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2015 KTM RC 390 Service Repair Manual

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🏷️ Basic Information Identification Make: KTM Model: RC 390 Year: 2015 Generation Model Generation: First Generation Codes Chassis Code: RC125/200/390 👋 Introduction Market Position Segment: Entry-level sportbike, lightweight supersport Target...
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Type: Motorcycle
Vendor:
Sku: 476042
2015 KTM RC 390 Service Repair Manual
🏷️ Basic Information
Identification
Make:
KTM
Model:
RC 390
Year:
2015
Generation
Model Generation:
First Generation
Codes
Chassis Code:
RC125/200/390
👋 Introduction
Market Position
Segment:
Entry-level sportbike, lightweight supersport
Target Audience:
Beginner riders, commuters, track day enthusiasts seeking an affordable and agile machine
Competitive Analysis
Competitors 2015:
Kawasaki Ninja 300, Yamaha R3, Honda CBR300R, Suzuki GSX250R (later models)
Key Features
Design Philosophy:
Race-bred styling, aggressive ergonomics, sharp handling
Technology:
Digital instrument cluster, WP suspension, Bosch ABS (often standard or optional)
Value Proposition
Manual Value:
Provides technicians and owners with the exact same factory-authorized information used by authorized service centers, enabling accurate and efficient repairs, saving time and money.
📋 Manual Details
Coverage Areas
Primary Coverage:
All models and all repairs A-Z
Diagnostic Coverage:
Diagnostic, maintenance, service, and repair
Page Count
Estimated Pages:
Varies based on specific model and edition, typically hundreds of pages for a comprehensive service manual.
Manual Type
Type:
Service Repair Manual
Authenticity:
Factory-issued, identical to dealership technician manuals
Language
Language:
English
Format
Digital Format:
PDF
Digital Features:
Searchable, zoomable images, printable pages
📖 Manual Coverage
Systems Covered
Engine:
Complete engine overhaul, internal components, timing, valve adjustments
Fuel System:
Fuel injection system, fuel pump, injectors, fuel pressure testing, fuel filter replacement
Cooling System:
Radiator, cooling fan, coolant types, pressure testing, thermostat replacement
Lubrication:
Oil change procedures, oil filter specifications, oil capacity, lubrication points
Ignition System:
Spark plugs, ignition coils, timing, troubleshooting ignition faults
Charging System:
Alternator, stator, regulator/rectifier, battery testing and replacement
Transmission Clutch:
Clutch operation, clutch adjustment, clutch component replacement, transmission servicing
Suspension:
Front fork (USD WP APEX 43), rear shock absorber, suspension adjustments, fork seal replacement
Brakes:
Brake caliper service, brake pad replacement, brake fluid flush and bleed, ABS system (if equipped), master cylinder service
Steering:
Handlebar replacement, steering head bearing service and adjustment
Electrical System:
Wiring schematics, component testing, battery, lighting, fuses, relays
Instrumentation:
Instrument cluster troubleshooting, indicator lights
Bodywork:
Fairing removal and installation, seat, fuel tank, body panel repair and replacement
Emission Control:
Emission system components and troubleshooting (where applicable)
Multiplex Can Communication:
Understanding and troubleshooting CAN bus communication (if applicable to the 2015 model)
Procedures Included
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, chain adjustment
Troubleshooting:
Diagnostic procedures for common and uncommon issues
Repair:
Step-by-step instructions for virtually all mechanical and electrical repairs
Rebuild:
Complete engine and component rebuild procedures
Wiring Schematics:
Detailed wiring diagrams for all electrical circuits
Illustrations:
Extensive diagrams and illustrations for clarity
Technical Depth
Depth:
Comprehensive, from basic maintenance to advanced diagnostics and complete rebuilds
📊 Manual Specifications
File Format
Format:
PDF
Requirements:
Adobe PDF Reader and Winzip (free downloads)
Print Quality
Printability:
All pages are printable
Image Resolution:
High-resolution, allowing for image blow-up and printing of enlarged copies
Binding Type
Binding:
Digital (PDF) - no physical binding
Paper Type
Paper Type:
Not applicable (digital format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Single-cylinder, four-stroke, liquid-cooled, DOHC
Displacement:
373.2 cc
Bore X Stroke:
89 mm x 60 mm
Performance
Horsepower Claimed:
Approximately 44 hp (32 kW) @ 9,500 rpm
Torque Claimed:
Approximately 35 Nm (25.8 lb-ft) @ 7,250 rpm
Fuel System
Fuel Delivery:
Bosch EFI (Electronic Fuel Injection) with throttle body
Fuel Type:
Unleaded gasoline, minimum 95 RON
Lubrication
Oil Capacity W Filter:
Approximately 1.1 Liters (1.2 US qt)
Recommended Oil Grade:
KTM recommends Motorex Power Synt 4T 15W/50 (verify with manual for exact specifications)
🔧 Transmission
Standard
Transmission Type:
6-speed, claw-shifted gearbox
Features
Clutch Type:
Wet multi-disc clutch, mechanically operated
Final Drive:
Chain drive
📐 Dimensions
Exterior
Length:
Approx. 1995 mm (78.5 in)
Width:
Approx. 720 mm (28.3 in) (handlebar width)
Height:
Approx. 1130 mm (44.5 in) (without mirrors)
Seat Height:
Approx. 820 mm (32.3 in)
Weights
Dry Weight:
Approx. 147 kg (324 lbs) (without fuel)
Curb Weight:
Approx. 159 kg (350.5 lbs) (ready to ride, with fuel)
Fuel Tank Capacity:
10 Liters (2.6 US gal)
🛡️ Safety Features
Ratings
ABS:
Bosch 9MB two-channel ABS (standard or optional, verify specific market)
Active Features
Braking System:
Front: ByBre (Brembo subsidiary) 300mm disc with four-piston radial caliper. Rear: ByBre 230mm disc with single-piston caliper.
Lighting:
Halogen headlight, LED taillight, LED turn signals
Passive Features
Frame Type:
Trellis frame, powder-coated
💡 Technology Features
Infotainment
Instrument Cluster:
Multi-function digital LCD display with speedometer, tachometer, odometer, trip meter, fuel level, gear indicator, clock, and warning lights.
Driver Assistance
ABS System:
Bosch ABS system, often with a track mode (disables rear ABS) on later models, but the 2015 likely has standard ABS.
Connectivity
Connectivity Features:
No native smartphone integration or Bluetooth connectivity on the 2015 model.
🔧 Maintenance
Service Intervals
First Service:
Typically around 1,000 km (600 miles) or 6 months (verify specific manual for exact interval).
Oil Change Interval:
Every 5,000 km (3,000 miles) or annually, whichever comes first (verify with manual).
Valve Check Interval:
Typically every 10,000 km (6,000 miles) (verify with manual).
Fluid Specifications
Brake Fluid Type:
DOT 4
Coolant Type:
Engine coolant, silicate-free, ethylene glycol based (e.g., Motorex Coolant M3.0) - check manual for specific KTM approved coolant.
Known Issues
Cooling Fan Operation:
Some owners reported early failure of cooling fans; manual will guide on testing and replacement.
Engine Stalling:
Infrequent reports of stalling, potentially related to fuel delivery or electrical gremlins; manual's diagnostic section is key.
Suspension Tuning:
While generally well-regarded, the manual will detail adjustments for optimal performance based on rider weight and conditions.
📚 Vehicle History
Brand Heritage
Heritage:
KTM, 'Ready to Race', known for off-road prowess and expanding into street bikes with a focus on performance and rider engagement.
Model Evolution
Rc Series Launch:
The RC series was launched as KTM's entry into the supersport segment, building on the success of the Duke naked bikes.
2015 Model Year:
Represents the first generation of the RC 390, establishing its aggressive styling and performance benchmark in the lightweight sportbike class.
Production
Manufacturing Location:
India (by Bajaj Auto) for global markets.
🏆 Awards & Recognition
Recognitions
Awards Received:
While specific awards vary by publication and region, the RC 390 consistently received praise for its value, performance, and handling in the lightweight sportbike class upon its release.
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