KTM 125 DUKE EU Repair Manual page 5

TABLE OF CONTENTS
14.11 Adding rear brake fluid .................................... 74
14.12 Changing the rear brake fluid ........................... 74
15 LIGHTING SYSTEM, INSTRUMENTS ........................... 76
15.1 Setting kilometers or miles............................... 76
15.2 Adjusting the shift speed RPM 1 ...................... 76
15.3 Adjusting the shift speed RPM 2 ...................... 76
15.4 Setting the time.............................................. 77
15.5 Resetting the service interval display ................ 77
15.6 Checking the headlight setting ......................... 77
15.7 Adjusting the headlight range........................... 78
15.8 Changing the parking light bulb........................ 79
15.9 Changing the headlight bulb ............................ 80
16 ENGINE .................................................................... 82
16.1 Removing the engine....................................... 82
16.2 Installing the engine........................................ 85
16.3 Disassembling the engine ................................ 90
16.3.1 Preparations (125 Duke) ............................. 90
16.3.2 Draining the engine oil (125 Duke)............... 90
16.3.3 Removing the chain securing guide (125
Duke) ........................................................ 91
16.3.4 Removing the valve cover (125 Duke) ........... 91
16.3.5 Removing the spark plug (125 Duke)............ 91
16.3.6 Removing the clutch cover (125 Duke) ......... 91
16.3.7 Setting the engine to ignition top dead
center (125 Duke) ...................................... 92
16.3.8 Removing the starter motor (125 Duke) ........ 92
16.3.9 Removing the timing chain tensioner (125
Duke) ........................................................ 93
16.3.10 Removing the camshaft (125 Duke).............. 93
16.3.11 Removing the cylinder head (125 Duke) ....... 94
16.3.12 Removing the piston (125 Duke) .................. 94
16.3.13 Removing the water pump wheel (125
Duke) ........................................................ 95
16.3.14 Removing the alternator cover (125 Duke)..... 96
16.3.15 Removing the rotor (125 Duke) .................... 96
16.3.16 Removing the starter drive (125 Duke).......... 97
16.3.17 Removing the balancer shaft drive wheel
(125 Duke) ................................................ 97
16.3.18 Removing the gear position sensor (125
Duke) ........................................................ 98
16.3.19 Removing the spacer (125 Duke) ................. 99
16.3.20 Removing the clutch basket (125 Duke) ....... 99
16.3.21 Removing the primary gear (125 Duke) ....... 100
16.3.22 Removing the oil pump (125 Duke) ............ 100
16.3.23 Removing the shift shaft (125 Duke) .......... 101
16.3.24 Removing the shift drum locating (125
Duke) ...................................................... 101
16.3.25 Removing the locking lever (125 Duke)....... 101
16.3.26 Removing the oil filter (125 Duke) ............. 101
16.3.27 Removing the left engine case (125
Duke) ...................................................... 102
16.3.28 Removing the shift rails (125 Duke) ........... 103
16.3.29 Removing the shift drum (125 Duke).......... 103
16.3.30 Removing the shift forks (125 Duke) .......... 103
16.3.31 Removing the transmission shafts (125
Duke) ...................................................... 103
16.3.32 Removing the balancer shaft (125 Duke) .... 104
16.3.33 Removing the crankshaft (125 Duke).......... 104
16.3.34 Preparations (200 Duke) ........................... 104
16.3.35 Draining the engine oil (200 Duke)............. 104
16.3.36 Removing the chain securing guide (200
Duke) ...................................................... 105
16.3.37 Removing the valve cover (200 Duke) ......... 105
16.3.38 Removing the spark plug (200 Duke).......... 105
16.3.39 Removing the clutch cover (200 Duke) ....... 105
16.3.40 Setting the engine to ignition top dead
center (200 Duke) .................................... 106
16.3.41 Removing the starter motor (200 Duke) ...... 106
16.3.42 Removing the timing chain tensioner (200
Duke) ...................................................... 107
16.3.43 Removing the camshaft (200 Duke)............ 107
16.3.44 Removing the cylinder head (200 Duke) ..... 108
16.3.45 Removing the piston (200 Duke) ................ 108
16.3.46 Removing the water pump wheel (200
Duke) ...................................................... 109
16.3.47 Removing the alternator cover (200
Duke) ...................................................... 110
16.3.48 Removing the rotor (200 Duke) .................. 110
16.3.49 Removing the starter drive (200 Duke)........ 111
16.3.50 Removing the balancer shaft drive wheel
(200 Duke) .............................................. 111
16.3.51 Removing the gear position sensor (200
Duke) ...................................................... 112
16.3.52 Removing the spacer (200 Duke) ............... 113
16.3.53 Removing the clutch basket (200 Duke) ..... 113
16.3.54 Removing the primary gear (200 Duke) ....... 114
16.3.55 Removing the oil pump (200 Duke) ............ 114
16.3.56 Removing the shift shaft (200 Duke) .......... 115
16.3.57 Removing the shift drum locating (200
Duke) ...................................................... 115
16.3.58 Removing the locking lever (200 Duke)....... 115
16.3.59 Removing the oil filter (200 Duke) ............. 115
16.3.60 Removing the left engine case (200
Duke) ...................................................... 116
16.3.61 Removing the shift rails (200 Duke) ........... 117
16.3.62 Removing the shift drum (200 Duke).......... 117
16.3.63 Removing the shift forks (200 Duke) .......... 117
16.3.64 Removing the transmission shafts (200
Duke) ...................................................... 117
16.3.65 Removing the balancer shaft (200 Duke) .... 118
16.3.66 Removing the crankshaft (200 Duke).......... 118
16.4 Work on individual parts ................................ 118
16.4.1 Work on the left section of the engine case
(125 Duke) .............................................. 118
16.4.2 Work on the right section of the engine
case (125 Duke) ....................................... 119
16.4.3 Changing the shaft seal ring of the water
pump (125 Duke) ..................................... 119
16.4.4 Removing the main bearing (125 Duke) ...... 120
16.4.5 Checking the radial play of the lower
conrod bearing (125 Duke) ........................ 121
16.4.6 Changing the conrod bearing (125 Duke) .... 122
16.4.7 Changing the balancer shaft bearing (125
Duke) ...................................................... 123
16.4.8 Changing the camshaft bearing (125
Duke) ...................................................... 123
16.4.9 Work on the cylinder head (125 Duke) ........ 124
16.4.10 Checking the cylinder head (125 Duke) ...... 125
16.4.11 Checking/measuring the cylinder (125
Duke) ...................................................... 125
16.4.12 Checking the piston ring end gap (125
Duke) ...................................................... 126
16.4.13 Checking/measuring the piston (125
Duke) ...................................................... 126
16.4.14 Checking the piston/cylinder mounting
clearance (125 Duke)................................ 127
16.4.15 Checking the oil pump (125 Duke) ............. 127
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