis coverage is similarly specific. It includes fork-leg removal, teardown, inspection, seal/bushing assembly and oil filling; lower triple-clamp and steering-head bearing work; rear shock removal, spring removal/installation and preload settings; front and rear wheel service; brake-disc replacement; brake-pad and brake-fluid service; chain wear and tension checks; and rear-hub rubber-damper inspection. Fuel-system work includes tank removal, fuel-filter replacement, fuel-pump replacement, and pressure testing. Cooling-system filling/bleeding, engine oil-pressure testing, and front/rear brake-fluid replacement with the specified pressure bleeding equipment are also documented.

Several of these procedures are jobs owners commonly send to a shop: valve-clearance adjustment by shims, fork overhaul, engine removal, full engine teardown, cylinder-head repair, clutch and transmission repair, fuel-pressure diagnosis, engine oil-pressure testing, brake-fluid pressure bleeding, stator testing, and cooling-system bleeding. The manual names the supporting KTM tools rather than leaving tooling generic. Examples include the engine assembly stand 61229001000 with fixing arms 90129002050/90129002060, case separating tool 90129048100, clutch holder 51129003000, rotor puller 90229009000, pressure testing tool 61029094000, and oil pressure adapter 75029094000.

There are also repair-specific cautions that can prevent expensive mistakes. During fuel-tank-cover removal, the manual specifies temporary screws installed one at a time; removing the originals without this support can distort the tank so the screw holes no longer align. When splitting the engine case, it specifically warns not to wedge the case half, and during reassembly the case halves must not be pulled together with the case screws. The inner clutch hub uses a left-hand M16LHx1.5 nut, while the rotor puller is also identified as left-hand threaded—important details before force is applied to either assembly.

Technical Data and Maintenance Specifications

The technical-data section identifies the 375 cm³ water-cooled single-cylinder engine, DOHC four-valve valve train, mechanically operated wet clutch, six-speed claw-shifted transmission, electronically controlled fuel injection, and 12 V / 238 W alternator. Engine reference data extends into measurement-level repair work: cylinder bore, piston diameter and mounting clearance, piston-ring end gap, connecting-rod bearing radial clearance, crankpin classifications, oil-pump clearances, camshaft-bearing clearance, clutch wear dimensions, shift-shaft play, and engine/chassis tightening torques.

Diagnostic coverage is equally concrete. Fuel-pressure testing uses the KTM diagnostics tool and an actuator test for the fuel-pump relay. Engine oil pressure is specified at a minimum of 0.7 bar (10 psi) at 1,500 rpm and 2.4 bar (35 psi) at 5,000 rpm once coolant temperature is at least 70 °C (158 °F). The charging-system section gives the 5,000-rpm voltage range, while the stator test specifies winding resistance of no more than 1 ohm at 20 °C (68 °F) plus a short-to-ground check. This is more useful for electrical diagnosis than treating the alternator’s 238 W rating as a stator test value.

Visual references include the nine-page Wiring Diagram, the labeled Oil circuit, and exploded component views under Checking the clutch, Checking the shift mechanism, Checking the timing assembly, and Checking the electric starter drive. The wiring pages identify circuits and components such as the EFI control unit, vehicle control unit, diagnostics connector, fuel-pump and radiator-fan relays, engine-management sensors, lighting controls, ABS control unit, and front/rear wheel-speed sensors.

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.