KTM 2013 125 DUKE Manuals

Manuals and User Guides for KTM 2013 125 DUKE. We have 2 KTM 2013 125 DUKE manuals available for free PDF download: Repair Manual, Owner's Manual

KTM 2013 125 DUKE Repair Manual

KTM 2013 125 DUKE Repair Manual (288 pages)

Brand: KTM | Category: Motorcycle | Size: 14.88 MB

Table of Contents

Table of Contents
4
Means of Representation
8
Symbols Used
8
Formats Used
8
Safety Advice
9
Repair Manual
9
Degrees of Risk and Symbols
9
Work Rules
9
Important Information
10
Guarantee, Warranty
10
Operating and Auxiliary Substances
10
Spare Parts, Accessories
10
Figures
10
Serial Numbers
11
Chassis Number/Type Label
11
Key Number
11
Engine Number
11
Motorcycle
12
Raising the Motorcycle with the Rear Wheel Stand
12
Taking the Motorcycle off of the Rear Wheel Stand
12
Raising the Motorcycle with the Front Wheel Stand
12
Taking the Motorcycle off of the Front Wheel Stand
13
Raising the Motorcycle with the Work Stand
13
Removing the Motorcycle from the Work Stand
14
Starting
15
Starting the Motorcycle to Make Checks
16
Fork, Triple Clamp
17
Cleaning the Dust Boots of the Fork Legs
17
Removing Fork Legs
17
Installing the Fork Legs
19
Disassembling the Fork Legs
22
Checking the Fork Legs
24
Assembling the Fork Legs
25
Removing the Lower Triple Clamp
26
Installing the Lower Triple Clamp
29
Checking the Steering Head Bearing Play
31
Adjusting the Steering Head Bearing Play
32
Handlebar, Controls
34
Checking the Play in the Throttle Cable
34
Adjusting the Play in the Throttle Cable
34
Checking the Clutch Lever Play
34
Adjusting the Clutch Cable Play
35
Shock Absorber, Swingarm
36
Adjusting the Spring Preload of the Shock Absorber
36
Removing the Shock Absorber
36
Installing the Shock Absorber
37
Removing the Spring
38
Installing the Spring
38
Exhaust
40
Removing the Exhaust Manifold
40
Installing the Exhaust Manifold
41
Removing the Main Silencer
42
Installing the Main Silencer
44
Air Filter
46
Removing the Air Filter
46
Installing the Air Filter
46
Fuel Tank, Seat, Trim
47
Opening the Filler Cap
47
Closing the Filler Cap
47
Removing the Seat
47
Mounting the Seat
48
Removing the Passenger Seat
48
Mounting the Passenger Seat
48
Removing the Fuel Tank Cover
48
Installing the Fuel Tank Cover
51
Removing the Fuel Tank
53
Installing the Fuel Tank
55
Removing the Front Spoiler
56
Fitting Front Spoiler
56
Dismounting the Front Fender
57
Installing the Front Fender
57
Checking the Fuel Pressure
58
Changing the Fuel Filter
59
Replacing the Fuel Pump
60
Wheels
62
Checking the Tire Air Pressure
62
Checking the Tire Condition
62
Checking the Brake Discs
63
Front Wheel
63
Removing the Front Wheel
63
Installing the Front Wheel
64
Removing the Brake Disc of the Front Brake
65
Installing the Brake Disc of the Front Brake
66
Rear Wheel
66
Removing the Rear Wheel
66
Installing the Rear Wheel
67
Removing the Brake Disc of the Rear Brake
68
Installing the Brake Disc of the Rear Brake
69
Checking the Chain Tension
70
Adjusting the Chain Tension
70
Checking the Chain, Rear Sprocket, and Engine Sprocket
71
Cleaning the Chain
74
Checking the Rear Hub Rubber Dampers
75
Wiring Harness, Battery
76
Removing the Battery
76
Installing the Battery
76
Disconnecting the Negative Cable of the Battery
77
Reconnecting the Negative Cable of the Battery
77
Recharging the Battery
77
Checking the Charging Voltage
78
Changing the Fuses of Individual Power Consumers
79
Brake System
81
Checking the Front Brake Linings
81
Changing the Front Brake Linings
81
Checking the Brake Fluid Level of the Front Brake
84
Adding Front Brake Fluid
85
Changing the Front Brake Fluid
85
Checking the Rear Brake Linings
88
Changing the Rear Brake Linings
88
Checking the Free Travel of Foot Brake Lever
91
Adjusting the Free Travel of the Foot Brake Lever
91
Checking the Rear Brake Fluid Level
92
Adding Rear Brake Fluid
92
Changing the Rear Brake Fluid
93
Lighting System, Instruments
96
Setting Kilometers or Miles
96
Adjusting the Shift Speed RPM 1
96
Adjusting the Shift Speed RPM 2
96
Setting the Time
97
Resetting the Service Interval Display
97
Checking the Headlight Setting
97
Adjusting the Headlight Range
98
Changing the Parking Light Bulb
99
Changing the Headlight Bulb
100
Engine
102
Removing the Engine
102
Installing the Engine
105
Engine Disassembly
110
Preparations (125 Duke)
110
Draining the Engine Oil (125 Duke)
110
Removing the Chain Securing Guide
111
Duke)
111
Removing the Valve Cover (125 Duke)
111
Removing the Spark Plug (125 Duke)
111
Removing the Clutch Cover (125 Duke)
111
Setting the Engine to Ignition Top Dead Center (125 Duke)
112
Removing the Starter Motor (125 Duke)
112
Removing the Timing Chain Tensioner
113
Duke)
113
Removing the Camshaft (125 Duke)
113
Removing the Cylinder Head (125 Duke)
114
Removing the Piston (125 Duke)
114
Removing the Water Pump Wheel
115
Duke)
115
Removing the Alternator Cover
116
Duke)
116
Removing the Rotor (125 Duke)
116
Removing the Starter Drive (125 Duke)
117
Removing the Balancer Shaft Drive Wheel (125 Duke)
117
Removing the Gear Position Sensor
118
Duke)
118
Removing the Spacer (125 Duke)
119
Removing the Clutch Basket (125 Duke)
119
Removing the Primary Gear (125 Duke)
120
Removing the Oil Pump (125 Duke)
120
Removing the Shift Shaft (125 Duke)
121
Removing the Shift Drum Locating
121
Duke)
121
Removing the Locking Lever (125 Duke)
121
Removing the Oil Filter (125 Duke)
121
Removing the Left Engine Case
122
Duke)
122
Removing the Shift Rails (125 Duke)
123
Removing the Shift Drum (125 Duke)
123
Removing the Shift Forks (125 Duke)
123
Removing the Transmission Shafts
123
Duke)
123
Removing the Balancer Shaft (125 Duke)
124
Removing the Crankshaft (125 Duke)
124
Preparations (200 Duke)
124
Draining the Engine Oil (200 Duke)
124
Removing the Chain Securing Guide
125
Duke)
125
Removing the Valve Cover (200 Duke)
125
Removing the Spark Plug (200 Duke)
125
Removing the Clutch Cover (200 Duke)
125
Setting the Engine to Ignition Top Dead Center (200 Duke)
126
Removing the Starter Motor (200 Duke)
126
Removing the Timing Chain Tensioner
127
Duke)
127
Removing the Camshaft (200 Duke)
127
Removing the Cylinder Head (200 Duke)
128
Removing the Piston (200 Duke)
128
Removing the Water Pump Wheel
129
Duke)
129
Removing the Alternator Cover
130
Duke)
130
Removing the Rotor (200 Duke)
130
Removing the Starter Drive (200 Duke)
131
Removing the Balancer Shaft Drive Wheel (200 Duke)
131
Duke)
132
Removing the Spacer (200 Duke)
133
Removing the Clutch Basket (200 Duke)
133
Removing the Primary Gear (200 Duke)
134
Removing the Oil Pump (200 Duke)
134
Removing the Shift Shaft (200 Duke)
135
Removing the Shift Drum Locating
135
Duke)
135
Removing the Locking Lever (200 Duke)
135
Removing the Oil Filter (200 Duke)
135
Removing the Left Engine Case
136
Duke)
136
Removing the Shift Rails (200 Duke)
137
Removing the Shift Drum (200 Duke)
137
Removing the Shift Forks (200 Duke)
137
Removing the Transmission Shafts
137
Duke)
137
Removing the Balancer Shaft (200 Duke)
138
Removing the Crankshaft (200 Duke)
138
Work on Individual Parts
138
Work on the Left Section of the Engine Case (125 Duke)
138
Work on the Right Section of the Engine Case (125 Duke)
139
Changing the Shaft Seal Ring of the Water Pump (125 Duke)
139
Removing the Main Bearing (125 Duke)
140
Checking the Radial Play of the Lower Conrod Bearing (125 Duke)
141
Changing the Conrod Bearing (125 Duke)
142
Changing the Balancer Shaft Bearing
143
Duke)
143
Changing the Camshaft Bearing
143
Work on the Cylinder Head (125 Duke)
144
Checking the Cylinder Head (125 Duke)
145
Checking/Measuring the Cylinder
145
Duke)
145
Checking the Piston Ring End Gap
146
Duke)
146
Checking/Measuring the Piston
146
Checking the Piston/Cylinder Mounting Clearance (125 Duke)
147
Checking the Oil Pump (125 Duke)
147
Checking the Oil Pressure Regulator Valve (125 Duke)
147
Checking the Clutch (125 Duke)
148
Preassembling the Clutch (125 Duke)
149
Checking the Shift Mechanism
150
Duke)
150
Preassembling the Shift Shaft (125 Duke)
151
Disassembling the Main Shaft
151
Duke)
151
Dismantling the Countershaft (125 Duke)
152
Checking the Transmission (125 Duke)
152
Assembling the Main Shaft (125 Duke)
153
Assembling the Countershaft (125 Duke)
154
Checking the Timing Assembly
156
Duke)
156
Changing the Stator (125 Duke)
156
Checking the Electric Starter Drive
157
Duke)
157
Checking the Freewheel (125 Duke)
158
Work on the Left Section of the Engine Case (200 Duke)
158
Work on the Right Section of the Engine Case (200 Duke)
159
Changing the Shaft Seal Ring of the Water Pump (200 Duke)
159
Removing the Main Bearing (200 Duke)
160
Checking the Radial Play of the Lower
161
Conrod Bearing (200 Duke)
161
Changing the Conrod Bearing (200 Duke)
162
Changing the Balancer Shaft Bearing
163
Duke)
163
Changing the Camshaft Bearing
163
Work on the Cylinder Head (200 Duke)
164
Checking the Cylinder Head (200 Duke)
165
Checking/Measuring the Cylinder
165
Duke)
165
Checking the Piston Ring End Gap
166
Duke)
166
Checking/Measuring the Piston
166
Checking the Piston/Cylinder Mounting Clearance (200 Duke)
167
Checking the Oil Pump (200 Duke)
167
Checking the Oil Pressure Regulator Valve (200 Duke)
167
Checking the Clutch (200 Duke)
168
Preassembling the Clutch (200 Duke)
169
Checking the Shift Mechanism
170
Duke)
170
Preassembling the Shift Shaft (200 Duke)
171
Disassembling the Main Shaft
171
Duke)
171
Dismantling the Countershaft (200 Duke)
172
Checking the Transmission (200 Duke)
172
Assembling the Main Shaft (200 Duke)
173
Assembling the Countershaft (200 Duke)
174
Checking the Timing Assembly
176
Duke)
176
Changing the Stator (200 Duke)
176
Checking the Electric Starter Drive
177
Duke)
177
Checking the Freewheel (200 Duke)
178
Engine Assembly
178
Installing the Crankshaft (125 Duke)
178
Installing the Balancer Shaft (125 Duke)
178
Duke)
179
Installing the Shift Forks (125 Duke)
179
Installing the Shift Drum (125 Duke)
179
Installing the Shift Rails (125 Duke)
180
Installing the Left Engine Case
180
Duke)
180
Installing the Oil Filter (125 Duke)
181
Installing the Locking Lever (125 Duke)
181
Installing the Shift Drum Locating
181
Duke)
181
Installing the Shift Shaft (125 Duke)
182
Installing the Oil Pump (125 Duke)
182
Installing the Primary Gear (125 Duke)
183
Installing the Clutch Basket (125 Duke)
183
Installing the Spacer (125 Duke)
184
Installing the Gear Position Sensor
184
Duke)
184
Installing the Balancer Shaft Drive Wheel (125 Duke)
185
Installing the Starter Drive (125 Duke)
186
Installing the Rotor (125 Duke)
187
Installing the Alternator Cover (125 Duke)
187
Installing the Water Pump Cover
187
Duke)
187
Installing the Piston (125 Duke)
188
Installing the Cylinder Head (125 Duke)
189
Installing the Camshafts (125 Duke)
190
Installing the Timing Chain Tensioner
191
Duke)
191
Checking the Valve Clearance (125 Duke)
192
Adjusting the Valve Clearance (125 Duke)
192
Installing the Starter Motor (125 Duke)
192
Installing the Clutch Cover (125 Duke)
193
Installing the Spark Plug (125 Duke)
193
Installing the Valve Cover (125 Duke)
194
Installing the Chain Securing Guide
194
Duke)
194
Installing the Oil Screen (125 Duke)
194
Removing the Engine from the Engine Assembly Stand (125 Duke)
195
Installing the Crankshaft (200 Duke)
195
Installing the Balancer Shaft (200 Duke)
195
Installing the Transmission Shafts
196
Duke)
196
Installing the Shift Forks (200 Duke)
196
Installing the Shift Drum (200 Duke)
196
Installing the Shift Rails (200 Duke)
197
Installing the Left Engine Case
197
Duke)
197
Installing the Oil Filter (200 Duke)
198
Installing the Locking Lever (200 Duke)
198
Installing the Shift Drum Locating
198
Duke)
198
Installing the Shift Shaft (200 Duke)
199
Installing the Oil Pump (200 Duke)
199
Installing the Primary Gear (200 Duke)
200
Installing the Clutch Basket (200 Duke)
200
Installing the Spacer (200 Duke)
201
Installing the Gear Position Sensor (200 Duke)
201
Installing the Balancer Shaft Drive Wheel (200 Duke)
202
Installing the Starter Drive (200 Duke)
203
Installing the Rotor (200 Duke)
204
Installing the Alternator Cover (200 Duke)
204
Installing the Water Pump Cover (200 Duke)
204
Installing the Piston (200 Duke)
205
Installing the Cylinder Head (200 Duke)
206
Installing the Camshafts (200 Duke)
207
Installing the Timing Chain Tensioner (200 Duke)
208
Checking the Valve Clearance (200 Duke)
209
Adjusting the Valve Clearance (200 Duke)
209
Installing the Starter Motor (200 Duke)
209
Installing the Clutch Cover (200 Duke)
210
Installing the Spark Plug (200 Duke)
210
Installing the Valve Cover (200 Duke)
211
Installing the Chain Securing Guide (200 Duke)
211
Installing the Oil Screen (200 Duke)
211
Removing the Engine from the Engine Assembly Stand (200 Duke)
212
Shift Mechanism
213
Adjusting the Shift Lever
213
Water Pump, Cooling System
214
Draining the Coolant
214
Filling/Bleeding the Cooling System
214
Checking the Antifreeze and Coolant Level
215
Checking the Coolant Level
216
Lubrication System
218
Oil Circuit
218
Checking the Engine Oil Level
218
Checking the Engine Oil Pressure
218
Changing the Engine Oil and Oil Filter, Cleaning the Oil Screen
220
Adding Engine Oil
221
Ignition System
222
Alternator - Checking the Stator Winding
222
Technical Data
223
Engine
223
125 Duke
223
Engine Tolerance, Wear Limits
224
125 Duke
224
200 Duke
225
Engine Tightening Torques
225
Capacities
226
Engine Oil
226
Coolant
226
Fuel
226
Chassis
227
Electrical System
227
Tires
228
Fork
228
Shock Absorber
228
Chassis Tightening Torques
228
Cleaning/Protective Treatment
231
Cleaning the Motorcycle
231
Checks and Maintenance Steps for Winter Operation
232
Storage
233
Preparing for Use after Storage
233
Service Schedule
234
Wiring Diagram
236
Duke EU/MAL)
236
Duke EU/MAL)
238
Duke EU/MAL)
240
Duke EU/MAL)
242
Duke EU/MAL)
244
Duke EU/MAL)
246
Duke EU/MAL)
248
Duke EU/MAL)
250
Duke EU/MAL)
252
Duke COL)
254
Duke COL)
256
Duke COL)
258
Duke COL)
260
Duke COL)
262
Duke COL)
264
Duke COL)
266
Duke COL)
268
Substances
270
Auxiliary Substances
272
Special Tools
274
Standards
283
Index
284

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KTM 2013 125 DUKE Owner's Manual

KTM 2013 125 DUKE Owner's Manual (185 pages)

2013

Brand: KTM | Category: Motorcycle | Size: 2.52 MB

Table of Contents

Table of Contents
5
1 Meansofrepresentation

9
- Means of Representation
  9
  - Symbols Used
    9
  - Formats Used
    9
2 Safety Advice

10
- Use Definition
  10
- Degrees of Risk and Symbols
  11
- Tampering Warning
  11
- Safe Operation
  12
- Protective Clothing
  13
- Work Rules
  13
- Environment
  13
- Owner's Manual
  14
3 Important Notes

15
- Guarantee, Warranty
  15
- Operating and Auxiliary Substances
  15
- Spare Parts, Accessories
  15
- Service
  15
- Figures
  16
- Customer Service
  16
4 View of Vehicle

18
- View of Vehicle, Front Left (Example)
  18
- View of Vehicle, Rear Right (Example)
  20
5 Serial Numbers

22
- Chassis Number/Type Label
  22
- Engine Number
  22
- Key Number
  23
6 Controls

24
- Clutch Lever
  24
- Hand Brake Lever
  24
- Throttle Grip
  25
- Horn Button
  25
- Light Switch
  26
- High Beam Flasher Button
  26
- Turn Signal Switch
  27
- Emergency off Switch
  27
- Electric Starter Button
  28
- Ignition/Steering Lock
  28
- Combination Instrument
  29
- Overview
  29
- Activation and Test
  30
- Warning Notes
  31
- Function Buttons
  34
- Indicator Lamps
  35
- Display
  36
- Filling Level Display in Fuel Tank
  37
- TRIP F Display
  38
- Coolant Temperature Indicator
  39
- Info Display
  40
- 6.11.11 Riding Time/Average Speed Menu
  41
- 6.11.12 Average Speed/Average Fuel Consumption 1 Menu
  41
- 6.11.13 Average Fuel Consumption 1/Average Fuel Consumption 2 Menu
  42
- 6.11.14 Average Fuel Consumption 2/Service Menu
  43
- 6.11.15 Service/Range Menu
  44
- 6.11.16 Range/Riding Time Menu
  45
- 6.11.17 Total Distance Menu ODO
  46
  - Distance Menu 1 TRIP 1
    46
  - Distance Menu 2 TRIP 2
    47
  - 6.11.20 Setting Kilometers or Miles
    47
  - 6.11.21 Setting the Time
    48
  - Adjusting the Shift Speed RPM 1
    49
  - Adjusting the Shift Speed RPM 2
    49
  - Opening the Filler Cap
    50
  - Closing the Filler Cap
    52
  - Seat Lock
    52
  - Tool Set
    53
  - Grab Handles
    53
  - Passenger Footrests
    54
  - Shift Lever
    54
  - Foot Brake Lever
    55
  - Side Stand
    56
7 Preparing for Use

57
- Advice on First Use
  57
- Running in the Engine
  58
- Loading the Vehicle
  59
8 Riding Instructions

61
- Checks and Maintenance When Preparing for Use
  61
- Starting
  62
- Starting off
  64
- Shifting, Riding
  64
- Applying the Brakes
  67
- Stopping, Parking
  69
- Transport
  70
- Refueling
  71
- Service Schedule
  73
9 Serviceschedule

75
10 Tuning the Chassis

75
11 Service Work on the Chassis

77
12 Brake System

94
13 Wheels, Tires

105
- Removing the Front Wheel
  105
- Installing the Front Wheel
  106
- Removing the Rear Wheel X
  107
- Installing the Rear Wheel X
  108
- Checking the Rear Hub Rubber Dampers
  110
- Checking the Tire Condition
  112
- Checking the Tire Air Pressure
  113
14 Electrical System

115
- Removing the Battery
  115
- Installing the Battery
  116
- Recharging the Battery
  117
- Changing the ABS Fuses
  120
- Changing the Fuses of Individual Power Consumers
  121
- Changing the Headlight Bulb
  123
- Changing the Parking Light Bulb
  126
- Checking the Headlight Setting
  130
- Adjusting the Headlight Range
  131
- Cooling System
  134
15 Coolingsystem

135
- Checking the Antifreeze and Coolant Level
  135
- Checking the Coolant Level
  137
- Draining the Coolant
  139
- Filling/Bleeding the Cooling System
  140
16 Tuning the Engine

143
17 Service Work on the Engine

146
18 Cleaning, Care

151
- Cleaning the Motorcycle
  151
  - Checks and Maintenance Steps for Winter Operation
    153
19 Storage

155
- Preparing for Use after Storage
  156
20 Troubleshooting

157
21 Technical Data

160
- Engine
  160
- Duke
  160
- Duke EU/MAL
  161
- Engine Tightening Torques
  163
- Capacities
  165
- Engine Oil
  165
- Coolant
  165
- Fuel
  165
- Chassis
  166
- Electrical System
  167
- Tires
  168
- Fork
  168
- Shock Absorber
  168
- Chassis Tightening Torques
  169
22 Substances

173
23 Auxiliary Substances

176
24 Standards

179
- Index
  180

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