1. Introduction
This manual provides detailed instructions for the installation and maintenance of the Evotech Performance Frame Crash Protection system, model PRN013992. This product is designed to fit KTM 890 Duke, 890 Duke R, 890 Duke GP, and 790 Duke motorcycles from 2018 onwards. The frame crash protection is engineered to minimize damage to your motorcycle's fairing and other critical components in the event of a fall or slide.
The system consists of high-performance engineering polymer bobbins with an aluminum core, mounted on aircraft-quality aluminum brackets. These components are designed for direct attachment to existing mounting points on your motorcycle, requiring no modifications.
2. Safety Information
- Always ensure the motorcycle is stable and securely supported before beginning any installation.
- Wear appropriate personal protective equipment, including gloves and eye protection.
- If you are unsure about any step of the installation process, consult a qualified motorcycle mechanic.
- Do not overtighten fasteners. Refer to your motorcycle's service manual for specific torque specifications if available, or tighten securely without excessive force.
- Keep all components out of reach of children.
3. Package Contents
Please verify that all the following components are present in your package:
- 2 x Frame Crash Bobbins (high-performance engineering polymer with aluminum core)
- 2 x Mounting Brackets (aircraft-quality aluminum, powder-coated black)
- Associated Fixings and Spacers (all necessary hardware for installation)
Figure 3.1: Exploded view of the crash protection components, highlighting the injection moulded nylon bobbins and anodised aluminium cores.
4. Setup and Installation
The Evotech Performance Frame Crash Protection system is designed for straightforward installation using your motorcycle's existing mounting points. No modifications to your motorcycle are required.
- Prepare the Motorcycle: Park your KTM motorcycle on a level surface and ensure it is stable, preferably on a paddock stand or center stand. Allow the engine to cool if it has been recently operated.
- Identify Mounting Points: Locate the designated mounting points on your motorcycle's frame. These are typically existing engine mount bolts or other structural points. Refer to the online fitting instructions provided by Evotech Performance for precise locations specific to your KTM model.
- Attach Mounting Brackets: Secure the powder-coated aluminum mounting brackets to the identified points on the motorcycle frame using the provided fixings. Ensure the brackets are oriented correctly as per the online instructions. Do not fully tighten bolts at this stage.
- Install Crash Bobbins: Attach the high-performance engineering polymer bobbins to the mounting brackets. The bobbins feature an aluminum core for enhanced strength.
- Final Tightening: Once all components are in place and correctly aligned, progressively tighten all bolts to secure the crash protection system. Ensure all fasteners are snug and secure. Avoid overtightening.
- Visual Inspection: After installation, visually inspect all components to ensure they are correctly positioned, securely fastened, and do not interfere with any moving parts or controls of the motorcycle.
Figure 4.1: Close-up of the crash protection installed on a KTM motorcycle.
Figure 4.2: Wider view of the crash protection installed on a KTM motorcycle, showing overall fitment.
5. Operation
The Evotech Performance Frame Crash Protection operates passively, providing protection in the event of a fall or slide. No active operation is required from the user.
It is recommended to periodically check the security of all mounting bolts, especially after the first few rides following installation, and then as part of your regular motorcycle maintenance schedule.
6. Maintenance
- Regular Inspection: Periodically inspect the bobbins and mounting brackets for any signs of wear, damage, or looseness.
- Cleaning: Clean the components with a mild soap and water solution. Avoid harsh chemicals or abrasive cleaners that could damage the finish or material.
- Fastener Check: Ensure all bolts and fasteners remain tight. Re-tighten if necessary, but do not overtighten.
- Post-Incident Check: After any incident involving a fall or slide, thoroughly inspect the crash protection system for damage. Even if visible damage is minimal, the structural integrity may be compromised. It is recommended to replace any components that have sustained impact.
7. Troubleshooting
- Loose Components: If any part of the crash protection feels loose, re-check the tightness of all fasteners. Ensure they are secured according to installation guidelines.
- Interference: If the installed crash protection interferes with any motorcycle components (e.g., fairing, controls), re-check the installation steps and ensure correct orientation of brackets and bobbins. Refer to online fitting instructions for specific model guidance.
- Missing Parts: If any components were missing from the package, contact Evotech Performance customer support immediately.
8. Specifications
| Brand | Evotech Performance |
| Model Number | PRN013992 |
| Compatible Motorcycles | KTM 890 Duke, 890 Duke R, 890 Duke GP, 790 Duke (2018 onwards) |
| Material (Bobbins) | High-performance engineering polymer with aluminum core |
| Material (Brackets) | Aircraft-quality aluminum, powder-coated black |
| Installation Position | Front (Frame) |
| Approximate Item Weight | 6 pounds (2.7 kg) |
| Package Dimensions | 11 x 9 x 5 inches (27.9 x 22.9 x 12.7 cm) |
9. Warranty and Support
For warranty information, detailed fitting instructions, or technical support, please refer to the official Evotech Performance website or contact their customer service directly. Online fitting instructions are available and recommended for precise model-specific guidance.
Note: For insurance purposes, packages with contents valued at $250 or above may require a signature upon delivery.
