Related Manuals for KTM 125 Duke EU 2015
Summary of Contents for KTM 125 Duke EU 2015
- Page 1 OWNER'S MANUAL 2015 125 Duke EU 200 Duke EU 200 Duke AR 200 Duke ASIA 200 Duke BR 200 Duke CN 200 Duke MY Art. no. 3213278en...
- Page 3 KTM accepts no liability for delivery options, devi- ations from illustrations and descriptions, misprints, and other errors.
- Page 4 DEAR KTM CUSTOMER ISO 9001(12 100 6061) According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead to the maximum possible quality of the products. Issued by: TÜV Management Service KTM Sportmotorcycle GmbH 5230 Mattighofen, Austria...
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Page 5: Table Of Contents
TABLE OF CONTENTS CONTROLS..............22 TABLE OF CONTENTS MEANS OF REPRESENTATION ........7 Clutch lever............22 Symbols used ............7 Hand brake lever..........22 Formats used............8 Throttle grip ............23 SAFETY ADVICE.............. 9 Horn button............23 Use definition............9 Light switch ............ - Page 6 TABLE OF CONTENTS 6.13.14 Average fuel consumption 2/service menu ..42 Applying the brakes..........66 6.13.15 Service/range menu........43 Stopping, parking..........68 6.13.16 Range/riding time menu ......... 44 Transport ............70 6.13.17 Total distance menu ODO ....... 45 Refueling ............71 6.13.18 Distance menu 1 TRIP 1 ........
- Page 7 TABLE OF CONTENTS 11.15 Fitting front spoiler ..........94 14.7 Changing the parking light bulb......134 12 BRAKE SYSTEM ............95 14.8 Checking the headlight setting ......137 12.1 ABS/antilock brake system (Option: With ABS) ..95 14.9 Adjusting the headlight range......138 12.2 Checking the brake discs ........
- Page 8 TABLE OF CONTENTS 21 TECHNICAL DATA............166 21.1 Engine ............166 21.1.1 125 Duke ........... 166 21.1.2 200 Duke ........... 167 21.2 Engine tightening torques ......... 169 21.3 Capacities ............171 21.3.1 Engine oil ........... 171 21.3.2 Coolant ............172 21.3.3 Fuel ............
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Page 9: Means Of Representation
All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own safety, have these jobs performed by an authorized KTM workshop. There, your motorcycle will be optimally cared for by specially trained experts using the specialist tools required. -
Page 10: Formats Used
MEANS OF REPRESENTATION Formats used The typographical formats used in this document are explained below. Specific name Identifies a proprietary name. Name ® Identifies a protected name. Brand™ Identifies a brand available on the open market. Underlined terms Refer to technical details of the vehicle or indicate technical terms that are explained in the glossary. -
Page 11: Safety Advice
SAFETY ADVICE Use definition KTM sport motorcycles are designed and constructed to meet the normal demands of regular road operation but not for use on race courses or offroad. Info The motorcycle is authorized for public road traffic in the homologous version only. -
Page 12: Degrees Of Risk And Symbols
SAFETY ADVICE Degrees of risk and symbols Danger Indicates a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken. Warning Indicates a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken. Caution Indicates a danger that may lead to minor injuries if the appropriate measures are not taken. -
Page 13: Safe Operation
Only operate the vehicle when it is in perfect technical condition, in accordance with its intended use, and in a safe and environmentally compatible manner. An appropriate driver's license is needed to ride the vehicle on public roads. Have malfunctions that impair safety promptly eliminated by an authorized KTM workshop. Adhere to the information and warning labels on the vehicle. -
Page 14: Protective Clothing
Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle. Always wear protective clothing that is in good condition and meets the legal requirements. In the interest of your own safety, KTM recommends that you only operate the vehicle while wearing protective clothing. Work rules Special tools are necessary for certain tasks. -
Page 15: Owner's Manual
Keep the Owner's Manual in an accessible place to enable you to refer to it as needed. If you would like to know more about the vehicle or have questions on the material you read, please contact an authorized KTM dealer. -
Page 16: Important Notes
Guarantee, warranty The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's Service & Warranty Booklet and in the KTM Dealer.net; otherwise, all warranty claims will be void. No warranty claims can be considered for damage resulting from manipulations and/or alterations to the vehicle. -
Page 17: Figures
Please follow the instructions in the text. Customer service Your authorized KTM dealer will be happy to answer any questions you may have on your vehicle and KTM. A list of authorized KTM dealers can be found on the KTM website. -
Page 18: View Of Vehicle
VIEW OF VEHICLE View of vehicle, front left (example) S00654-10... - Page 19 VIEW OF VEHICLE Combination instrument Rear mirror Clutch lever ( p. 22) Seat Passenger seat Seat lock ( p. 51) Grab handles ( p. 52) Engine number ( p. 21) Side stand ( p. 55) Shift lever ( p. 53)
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Page 20: View Of Vehicle, Rear Right (Example)
VIEW OF VEHICLE View of vehicle, rear right (example) S00655-10... - Page 21 VIEW OF VEHICLE Tool set ( p. 52) Light switch ( p. 24) High beam flasher button ( p. 24) Turn signal switch ( p. 25) Horn button ( p. 23) Filler cap Electric starter button ( p. 26) Emergency OFF switch ( p.
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Page 22: Serial Numbers
SERIAL NUMBERS Chassis number The chassis number is stamped on the right side of the steering head. 0 0 1 402408-10 Type label The type label is on the right of the frame behind the steering head. 0 0 1 402174-10... -
Page 23: Engine Number
SERIAL NUMBERS Engine number The engine number is stamped on the left side of the engine under the engine sprocket. 401949-10 Key number The key number can be found on the KEYCODECARD. Info You need the key number to order a spare key. Keep the KEYCODECARD in a safe place. -
Page 24: Controls
CONTROLS Clutch lever The clutch lever is fitted on the left side of the handlebar. S00656-10 Hand brake lever The hand brake lever is fitted on the right side of the handlebar. The front brake is engaged using the hand brake lever. S00663-10... -
Page 25: Throttle Grip
CONTROLS Throttle grip The throttle grip is fitted on the right side of the handlebar. S00664-10 Horn button The horn button is fitted on the left side of the handlebar. Possible states • Horn button in neutral position pressed –... -
Page 26: Light Switch
CONTROLS Light switch The light switch is fitted on the left side of the handlebar. Possible states Low beam on – The light switch is turned downward. In this position, the low beam and the tail light are switched on. High beam on –... -
Page 27: Turn Signal Switch
CONTROLS Turn signal switch The turn signal switch is fitted on the left side of the handlebar. Possible states Turn signal off Turn signal, left, on – Turn signal switch pressed to the left. The turn signal switch returns automatically to the central position after use. Turn signal, right, on –... -
Page 28: Electric Starter Button
CONTROLS Electric starter button The electric starter button is fitted on the right side of the handlebar. Possible states • Electric starter button in basic position pressed – In this position, the electric starter is actuated. • Electric starter button S00662-10 6.10 Ignition/steering lock... -
Page 29: Locking The Steering
CONTROLS 6.11 Locking the steering Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Park the vehicle. – Turn the handlebar all the way to the left. –... -
Page 30: Combination Instrument
CONTROLS 6.13 Combination instrument 6.13.1 Overview Display ( p. 35) Function buttons ( p. 33) Info display ( p. 39) Indicator lamps ( p. 34) 401685-10... -
Page 31: Activation And Test
CONTROLS 6.13.2 Activation and test Activation The combination instrument is activated when the ignition is switched on. Test The segments of the tachometer and the gear display light up and switch off in sequence. The speed display counts from 0 to 199 and back. The remaining display segments outside the info display light up briefly. -
Page 32: Warning Notes
CONTROLS 6.13.3 Warning notes Low Oil Pressure appears on the info display if the oil pressure is too low. 401309-01 Low Fuel Level appears on the info display if the fuel level reaches the reserve mark. 401310-01... - Page 33 CONTROLS High Coolant Temperature appears on the info display if the coolant temperature rises above the specified value. Coolant temperature 125 °C (257 °F) 401311-01 Side Stand Down appears on the info display if the side stand is folded down. 401312-01 Low Battery appears on the info display if the battery voltage falls below the specified value.
- Page 34 CONTROLS Service Not Reset appears on the info display for 10 seconds when the ignition is switched on and the distance interval between service appointments has been exceeded or the service interval display was not reset during a service appointment. 401461-01...
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Page 35: Function Buttons
CONTROLS 6.13.4 Function buttons You can change the display mode with the MODE button Possible display modes are total distance traveled (TRIP 1), distance 1 (ODO) and distance 2 (TRIP 2). Pressing and holding the SET button resets the distance 1 (TRIP 1) and ... -
Page 36: Indicator Lamps
CONTROLS 6.13.5 Indicator lamps Possible states The turn signal indicator light flashes green simultaneously with the turn signal – The turn signal is switched on. The engine diagnosis warning lamp (MIL) lights up red – The OBD (on- board diagnosis) has detected an emission- or safety-critical error. The shift warning lights up/flashes red –... -
Page 37: Display
CONTROLS 6.13.6 Display The speed is shown in kilometers per hour km/h or in miles per hour mph. The tachometer shows the engine speed in revolutions per minute. The gear display shows the engaged gear. The coolant temperature appears in segment ... -
Page 38: Filling Level Display In Fuel Tank
CONTROLS 6.13.7 Filling level display in fuel tank The filling level display consists of 9 bars. The more bars are lit, the more fuel is in the fuel tank. 401292-01... -
Page 39: Trip F Display
CONTROLS 6.13.8 TRIP F display If the fuel level drops to the reserve mark, the display mode automatically changes to TRIP F and starts to count from 0.0, regardless of the previous display mode. Info At the same time as the display mode TRIP F, the general warning lamp lights up and the warning note Low Fuel Level appears on the info display. -
Page 40: Coolant Temperature Indicator
CONTROLS 6.13.9 Coolant temperature indicator The temperature display consists of 13 bars. The more bars that light up, the hotter the coolant. When all bars light up, the following warning note appears on the info display: High Coolant Temperature. Possible states Engine cold –... -
Page 41: Info Display
CONTROLS 6.13.10 Info display Various warning notes appear on info display If the general warning lamp lights up, the corresponding warning note is shown on the info display. 401291-10... -
Page 42: 6.13.11 Riding Time/Average Speed Menu
CONTROLS 6.13.11 Riding time/average speed menu Condition Alternative 1 • The ignition is on. • The motorcycle is stationary. Alternative 2 • The ignition is on. • The motorcycle is moving. – Press the SET button briefly and repeatedly until the desired info display appears. The riding time and average speed are displayed in this menu. -
Page 43: 6.13.13 Average Fuel Consumption 1/Average Fuel Consumption 2 Menu
CONTROLS Info The average fuel consumption 1 is displayed after several 100 meters of travel after the ignition is switched on. If the ignition was switched off for over 60 minutes, the display of the average speed and average fuel consumption 1 is reset to 0. Press the SET button Next display mode on the info display briefly. -
Page 44: 6.13.14 Average Fuel Consumption 2/Service Menu
CONTROLS 6.13.14 Average fuel consumption 2/service menu Condition Alternative 1 • The ignition is on. • The motorcycle is stationary. Alternative 2 • The ignition is on. • The motorcycle is moving. – Press the SET button briefly and repeatedly until the desired info display appears. The average fuel consumption 2 in km/L (or miles/L) and the distance to the next service 401467-01 are displayed in this menu. -
Page 45: 6.13.15 Service/Range Menu
CONTROLS 6.13.15 Service/range menu Condition Alternative 1 • The ignition is on. • The motorcycle is stationary. Alternative 2 • The ignition is on. • The motorcycle is moving. – Press the SET button briefly and repeatedly until the desired info display appears. This menu shows the distance to the next service and the range. -
Page 46: 6.13.16 Range/Riding Time Menu
CONTROLS 6.13.16 Range/riding time menu Condition Alternative 1 • The ignition is on. • The motorcycle is stationary. Alternative 2 • The ignition is on. • The motorcycle is moving. – Press the SET button briefly and repeatedly until the desired info display appears. The range and the riding time are displayed in this menu. -
Page 47: 6.13.17 Total Distance Menu Odo
CONTROLS 6.13.17 Total distance menu ODO Condition Alternative 1 • The ignition is on. • The motorcycle is stationary. Alternative 2 • The ignition is on. • The motorcycle is moving. – Press the MODE button briefly and repeatedly until ODO appears on the display. ODO shows the total distance covered. -
Page 48: Distance Menu 2 Trip 2
CONTROLS Press the SET button Display of TRIP 1 is reset for 5 - 10 seconds. Press the MODE but- Next display mode on the display ton. 6.13.19 Distance menu 2 TRIP 2 Condition Alternative 1 • The ignition is on. •... -
Page 49: 6.13.21 Setting The Time
CONTROLS The motorcycle is stationary. – Press the MODE button briefly and repeatedly until ODO appears on the display. – Press the MODE button for 5 - 10 seconds. The display changes from km/h to mph or from mph to km/h. 401303-01 6.13.21 Setting the time Condition... -
Page 50: Adjusting The Shift Speed Rpm 1
CONTROLS 6.13.22 Adjusting the shift speed RPM 1 Condition The ignition is on. The motorcycle is stationary. – Press the MODE button briefly and repeatedly until TRIP 2 appears on the display. – Press the MODE button for 5 - 10 seconds. The display RPM 1 appears. -
Page 51: Opening The Filler Cap
CONTROLS – Press the MODE button briefly and repeatedly until TRIP 2 appears on the display. – Press the SET button for 5 - 10 seconds. The display RPM 2 appears. Info The engine speed can be set at intervals of 50. RPM 2 is the engine speed above which the shift warning light lights up con- stantly. - Page 52 CONTROLS Warning Danger of poisoning Fuel is poisonous and a health hazard. – Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with soap and water.
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Page 53: Closing The Filler Cap
CONTROLS 6.15 Closing the filler cap Warning Fire hazard Fuel is highly flammable, poisonous and harmful to your health. – After closing the filler cap, ensure that it is locked properly. Change cloth- ing that has been contaminated with fuel. Immediately clean contaminated areas on the skin with soap and water. -
Page 54: Tool Set
CONTROLS 6.17 Tool set The tool set is located under the passenger seat. B00758-10 6.18 Grab handles The grab handles are used for moving the motorcycle around. If you carry a passenger, the passenger can hold onto the grab handles during the trip. B00717-10... -
Page 55: Passenger Footrests
CONTROLS 6.19 Passenger footrests The passenger footrests can be folded in and out. Possible states Passenger footrests folded up – For operation without a passenger. • Passenger footrests folded down – For operation with a passenger. • S00666-10 6.20 Shift lever ... -
Page 56: Foot Brake Lever
CONTROLS The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. 401950-11 6.21 Foot brake lever Foot brake lever is located in front of the right footrest. The foot brake lever is used to activate the rear brake. 402177-10... -
Page 57: Side Stand
CONTROLS 6.22 Side stand The side stand is on the left side of the vehicle. The side stand is used to park the motorcycle. Info The side stand must be folded up during motorcycle use. Side stand is coupled with the safety start system; see the riding instructions. Possible states Side stand folded out –... -
Page 58: Preparing For Use
The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle. Warning Danger of accidents Uncontrollable handling characteristic due to non-approved and/or non-recommended tires/wheels. – Only tires/wheels approved by KTM and with the corresponding speed index should be used. Warning Danger of accidents Reduced road grip with new tires. –... -
Page 59: Running In The Engine
PREPARING FOR USE – Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop. You receive a delivery certificate and the Service and Warranty Booklet at vehicle handover. – Before your first trip, read the entire operating instructions carefully. -
Page 60: Loading The Vehicle
PREPARING FOR USE Loading the vehicle Warning Danger of accidents Unstable handling characteristics. – Do not exceed the maximum permitted weight and axle loads. The overall weight consists of: motorcycle operational and with a full tank, driver and passenger with protective clothing and helmet, baggage. Warning Danger of accidents Unstable handling characteristics due to incorrect mounting of suitcase and/or tank rucksack. - Page 61 PREPARING FOR USE – If you carry any baggage, make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight distribu- tion between the front and rear wheels. – Do not exceed the overall maximum permitted weight and the axle loads. Guideline Maximum permissible overall weight 335 kg (739 lb.)
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Page 62: Riding Instructions
RIDING INSTRUCTIONS Checks and maintenance when preparing for use Info Before every trip, check the condition of the vehicle and ensure that it is roadworthy. The vehicle must be in perfect technical condition when used. – Check the engine oil level. ( p. -
Page 63: Starting
RIDING INSTRUCTIONS Starting Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system. - Page 64 RIDING INSTRUCTIONS – Sit on the vehicle, take the weight off of the side stand, and move up all the way. – Turn the emergency OFF switch to the position – Switch on the ignition by turning the ignition key to the position After you switch on the ignition, you can hear the fuel pump working for about two seconds.
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Page 65: Starting Off
RIDING INSTRUCTIONS Switching off ABS (Option: With ABS) KTM recommends riding with ABS at all times. However, situations may arise in which ABS is not advantageous. Condition Vehicle stationary, engine running. – button for 3 – 5 seconds. Press the ... - Page 66 RIDING INSTRUCTIONS Warning Danger of accidents Malfunctions caused by incorrect ignition key position. – Do not change the ignition key position during a journey. Warning Danger of accidents Distraction from traffic activity by adjustments to the vehicle. – Make all adjustments when the vehicle is at a standstill. Warning Risk of injury Falling off of the passenger.
- Page 67 If you continue with the coolant temperature warning lamp alight, you may have engine failure. Info If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized KTM workshop. – When conditions allow (incline, road situation, etc.), you can shift into a higher gear.
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Page 68: Applying The Brakes
Danger of accidents Reduced braking efficiency caused by spongy pressure point of front or rear brake. – Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Failure of brake system. - Page 69 RIDING INSTRUCTIONS Warning Danger of accidents Delayed brake action on salted roads. – There may be salt deposits on the brake discs. In order to restore the normal braking efficiency, you will need to remove the deposits from the discs by carefully applying the brakes. (Option: Without ABS) Warning Danger of accidents If you brake too hard, the wheels can lock.
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Page 70: Stopping, Parking
RIDING INSTRUCTIONS Info When ABS is active, you can achieve maximum braking power even on low grip surfaces such as sandy, wet, or slippery ter- rain without locking of the wheels. Warning Danger of accidents Locking of the wheels due to braking action of the engine. –... - Page 71 RIDING INSTRUCTIONS – Always place the vehicle on a firm and even surface. Note Fire hazard Some vehicle components become very hot when the vehicle is operated. – Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from being run.
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Page 72: Transport
RIDING INSTRUCTIONS Transport Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. Note Fire hazard Some vehicle components become very hot when the vehicle is operated. – Do not park the vehicle near flammable or explosive substances. -
Page 73: Refueling
– In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the fuel system. (Your authorized KTM workshop will be glad to help.) – Only refuel with clean fuel that meets the specified standards. - Page 74 RIDING INSTRUCTIONS – Switch off the engine. – Open the filler cap. ( p. 49) – Fill the fuel tank with fuel up to the lower edge of the fuel filler. Total fuel tank 11 l (2.9 US gal) Super unleaded (ROZ 95/RON 95/PON capacity, approx.
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Page 75: Service Schedule
○ ● ● Check the functioning of the electrical equipment. ○ ● ● Read out the fault memory using the KTM diagnostics tool. ○ ● ● Change the engine oil and oil filter, clean the oil screen. p. 152) ○... - Page 76 Read out the fault memory using the KTM diagnostics tool after a test ride. ○ ● ● Reset the service interval display. ○ ● ● Make the service entry in the KTM Dealer.net and in the Service and Warranty Booklet. ○ One-time interval ● Periodic interval...
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Page 77: Tuning The Chassis
TUNING THE CHASSIS 10.1 Adjusting the spring preload of the shock absorber Warning Danger of accidents Modifications to the suspension settings can seriously alter the vehicle's ride behavior. – Following modifications, ride slowly at first to get the feel of the new ride behavior. Info The spring preload defines the initial situation of the spring process on the shock absorber. -
Page 78: Adjusting The Shift Lever
TUNING THE CHASSIS 10.2 Adjusting the shift lever Info The adjustment range of the shift lever is limited. – Loosen nuts – Adjust the shift lever by turning shift rod Guideline 110… 122 mm (4.33… 4.8 in) Shift rod adjustment range Info Make the same adjustments on both sides. -
Page 79: Service Work On The Chassis
SERVICE WORK ON THE CHASSIS 11.1 Raising the motorcycle with the rear wheel stand Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Mount the supports of the wheel stand. –... -
Page 80: Raising The Motorcycle With The Front Wheel Stand
SERVICE WORK ON THE CHASSIS – Secure the motorcycle against falling over. – Remove the rear wheel stand and lean the vehicle on the side stand 402029-10 11.3 Raising the motorcycle with the front wheel stand Note Danger of damage The parked vehicle may roll away or fall over. –... -
Page 81: Taking The Motorcycle Off Of The Front Wheel Stand
SERVICE WORK ON THE CHASSIS – Move the handlebar to the straight-ahead position. Position the wheel stand. Adapter (61029955620) Front wheel stand (61029055500) Info Always raise the rear of the motorcycle first. – Raise the front of the motorcycle. C00197-01 11.4 Taking the motorcycle off of the front wheel stand Note... -
Page 82: Removing The Passenger Seat
SERVICE WORK ON THE CHASSIS – Mount protection cap M00005-10 Finishing work – Take the motorcycle off of the rear wheel stand. ( p. 77) 11.5 Removing the passenger seat – Insert the ignition key in seat lock and turn it clockwise. -
Page 83: Mounting The Passenger Seat
SERVICE WORK ON THE CHASSIS 11.6 Mounting the passenger seat – Attach hooks on the passenger seat to brackets on the subframe, and lower it at the rear while pushing forward. – Press down the passenger seat until it clicks into place. Warning Danger of accidents The passenger seat can come loose from the anchoring if it is not mounted correctly. -
Page 84: Mounting The Seat
SERVICE WORK ON THE CHASSIS 11.8 Mounting the seat Main work – Attach seat recesses at screws and lower at the rear. – Mount and tighten screws Guideline Screw, seat 10 Nm (7.4 lbf ft) B00727-10 Finishing work –... -
Page 85: Checking For Chain Dirt Accumulation
SERVICE WORK ON THE CHASSIS 11.9 Checking for chain dirt accumulation – Check the chain for coarse dirt accumulation. » If the chain is very dirty: – Clean the chain. ( p. 83) 400678-01 11.10 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces their grip. –... -
Page 86: Checking The Chain Tension
SERVICE WORK ON THE CHASSIS Info The service life of the chain depends largely on its maintenance. Preparatory work – Raise the motorcycle with the rear wheel stand. ( p. 77) Main work – Clean the chain regularly. – Rinse off loose dirt with a soft jet of water. –... - Page 87 SERVICE WORK ON THE CHASSIS – Lean the motorcycle on the side stand. – Shift gear to neutral. – In the area of chain sliding guard, press the chain upward toward the swingarm and determine chain tension Info The upper chain section must be taut.
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Page 88: Adjusting The Chain Tension
SERVICE WORK ON THE CHASSIS 11.12 Adjusting the chain tension Warning Danger of accidents Danger caused by incorrect chain tension. – If the chain is too taut, the components of the secondary power transmission (chain, engine sprocket, rear sprocket, bearings in the transmission and in the rear wheel) will be under additional load. - Page 89 SERVICE WORK ON THE CHASSIS Main work (Option: Without ABS) – Loosen nut – Loosen nuts – Adjust the chain tension by turning adjusting screws on the left and right. Guideline Chain tension 5… 7 mm (0.2… 0.28 in) ...
- Page 90 SERVICE WORK ON THE CHASSIS (Option: With ABS) – Loosen nut – Loosen nuts – Adjust the chain tension by turning adjusting screws on the left and right. Guideline Chain tension 5… 7 mm (0.2… 0.28 in) ...
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Page 91: Checking The Chain, Rear Sprocket, And Engine Sprocket
SERVICE WORK ON THE CHASSIS 11.13 Checking the chain, rear sprocket, and engine sprocket – Check rear sprocket and engine sprocket for wear. » If the rear sprocket or engine sprocket are worn: – Change the power set. Info The engine sprocket, rear sprocket and chain should only be changed together. - Page 92 SERVICE WORK ON THE CHASSIS – Shift gear to neutral. – Pull the lower chain section with specified weight Guideline Weight, chain wear measurement 15 kg (33 lb.) – Measure the distance of 20 chain links in the lower chain section. Info 0 0 A Chain wear is not always even, so you should repeat this measurement at differ-...
- Page 93 SERVICE WORK ON THE CHASSIS – Remove screw . Push the chain guard aside. S00670-10 – Check the chain sliding guard for wear. » If the chain sliding guard has lost material due to wear to the extent that, in area ...
- Page 94 SERVICE WORK ON THE CHASSIS – Position the chain guard and tighten screw Guideline Screw, chain guard EJOT PT ® 4 Nm (3 lbf ft) – Tighten screw Guideline Screw, chain guard EJOT PT ® 4 Nm (3 lbf ft) –...
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Page 95: Removing The Front Spoiler
SERVICE WORK ON THE CHASSIS 11.14 Removing the front spoiler – Remove screws B00770-10 – Remove screws – Take off the front spoiler. B00771-10... -
Page 96: Fitting Front Spoiler
SERVICE WORK ON THE CHASSIS 11.15 Fitting front spoiler – Position the front spoiler. Mount screws but do not tighten yet. B00770-10 – Mount and tighten screws Guideline Screw, front spoiler 9 Nm (6.6 lbf ft) – Tighten screw ... -
Page 97: Brake System
KTM. – Service work and repairs must be performed properly. (Your authorized KTM workshop will be glad to help.) The ABS is a safety system that prevents locking of the wheels when the vehicle is traveling straight ahead without the action of lateral forces. -
Page 98: Checking The Brake Discs
Danger of accidents Reduced braking efficiency due to worn brake disc(s). – Change the worn brake disc(s) without delay. (Your authorized KTM workshop will be glad to help.) – Check the thickness of the front and rear brake discs at several places on the disk to ... -
Page 99: Checking The Brake Fluid Level Of The Front Brake
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. -
Page 100: Adding Front Brake Fluid
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage. -
Page 101: Checking The Front Brake Linings
Checking the front brake linings Warning Danger of accidents Reduced braking efficiency caused by worn brake linings. – Change worn brake linings immediately. (Your authorized KTM workshop will be glad to help.) Note Danger of accidents Reduced braking efficiency caused by damaged brake discs. –... -
Page 102: Checking The Free Travel Of Foot Brake Lever
BRAKE SYSTEM – Check the brake linings for minimum thickness ≥ 1 mm (≥ 0.04 in) Minimum thickness » If the minimum thickness is less than specified: – Change the front brake linings. – Check the brake linings for damage and cracking. »... -
Page 103: Adjusting The Free Travel Of The Foot Brake Lever
BRAKE SYSTEM – Disconnect spring – Move the foot brake lever back and forth between the end stop and the contact to the foot brake cylinder piston and check free travel Guideline Free travel at foot brake lever 3…... -
Page 104: Checking The Rear Brake Fluid Level
If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.) - Page 105 Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) (Option: Without ABS) –...
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Page 106: Adding Rear Brake Fluid
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage. -
Page 107: Checking The Rear Brake Linings
Clean up overflowed or spilt brake fluid immediately with water. 12.10 Checking the rear brake linings Warning Danger of accidents Reduced braking efficiency caused by worn brake linings. – Change worn brake linings immediately. (Your authorized KTM workshop will be glad to help.) - Page 108 BRAKE SYSTEM Note Danger of accidents Reduced braking efficiency caused by damaged brake discs. – If the brake linings are not changed in time, the steel brake lining carriers grind on the brake disc. The braking effect is greatly reduced and the brake discs are destroyed. Check the brake linings regularly. –...
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Page 109: Wheels, Tires
WHEELS, TIRES 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with the rear wheel stand. ( p. 77) – Raise the motorcycle with the front wheel stand. ( p. 78) Main work (Option: Without ABS) – Loosen screw by several rotations. -
Page 110: Installing The Front Wheel
WHEELS, TIRES (Option: With ABS) – Remove screws and push the fender to the side. – Remove screw and pull wheel speed sensor out of the hole. – Loosen screw by several rotations. – Release screws –... - Page 111 WHEELS, TIRES Main work (Option: Without ABS) – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – Change the wheel bearing. – Clean and grease the shaft seal rings and mating surfaces of the spacers.
- Page 112 WHEELS, TIRES (Option: With ABS) – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – Change the wheel bearing. – Clean and grease the shaft seal rings and mating surfaces ...
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Page 113: Removing The Rear Wheel
WHEELS, TIRES The fork legs straighten. – Tighten screws Guideline Screw, fork stub 15 Nm (11.1 lbf ft) Finishing work – Take the motorcycle off of the rear wheel stand. ( p. 77) 13.3 Removing the rear wheel Preparatory work –... - Page 114 WHEELS, TIRES Main work (Option: Without ABS) – Remove nut and washer. – Remove chain adjuster – Hold rear wheel and wheel spindle pull out with washer and chain adjuster – Push the rear wheel forward as far as possible and take the chain off the rear sprocket.
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Page 115: Installing The Rear Wheel
WHEELS, TIRES (Option: With ABS) – Remove screw and pull wheel speed sensor out of the hole. – Remove nut and washer. – Remove chain adjuster – Hold rear wheel and wheel spindle pull out with washer and chain adjuster –... - Page 116 WHEELS, TIRES Warning Danger of accidents No braking effect when operating the rear brake. – After installing the rear wheel, always operate the foot brake until the pressure point is reached. Main work (Option: Without ABS) – Check the rear hub rubber dampers. p.
- Page 117 WHEELS, TIRES – Pull the rear wheel back and mount wheel spindle with the washer and chain adjuster Guideline Mount the left and right chain adjusters in the same position. – Mount nut and washer. – Push the rear wheel forward so that the chain adjusters are on the screws, and ...
- Page 118 WHEELS, TIRES – Install the rubber damper and rear sprocket carrier on the rear wheel. – Position the rear wheel. The brake linings are correctly positioned. – Push the rear wheel as far forward as possible and place the chain on the rear sprocket.
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Page 119: Checking The Rear Hub Rubber Dampers
WHEELS, TIRES 13.5 Checking the rear hub rubber dampers Info The engine power is transmitted from the rear sprocket to the rear wheel via 6 rubber dampers. They eventually wear out during operation. If the rubber dampers are not changed in time, the rear sprocket carrier and the rear hub will be damaged. Preparatory work –... -
Page 120: Checking The Tire Condition
Danger of accidents Uncontrollable vehicle handling in the event of a flat tire. – In the interest of safety, replace damaged or worn tires immediately. (Your authorized KTM workshop will be glad to help.) Warning Danger of crashing Poor vehicle handling due to different tire tread patterns on front and rear wheels. -
Page 121: Checking The Tire Air Pressure
DOT marking. The first two digits refer to the week of manufacture and last two digits refer to the year of manufacture. KTM recommends that the tires are changed regardless of the actual wear, at the latest after 5 years. - Page 122 WHEELS, TIRES – Remove the dust cap. – Check tire air pressure when the tires are cold. Tire air pressure, solo Front 2.0 bar (29 psi) Rear 2.0 bar (29 psi) Tire air pressure with passenger/full payload Front 2.0 bar (29 psi) 400695-01 Rear 2.2 bar (32 psi)
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Page 123: Electrical System
ELECTRICAL SYSTEM 14.1 Removing the battery Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. – Avoid contact with battery acid and battery gases. –... -
Page 124: Installing The Battery
ELECTRICAL SYSTEM – Pull back the positive terminal cover – Disconnect positive cable from the battery. – Detach rubber band – Pull the battery up and out of the battery holder. Info Never operate the motorcycle with a discharged battery or without a battery. In both cases, electrical components and safety devices can be damaged. -
Page 125: Recharging The Battery
ELECTRICAL SYSTEM – Position the negative cable and mount and tighten the screw. – Position the negative terminal cover B00750-11 Finishing work – Mount the seat. ( p. 82) – Mount the passenger seat. ( p. 81) – Set the clock. - Page 126 – Do not dispose of batteries with the household waste. Dispose of a defective battery in an environmentally friendly manner. Give the battery to your authorized KTM dealer or dispose of it at a collection point for used batteries. Info Even when there is no load on the battery, it discharges steadily.
- Page 127 ELECTRICAL SYSTEM Main work – Connect the battery charger to the battery. Switch on the battery charger. Battery charger (58429074000) You can also use the battery charger to test rest potential and start potential of the bat- tery, and to test the alternator. With this device, you cannot overcharge the battery. Info ...
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Page 128: Changing The Abs Fuses (Option: With Abs)
ELECTRICAL SYSTEM 14.4 Changing the ABS fuses (Option: With ABS) Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used. – Use only fuses with the prescribed amperage. Never bypass or repair fuses. Info Two fuses for the ABS are located under the passenger seat. These fuses protect the return pump and the hydraulic unit of the ABS. -
Page 129: Changing The Fuses Of Individual Power Consumers
ELECTRICAL SYSTEM Replace spare fuse in the fuse box so that it is available if needed. – Mount the protection cap. To change the fuse of the ABS return pump: – Take off the protection cap and remove fuse Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used. - Page 130 ELECTRICAL SYSTEM Preparatory work – Switch off all power consumers and switch off the engine. – Remove the passenger seat. ( p. 80) Main work (Option: Without ABS) – Open fuse box cover B00753-10 – Remove the defective fuse. Guideline Fuse 1 - 30 A - main fuse Fuse 2 - 15 A - combination instrument...
- Page 131 ELECTRICAL SYSTEM Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used. – Use only fuses with the prescribed amperage. Never bypass or repair fuses. – Use spare fuses with the correct rating only. Fuse (75011088010) ( p.
- Page 132 ELECTRICAL SYSTEM – Remove the defective fuse. Guideline Fuse 1 - 30 A - main fuse Fuse 2 - 15 A - start auxiliary relay, alarm system (OPTIONAL) Fuse 3 - 15 A - control unit, power relay Fuse 4 - 15 A - ignition coil Fuse 5 - 15 A - radiator fan Fuse 6 - 15 A - horn, brake light, turn signal, high beam, low beam, parking light, S00680-10...
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Page 133: Changing The Headlight Bulb
ELECTRICAL SYSTEM Replace the spare fuse in the fuse box so that it is available if needed. – Check that the power consumer is functioning properly. – Close the fuse box cover. Finishing work – Mount the passenger seat. ( p. - Page 134 ELECTRICAL SYSTEM – Remove screws – Lift the headlight mask slightly and swing forward. 601914-10 – Remove protection cap – Unplug connector B00760-10 – Detach retaining clamp – Remove headlight bulb – Position the new headlight bulb in the headlight housing. Guideline Insert the headlight bulb so that the catches latch into the recesses.
- Page 135 ELECTRICAL SYSTEM – Plug in connector – Mount protection cap B00760-10 – Fold the headlight mask up. – Mount and tighten screws Guideline Screw, headlight mask 11 Nm Loctite ® 243™ (8.1 lbf ft) 601914-10 – Mount expanding rivets on both sides.
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Page 136: Changing The Parking Light Bulb
ELECTRICAL SYSTEM 14.7 Changing the parking light bulb Note Damage to reflector Reduced brightness. – Grease on the lamp will evaporate due to the heat and be deposited on the reflector. Clean the lamp and keep it free of grease before mounting. - Page 137 ELECTRICAL SYSTEM – Remove screws – Remove cover B00762-10 – Pull the socket with bulb out of the housing. – Remove the bulb. – Position a new light bulb in the socket. Parking light (W5W/socket W2.1x9.5d) ( p.
- Page 138 ELECTRICAL SYSTEM – Position cover – Mount and tighten screws B00762-10 – Fold the headlight mask up. – Mount and tighten screws Guideline Screw, headlight mask 11 Nm Loctite ® 243™ (8.1 lbf ft) 307324-10 – Mount expanding rivets on both sides.
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Page 139: Checking The Headlight Setting
ELECTRICAL SYSTEM 14.8 Checking the headlight setting – Position the vehicle upright on a horizontal surface in front of a light wall and make a 0 0 A mark at the height of the center of the low beam headlight. –... -
Page 140: Adjusting The Headlight Range
ELECTRICAL SYSTEM 14.9 Adjusting the headlight range Main work – Remove expanding rivets 601915-10 – Remove screws – Lift the headlight mask slightly and swing forward. 601914-10... - Page 141 ELECTRICAL SYSTEM – Adjust the beam distance of the headlight by turning screw Guideline For a motorcycle with rider, and with luggage and a passenger if applicable, the light/dark boundary must be exactly on the lower mark (applied in: Checking headlight adjustment).
- Page 142 ELECTRICAL SYSTEM Finishing work – Check the headlight setting. ( p. 137)
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Page 143: Cooling System
COOLING SYSTEM 15.1 Cooling system Water pump in the engine circulates the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap . Heat expansion causes excess coolant to flow into compensating tank When the temperature falls, this surplus coolant is sucked back into the cooling system. -
Page 144: Checking The Antifreeze And Coolant Level
COOLING SYSTEM The coolant is cooled by the air stream and a radiator fan , which is controlled by a ther- moswitch. The lower the speed, the less the cooling effect. Dirty cooling fins also reduce the cooling effect. 401768-10 15.2 Checking the antifreeze and coolant level... - Page 145 COOLING SYSTEM Warning Danger of poisoning Coolant is poisonous and a health hazard. – Coolant must not come into contact with the skin, eyes, or clothing. If contact occurs with the eyes, rinse with water immedi- ately and contact a physician. Immediately clean contaminated areas on the skin with soap and water. If fuel is swallowed, con- tact a physician immediately.
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Page 146: Checking The Coolant Level
COOLING SYSTEM – Remove radiator cap – Check the coolant antifreeze. −25… −45 °C (−13… −49 °F) » If the antifreeze in the coolant does not match the specified value: – Correct the coolant antifreeze. – Check the coolant level in the radiator. The radiator must be completely filled. - Page 147 COOLING SYSTEM Warning Danger of poisoning Coolant is poisonous and a health hazard. – Coolant must not come into contact with the skin, eyes, or clothing. If contact occurs with the eyes, rinse with water immedi- ately and contact a physician. Immediately clean contaminated areas on the skin with soap and water. If fuel is swallowed, con- tact a physician immediately.
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Page 148: Draining The Coolant
COOLING SYSTEM – Mount the radiator cap. 15.4 Draining the coolant Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down. -
Page 149: Filling/Bleeding The Cooling System
COOLING SYSTEM Guideline Plug, water pump drain hole (125 Duke) 8 Nm (5.9 lbf ft) Plug, water pump drain hole (200 Duke) 8 Nm (5.9 lbf ft) 15.5 Filling/bleeding the cooling system Warning Danger of poisoning Coolant is poisonous and a health hazard. –... - Page 150 COOLING SYSTEM – Release bleeder screw by three turns. – Tilt the vehicle slightly to the right. – Pour in coolant until it emerges without bubbles at the bleeder screw, and then mount and tighten the bleeder screw immediately. Coolant ( p.
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Page 151: Tuning The Engine
TUNING THE ENGINE 16.1 Checking the play in the throttle cable – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Move the throttle grip back and forth to ascertain play in the throttle cable. Throttle cable play 3…... -
Page 152: Adjusting The Play In The Throttle Cable
TUNING THE ENGINE 16.2 Adjusting the play in the throttle cable – Move the handlebar to the straight-ahead position. – Push back sleeve – Loosen lock nut – Adjust the play in the throttle cable by turning adjusting screw Guideline Throttle cable play 3…... -
Page 153: Adjusting The Clutch Cable Play
TUNING THE ENGINE » If the clutch lever play changes: – Check the routing of the clutch cable. 16.4 Adjusting the clutch cable play – Move the handlebar to the straight-ahead position. – Push back sleeve – Loosen lock nut ... -
Page 154: Service Work On The Engine
SERVICE WORK ON THE ENGINE 17.1 Checking the engine oil level Condition The engine is at operating temperature. Preparatory work – Stand the motorcycle upright on a horizontal surface. Main work – Check the engine oil level. Info After switching off the engine, wait one minute before checking the level. ... - Page 155 SERVICE WORK ON THE ENGINE Info Drain the engine oil only when the engine is warm. Preparatory work – Remove the front spoiler. ( p. 93) – Stand the motorcycle on its side stand on a horizontal surface. Main work –...
- Page 156 SERVICE WORK ON THE ENGINE – Remove screws . Remove the oil filter cover with the O-ring. – Pull oil filter out of the oil filter housing. Circlip pliers reverse (51012011000) – Completely drain the engine oil. –...
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Page 157: Adding Engine Oil
SERVICE WORK ON THE ENGINE – Remove the oil filler plug with the O-ring from the clutch cover and fill up with engine oil. Engine oil 1.5 l (1.6 qt.) External temper- Engine oil ature: 0… 50 °C (SAE 15W/50) (32…... - Page 158 SERVICE WORK ON THE ENGINE Main work – Remove the oil filler plug with the O-ring from the clutch cover and fill up with engine oil. Engine oil (SAE 15W/50) ( p. 181) Engine oil (SAE 10W/40) ( p. 182) Info For optimal performance of the engine oil, do not mix different types of engine oil.
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Page 159: Cleaning, Care
CLEANING, CARE 18.1 Cleaning the motorcycle Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – When cleaning the vehicle with a pressure cleaner, do not point the water jet directly onto electrical components, connectors, cables, bearings, etc. Maintain a minimum distance of 60 cm between the nozzle of the pressure cleaner and the component. Excessive pres- sure can cause malfunctions or destroy these parts. - Page 160 CLEANING, CARE Info Use warm water containing normal motorcycle cleaner and a soft sponge. Never apply motorcycle cleaner to a dry vehicle; always rinse the vehicle with water first. If the vehicle was operated in road salt, clean it with cold water. Warm water would enhance the corrosive effects of salt.
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Page 161: Checks And Maintenance Steps For Winter Operation
CLEANING, CARE Perfect Finish and high gloss polish for paints ( p. 185) Info Do not polish parts that were matte when delivered as this would strongly impair the material quality. – Treat all plastic parts and powder-coated parts with a mild cleaning and care product. Special cleaner for glossy and matte paint finishes, metal and plastic surfaces p. - Page 162 CLEANING, CARE – Treat the engine, swingarm, and all other bright and zinc-plated parts (except for the brake discs) with a wax-based corrosion inhibitor. Info Corrosion inhibitor is not permitted to come in contact with the brake discs as this would greatly reduce the braking force. –...
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Page 163: Storage
0… 35 °C (32… 95 °F) direct sunlight – Store the vehicle in a dry location that is not subject to large fluctuations in tempera- ture. Info KTM recommends jacking up the motorcycle. – Raise the motorcycle with the rear wheel stand. ( p. 77) -
Page 164: Preparing For Use After Storage
STORAGE – Raise the motorcycle with the front wheel stand. ( p. 78) – Cover the motorcycle with a tarp or similar cover that is permeable to air. Info Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion. -
Page 165: Troubleshooting
Operating error Go through the steps of starting the engine. p. 61) – Fault in fuel injection system Read out the fault memory using the KTM diag- nostics tool. – Engine has too little power Air filter is very dirty Change the air filter. - Page 166 Defect in radiator fan system Check the radiator fan system. – The engine diagnosis warning Fault in fuel injection system Read out the fault memory using the KTM diag- lamp (MIL) lights up red nostics tool. – Engine dies during the trip Lack of fuel Refuel.
- Page 167 TROUBLESHOOTING Faults Possible cause Action – Battery discharged Ignition was not switched off when Recharge the battery. p. 123) vehicle was parked – Battery is not being charged by alter- Check the charging voltage. nator – Check the open-circuit current. –...
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Page 168: Technical Data
TECHNICAL DATA 21.1 Engine 21.1.1 125 Duke Design 1-cylinder 4-stroke engine, water-cooled Displacement 125 cm³ (7.63 cu in) Stroke 47.2 mm (1.858 in) Bore 58 mm (2.28 in) Compression ratio 12.8:1 Control DOHC, 4 valves controlled via cam lever, chain drive Valve diameter, intake 22.5 mm (0.886 in) Valve diameter, exhaust... -
Page 169: Duke
TECHNICAL DATA 3rd gear 18:28 4th gear 21:26 5th gear 22:23 6th gear 24:22 Mixture preparation Electronically controlled fuel injection Ignition Contactless controlled fully electronic ignition with digital ignition adjustment Alternator 12 V, 230 W Spark plug BOSCH VR 5 NE Spark plug electrode gap 0.8 mm (0.031 in) Spark plug... - Page 170 TECHNICAL DATA Valve diameter, exhaust 24 mm (0.94 in) Valve clearance, intake, cold 0.08… 0.12 mm (0.0031… 0.0047 in) Valve clearance, exhaust, cold 0.13… 0.17 mm (0.0051… 0.0067 in) Crankshaft bearing Two ball bearings Conrod bearing Sleeve bearing Pistons Cast light alloy Piston rings 1 compression ring, 1 tapered compression piston ring, 1 oil scraper ring...
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Page 171: Engine Tightening Torques
TECHNICAL DATA Spark plug BOSCH Super R6 VR 5 NEW Spark plug electrode gap 1 mm (0.04 in) Cooling Water cooling, permanent circulation of coolant by water pump Idle speed 1,450… 1,550 rpm Starting aid Electric starter 21.2 Engine tightening torques Oil nozzle 6 Nm (4.4 lbf ft) Loctite... - Page 172 TECHNICAL DATA Screw, chain securing guide 11 Nm (8.1 lbf ft) Loctite ® 243™ – Screw, clutch cover 12 Nm (8.9 lbf ft) – Screw, engine case M6x40 12 Nm (8.9 lbf ft) Loctite ® 243™ Screw, engine case M6x60 12 Nm (8.9 lbf ft) Screw, freewheel gear retaining bracket 12 Nm (8.9 lbf ft)
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Page 173: Capacities
TECHNICAL DATA Screw, camshaft drive sprocket (200 25 Nm (18.4 lbf ft) Loctite ® 243™ Duke) Loctite 243™ Screw, return spring, quick shifter 12 Nm (8.9 lbf ft) ® – Stud, exhaust flange 22 Nm (16.2 lbf ft) Cylinder head screw (125 Duke) Step 1 Thread is oiled, head flat is greased... -
Page 174: Coolant
TECHNICAL DATA 21.3.2 Coolant Coolant 1 l (1 qt.) Coolant ( p. 181) 21.3.3 Fuel Total fuel tank capacity, approx. 11 l (2.9 US gal) Super unleaded (ROZ 95/RON 95/PON 91) ( p. 183) Fuel reserve, approx. 1.5 l (1.6 qt.) 21.4 Chassis Frame... -
Page 175: Electrical System
TECHNICAL DATA Brake discs - wear limit Front 3.6 mm (0.142 in) Rear 3.6 mm (0.142 in) Tire air pressure, solo Front 2.0 bar (29 psi) Rear 2.0 bar (29 psi) Tire air pressure with passenger/full payload Front 2.0 bar (29 psi) Rear 2.2 bar (32 psi) Secondary ratio (125 Duke) -
Page 176: Tires
Turn signal Brake/tail light License plate lamp 21.6 Tires Front tires Rear tires 110/70 R 17 M/C 54S TL 150/60 R 17 M/C 66S TL MRF revz FC MRF revz C Additional information is available in the Service section under: http://www.ktm.com... -
Page 177: Fork
TECHNICAL DATA 21.7 Fork Fork part number 90601000044 Fork WP Suspension Fork length 736 mm (28.98 in) Fork oil 450 ml (15.21 fl. oz.) Fork oil (SAE 4) (48601166S1) ( p. 182) 21.8 Shock absorber Shock absorber part number 90604010000 WP Suspension Shock absorber Spring preload... - Page 178 TECHNICAL DATA – Screw, trim, subframe, bottom 2 Nm (1.5 lbf ft) – Remaining nuts, chassis 5 Nm (3.7 lbf ft) – Remaining screws, chassis 5 Nm (3.7 lbf ft) – Screw, ABS hose clamp (Option: With 7 Nm (5.2 lbf ft) ABS) Screw, brake line holder, rear 7 Nm (5.2 lbf ft)
- Page 179 TECHNICAL DATA – Remaining nuts, chassis 10 Nm (7.4 lbf ft) – Remaining screws, chassis 10 Nm (7.4 lbf ft) – Screw, air filter box 6 Nm (4.4 lbf ft) – Screw, air filter box lid 3 Nm (2.2 lbf ft) –...
- Page 180 TECHNICAL DATA – Screw, rollover sensor holder 10 Nm (7.4 lbf ft) – Screw, seat 10 Nm (7.4 lbf ft) Screw, shift lever linkage 11 Nm (8.1 lbf ft) Loctite ® 243™ – Screw, voltage regulator 11 Nm (8.1 lbf ft) –...
- Page 181 TECHNICAL DATA Screw, front brake caliper M8x1 30 Nm (22.1 lbf ft) Loctite ® 204™ – Banjo bolt, brake line 24 Nm (17.7 lbf ft) Fitting side stand 35 Nm (25.8 lbf ft) Loctite ® 243™ – Nut mirror image left 20 Nm (14.8 lbf ft) –...
- Page 182 TECHNICAL DATA – Nut, steering head M30x1 Step 1 55 Nm (40.6 lbf ft) 2nd stage (loosen, counter- clockwise) 2 turns Step 3 5 Nm (3.7 lbf ft)
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Page 183: Substances
SUBSTANCES Brake fluid DOT 4 / DOT 5.1 Standard/classification – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that exhibits the corresponding properties. Recommended supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 Motorex ®... - Page 184 SUBSTANCES Guideline – Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties. Partially synthetic engine oil Recommended supplier Motorex ® – Formula 4T Engine oil (SAE 10W/40) Standard/classification –...
- Page 185 SUBSTANCES Super unleaded (ROZ 95/RON 95/PON 91) Standard/classification – DIN EN 228 (ROZ 95/RON 95/PON 91) Guideline – Only use unleaded super fuel that matches or is equivalent to the specified fuel grade. – Fuel with an ethanol content of up to 10 % (E10 fuel) is safe to use. Info Do not use fuel containing methanol (e.
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Page 186: Auxiliary Substances
AUXILIARY SUBSTANCES Chain cleaner Recommended supplier Motorex ® – Chain Clean Chain lube for road use Guideline Recommended supplier Motorex ® – Chainlube Road Fuel additive Recommended supplier Motorex ® – Fuel Stabilizer Long-life grease Recommended supplier Motorex ® – Bike Grease 2000 Motorcycle cleaner Recommended supplier... - Page 187 AUXILIARY SUBSTANCES Perfect Finish and high gloss polish for paints Recommended supplier Motorex ® – Moto Polish & Shine Preserving materials for paints, metal and rubber Recommended supplier Motorex ® – Moto Protect Special cleaner for glossy and matte paint finishes, metal and plastic surfaces Recommended supplier Motorex ®...
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Page 188: Standards
STANDARDS JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Ear- lier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specification. Whereas long service intervals are demanded for automobile engines, high performance at high engine speeds are in the foreground for motorcycle engines. -
Page 189: Index
INDEX INDEX Brakes, applying ....... . . 66 ABS ......... 95 Capacity Accessories . - Page 190 INDEX display TRIP F ....... . 37 changing ........152 distance menu 1 TRIP 1 .
- Page 191 INDEX raising with the rear wheel stand ....77 taking off of the front wheel stand ....79 Grab handles .
- Page 192 INDEX Shock absorber spring preload, adjusting ......75 Rear hub rubber dampers Side stand ........55 checking .
- Page 193 INDEX Tire condition checking ........118 Tool set ........52 Transport .
- Page 194 *3213278en* 3213278en 01/2015 KTM Sportmotorcycle GmbH Photo: Mitterbauer/KTM 5230 Mattighofen/Austria http://www.ktm.com...