2018 KTM 790 Duke Service Repair Manual
Table of Contents
1. Means of Representation – Page 7
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1.1 Symbols Used – 7
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1.2 Formats Used – 7
2. Safety Advice – Page 8
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2.1 Repair Manual – 8
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2.2 Safety Advice – 8
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2.3 Degrees of Risk and Symbols – 8
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2.4 Work Rules – 8
3. Important Notes – Page 9
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3.1 Manufacturer and Implied Warranty – 9
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3.2 Operating and Auxiliary Substances – 9
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3.3 Spare Parts and Accessories – 9
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3.4 Figures – 9
4. Serial Numbers – Page 10
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4.1 Type Label – 10
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4.2 Key Number – 10
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4.3 Engine Number – 10
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4.4 Fork Part Number – 10
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4.5 Shock Absorber Article Number – 11
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4.6 Steering Damper Article Number – 11
2018 KTM 790 Duke Service Repair Manual
5. Motorcycle – Page 12
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5.1 Raising the Motorcycle with the Rear Lifting Gear – 12
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5.2 Removing the Rear of the Motorcycle from the Lifting Gear – 12
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5.3 Lifting the Motorcycle with the Front Lifting Gear – 12
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5.4 Taking the Motorcycle off the Front Lifting Gear – 13
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5.5 Raising the Motorcycle with the Work Stand – 13
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5.6 Removing the Motorcycle from the Work Stand – 14
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5.7 Starting the Vehicle – 14
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5.8 Starting the Motorcycle to Check the Function – 15
6. Fork, Triple Clamp – Page 16
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6.1 Removing the Fork Legs – 16
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6.2 Installing the Fork Legs – 16
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6.3 Disassembling the Fork Legs – 19
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6.4 Removing the Spring – 21
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6.5 Checking the Fork Legs – 21
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6.6 Installing the Spring – 22
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6.12 Changing the Steering Head Bearing – 36
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6.13 Changing the Steering Damper – 37
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6.14 Cleaning the Dust Boots of the Fork Legs – 38
7. Handlebar and Controls – Page 39
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7.1 Checking the Free Travel of the Clutch Lever – 39
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7.2 Setting the Free Travel of the Clutch Lever – 39
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7.3 Changing the Throttle Grip – 40
8. Frame – Page 45
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8.1 Checking the Frame – 45
9. Shock Absorber and Swingarm – Page 46
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9.1 Adjusting the Spring Preload of the Shock Absorber – 46
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9.2 Checking the Heim Joint for Play – 46
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9.3 Removing the Shock Absorber – 47
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9.4 Installing the Shock Absorber – 48
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9.5 Changing the Heim Joint – 49
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9.6 Removing the Spring – 51
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9.7 Installing the Spring – 52
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9.8 Removing the Heim Joint – 53
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9.9 Installing the Heim Joint – 54
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9.10 Checking the Swingarm – 54
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9.11 Checking the Swingarm Bearing for Play – 55
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9.12 Removing the Swingarm – 55
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9.13 Changing the Swingarm Bearing – 57
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9.14 Installing the Swingarm – 61
10. Exhaust – Page 64
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10.1 Removing the Main Silencer – 64
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10.2 Installing the Main Silencer – 64
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10.3 Removing the Exhaust System – 65
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10.4 Installing the Exhaust System – 67
11. Air Filter – Page 71
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11.1 Removing the Air Filter – 71
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11.2 Installing the Air Filter – 72
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11.3 Changing the Air Filter / Cleaning the Air Filter Box – 73
12. Fuel Tank, Seat, and Trim – Page 76
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12.1 Opening the Filler Cap – 76
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12.2 Closing the Filler Cap – 76
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12.3 Removing the Passenger Seat – 77
2018 KTM 790 Duke Service Repair Manual