KTM 200 DUKE 2013 COL Manuals

Manuals and User Guides for KTM 200 DUKE 2013 COL. We have 1 KTM 200 DUKE 2013 COL manual available for free PDF download: Repair Manual

KTM 200 DUKE 2013 COL Repair Manual

KTM 200 DUKE 2013 COL Repair Manual (267 pages)

Brand: KTM | Category: Motorcycle | Size: 13.58 MB

Table of Contents

Table of Contents
4
1 Means of Representation

8
- Symbols Used
  8
- Formats Used
  8
2 Safety Advice

9
- Repair Manual
  9
- Degrees of Risk and Symbols
  9
- Work Rules
  9
3 Important Notes

10
- Guarantee, Warranty
  10
- Operating and Auxiliary Substances
  10
- Spare Parts, Accessories
  10
- Figures
  10
4 Serial Numbers

11
- Chassis Number/Type Label
  11
- Key Number
  11
- Engine Number
  11
5 Motorcycle

12
6 Fork, Triple Clamp

17
7 Handlebar, Controls

30
8 Shock Absorber, Swingarm

32
9 Exhaust

35
10 Air Filter

39
- Removing the Air Filter
  39
- Installing the Air Filter
  39
11 Fuel Tank, Seat, Trim

40
- Opening the Filler Cap
  40
- Closing the Filler Cap
  40
- Removing the Seat
  40
- Mounting the Seat
  41
- Removing the Passenger Seat
  41
- Mounting the Passenger Seat
  41
- Removing the Fuel Tank Cover
  41
- Installing the Fuel Tank Cover
  44
- Removing the Fuel Tank
  46
- Installing the Fuel Tank
  48
- Removing the Front Spoiler
  49
- Fitting Front Spoiler
  49
- Dismounting the Front Fender
  50
- Installing the Front Fender
  50
- Checking the Fuel Pressure
  50
- Changing the Fuel Filter
  52
- Replacing the Fuel Pump
  53
12 Wheels

55
13 Wiring Harness, Battery

64
14 Brake System

68
15 Lighting System, Instruments

78
16 Engine

84
- Removing the Engine
  84
- Installing the Engine
  87
- Disassembling the Engine
  92
- Preparations (125 Duke)
  92
- Draining the Engine Oil (125 Duke)
  92
- Removing the Chain Securing Guide
  93
  - Duke)
    93
- Removing the Valve Cover (125 Duke)
  93
- Removing the Spark Plug (125 Duke)
  93
- Removing the Clutch Cover (125 Duke)
  93
- Setting the Engine to Ignition Top Dead Center (125 Duke)
  94
- Removing the Starter Motor (125 Duke)
  94
- Removing the Timing Chain Tensioner
  95
  - Duke)
    95
- Removing the Camshaft (125 Duke)
  95
- Removing the Cylinder Head (125 Duke)
  96
- Removing the Piston (125 Duke)
  96
- Removing the Water Pump Wheel
  97
  - Duke)
    97
- Removing the Alternator Cover (125 Duke)
  98
- Removing the Rotor (125 Duke)
  98
- Removing the Starter Drive (125 Duke)
  99
- Removing the Balancer Shaft Drive Wheel (125 Duke)
  99
- Removing the Gear Position Sensor
  100
  - Duke)
    100
- Removing the Spacer (125 Duke)
  101
- Removing the Clutch Basket (125 Duke)
  101
- Removing the Primary Gear (125 Duke)
  102
- Removing the Oil Pump (125 Duke)
  102
- Removing the Shift Shaft (125 Duke)
  103
- Removing the Shift Drum Locating
  103
  - Duke)
    103
- Removing the Locking Lever (125 Duke)
  103
- Removing the Oil Filter (125 Duke)
  103
- Removing the Left Engine Case
  104
  - Duke)
    104
- Removing the Shift Rails (125 Duke)
  105
- Removing the Shift Drum (125 Duke)
  105
- Removing the Shift Forks (125 Duke)
  105
- Removing the Transmission Shafts
  105
  - Duke)
    105
  - Removing the Balancer Shaft (125 Duke)
    106
  - Removing the Crankshaft (125 Duke)
    106
- Preparations (200 Duke)
  106
- Draining the Engine Oil (200 Duke)
  106
- Removing the Chain Securing Guide
  107
  - Duke)
    107
  - Removing the Valve Cover (200 Duke)
    107
  - Removing the Spark Plug (200 Duke)
    107
- Removing the Clutch Cover (200 Duke)
  107
- Setting the Engine to Ignition Top Dead Center (200 Duke)
  108
- Removing the Starter Motor (200 Duke)
  108
- Removing the Timing Chain Tensioner
  109
  - Duke)
    109
- Removing the Camshaft (200 Duke)
  109
- Removing the Cylinder Head (200 Duke)
  110
- Removing the Piston (200 Duke)
  110
- Removing the Water Pump Wheel
  111
  - Duke)
    111
- Removing the Alternator Cover
  112
  - Duke)
    112
- Removing the Rotor (200 Duke)
  112
- Removing the Starter Drive (200 Duke)
  113
- Removing the Balancer Shaft Drive Wheel (200 Duke)
  113
  - Duke)
    114
- Removing the Spacer (200 Duke)
  115
- Removing the Clutch Basket (200 Duke)
  115
- Removing the Primary Gear (200 Duke)
  116
- Removing the Oil Pump (200 Duke)
  116
- Removing the Shift Shaft (200 Duke)
  117
- Removing the Shift Drum Locating
  117
  - Duke)
    117
- Removing the Locking Lever (200 Duke)
  117
- Removing the Oil Filter (200 Duke)
  117
- Removing the Left Engine Case
  118
  - Duke)
    118
- Removing the Shift Rails (200 Duke)
  119
- Removing the Shift Drum (200 Duke)
  119
- Removing the Shift Forks (200 Duke)
  119
- Removing the Transmission Shafts
  119
  - Duke)
    119
- Removing the Balancer Shaft (200 Duke)
  120
- Removing the Crankshaft (200 Duke)
  120
- Work on Individual Parts
  120
- Work on the Left Section of the Engine Case (125 Duke)
  120
- Work on the Right Section of the Engine Case (125 Duke)
  121
- Changing the Shaft Seal Ring of the Water Pump (125 Duke)
  121
- Removing the Main Bearing (125 Duke)
  122
- Checking the Radial Play of the Lower Conrod Bearing (125 Duke)
  123
- Changing the Conrod Bearing (125 Duke)
  124
- Changing the Balancer Shaft Bearing
  125
  - Duke)
    125
- Changing the Camshaft Bearing
  125
- Work on the Cylinder Head (125 Duke)
  126
- Checking the Cylinder Head (125 Duke)
  127
- Checking/Measuring the Cylinder
  127
  - Duke)
    127
  - Checking the Piston Ring End Gap
    128
  - Duke)
    128
  - Checking/Measuring the Piston
    128
  - Checking the Piston/Cylinder Mounting Clearance (125 Duke)
    129
  - Checking the Oil Pump (125 Duke)
    129
  - Checking the Oil Pressure Regulator Valve (125 Duke)
    129
- Checking the Clutch (125 Duke)
  130
- Preassembling the Clutch (125 Duke)
  131
- Checking the Shift Mechanism
  132
  - Duke)
    132
- Preassembling the Shift Shaft (125 Duke)
  133
- Disassembling the Main Shaft
  133
  - Duke)
    133
- Dismantling the Countershaft (125 Duke)
  134
- Checking the Transmission (125 Duke)
  134
- Assembling the Main Shaft (125 Duke)
  135
- Assembling the Countershaft (125 Duke)
  136
- Checking the Timing Assembly
  138
  - Duke)
    138
- Changing the Stator (125 Duke)
  138
- Checking the Electric Starter Drive
  139
  - Duke)
    139
- Checking the Freewheel (125 Duke)
  140
- Work on the Left Section of the Engine Case (200 Duke)
  140
- Work on the Right Section of the Engine Case (200 Duke)
  141
- Changing the Shaft Seal Ring of the Water Pump (200 Duke)
  141
- Removing the Main Bearing (200 Duke)
  142
- Checking the Radial Play of the Lower Conrod Bearing (200 Duke)
  143
- Changing the Conrod Bearing (200 Duke)
  144
- Changing the Balancer Shaft Bearing
  145
  - Duke)
    145
- Changing the Camshaft Bearing
  145
- Work on the Cylinder Head (200 Duke)
  146
- Checking the Cylinder Head (200 Duke)
  147
- Checking/Measuring the Cylinder
  147
  - Duke)
    147
- Checking the Piston Ring End Gap
  148
  - Duke)
    148
- Checking/Measuring the Piston
  148
- Checking the Piston/Cylinder Mounting Clearance (200 Duke)
  149
- Checking the Oil Pump (200 Duke)
  149
- Checking the Oil Pressure Regulator Valve (200 Duke)
  149
- Checking the Clutch (200 Duke)
  150
- Preassembling the Clutch (200 Duke)
  151
- Checking the Shift Mechanism
  152
  - Duke)
    152
- Preassembling the Shift Shaft (200 Duke)
  153
- Disassembling the Main Shaft
  153
  - Duke)
    153
- Dismantling the Countershaft (200 Duke)
  154
- Checking the Transmission (200 Duke)
  154
- Assembling the Main Shaft (200 Duke)
  155
- Assembling the Countershaft (200 Duke)
  156
- Checking the Timing Assembly
  158
  - Duke)
    158
  - Changing the Stator (200 Duke)
    158
  - Checking the Electric Starter Drive
    159
  - Duke)
    159
  - Checking the Freewheel (200 Duke)
    160
  - Assembling the Engine
    160
- Installing the Crankshaft (125 Duke)
  160
- Installing the Balancer Shaft (125 Duke)
  160
  - Duke)
    161
- Installing the Shift Forks (125 Duke)
  161
- Installing the Shift Drum (125 Duke)
  161
- Installing the Transmission Shafts (125 Duke)
  161
- Installing the Shift Rails (125 Duke)
  162
- Installing the Left Engine Case
  162
  - Duke)
    162
- Installing the Oil Filter (125 Duke)
  163
- Installing the Locking Lever (125 Duke)
  163
- Installing the Shift Drum Locating
  163
  - Duke)
    163
- Installing the Shift Shaft (125 Duke)
  164
- Installing the Oil Pump (125 Duke)
  164
- Installing the Primary Gear (125 Duke)
  165
- Installing the Clutch Basket (125 Duke)
  165
- Installing the Spacer (125 Duke)
  166
- Installing the Gear Position Sensor
  166
  - Duke)
    166
- Installing the Balancer Shaft Drive Wheel (125 Duke)
  167
- Installing the Starter Drive (125 Duke)
  168
- Installing the Rotor (125 Duke)
  169
- Installing the Alternator Cover (125 Duke)
  169
- Installing the Water Pump Cover
  169
  - Duke)
    169
- Installing the Piston (125 Duke)
  170
- Installing the Cylinder Head (125 Duke)
  171
- Installing the Camshafts (125 Duke)
  172
- Installing the Timing Chain Tensioner
  173
  - Duke)
    173
- Checking the Valve Clearance (125 Duke)
  174
- Adjusting the Valve Clearance (125 Duke)
  174
- Installing the Starter Motor (125 Duke)
  174
- Installing the Clutch Cover (125 Duke)
  175
- Installing the Spark Plug (125 Duke)
  175
- Installing the Valve Cover (125 Duke)
  176
- Installing the Chain Securing Guide
  176
  - Duke)
    176
- Installing the Oil Screen (125 Duke)
  176
- Removing the Engine from the Engine Assembly Stand (125 Duke)
  177
- Installing the Crankshaft (200 Duke)
  177
- Installing the Balancer Shaft (200 Duke)
  177
- Installing the Transmission Shafts
  178
  - Duke)
    178
- Installing the Shift Forks (200 Duke)
  178
- Installing the Shift Drum (200 Duke)
  178
- Installing the Shift Rails (200 Duke)
  179
- Installing the Left Engine Case
  179
  - Duke)
    179
- Installing the Oil Filter (200 Duke)
  180
- Installing the Locking Lever (200 Duke)
  180
- Installing the Shift Drum Locating
  180
17 Shift Mechanism

195
- Adjusting the Shift Lever
  195
18 Water Pump, Cooling System

196
- Draining the Coolant
  196
- Filling/Bleeding the Cooling System
  196
- Checking the Antifreeze and Coolant Level
  197
- Checking the Coolant Level
  198
19 Lubrication System

200
- Oil Circuit
  200
- Checking the Engine Oil Level
  200
- Checking the Engine Oil Pressure
  200
- Changing the Engine Oil and Oil Filter, Cleaning the Oil Screen
  202
- Adding Engine Oil
  203
20 Ignition System

204
- Alternator - Checking the Stator Winding
  204
21 Technical Data

205
- Engine
  205
- 125 Duke
  205
- Engine Tolerance, Wear Limits
  206
- 125 Duke
  206
- 200 Duke
  207
- Engine Tightening Torques
  207
- Capacities
  208
- Engine Oil
  208
- Coolant
  208
- Fuel
  208
- Chassis
  209
- Electrical System
  209
- Tires
  210
- Fork
  210
- Shock Absorber
  210
- Chassis Tightening Torques
  210
22 Cleaning/Protective Treatment

213
- Cleaning the Motorcycle
  213
  - Checks and Maintenance Steps for Winter Operation
    214
23 Storage

215
- Preparing for Use after Storage
  215
24 Service Schedule

216
25 Wiring Diagram

218
- 125 Duke, 200 Duke EU)
  218
- 125 Duke, 200 Duke EU)
  220
- 125 Duke, 200 Duke EU)
  222
- 125 Duke, 200 Duke EU)
  224
- 125 Duke, 200 Duke EU)
  226
- 125 Duke, 200 Duke EU)
  228
- 125 Duke, 200 Duke EU)
  230
- 125 Duke, 200 Duke EU)
  232
- 200 Duke 2013 COL)
  234
- 200 Duke 2013 COL)
  236
- 200 Duke 2013 COL)
  238
- 200 Duke 2013 COL)
  240
- 200 Duke 2013 COL)
  242
- 200 Duke 2013 COL)
  244
- 200 Duke 2013 COL)
  246
- 200 Duke 2013 COL)
  248
26 Substances

250
27 Auxiliary Substances

252
28 Special Tools

254
29 Standards

263
- Index
  264

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