KTM 125 DUKE EU Repair Manual page 6

TABLE OF CONTENTS
16.4.16 Checking the oil pressure regulator valve
(125 Duke) .............................................. 127
16.4.17 Checking the clutch (125 Duke)................. 128
16.4.18 Preassembling the clutch (125 Duke) ......... 129
16.4.19 Checking the shift mechanism (125
Duke) ...................................................... 130
16.4.20 Preassembling the shift shaft (125 Duke) ... 131
16.4.21 Disassembling the main shaft (125
Duke) ...................................................... 131
16.4.22 Dismantling the countershaft (125 Duke).... 132
16.4.23 Checking the transmission (125 Duke)........ 132
16.4.24 Assembling the main shaft (125 Duke) ....... 133
16.4.25 Assembling the countershaft (125 Duke) .... 134
16.4.26 Checking the timing assembly (125
Duke) ...................................................... 136
16.4.27 Changing the stator (125 Duke) ................. 136
16.4.28 Checking the electric starter drive (125
Duke) ...................................................... 137
16.4.29 Checking the freewheel (125 Duke) ............ 138
16.4.30 Work on the left section of the engine case
(200 Duke) .............................................. 138
16.4.31 Work on the right section of the engine
case (200 Duke) ....................................... 139
16.4.32 Changing the shaft seal ring of the water
pump (200 Duke) ..................................... 139
16.4.33 Removing the main bearing (200 Duke) ...... 140
16.4.34 Checking the radial play of the lower
conrod bearing (200 Duke) ........................ 141
16.4.35 Changing the conrod bearing (200 Duke) .... 142
16.4.36 Changing the balancer shaft bearing (200
Duke) ...................................................... 143
16.4.37 Changing the camshaft bearing (200
Duke) ...................................................... 143
16.4.38 Work on the cylinder head (200 Duke) ........ 144
16.4.39 Checking the cylinder head (200 Duke) ...... 145
16.4.40 Checking/measuring the cylinder (200
Duke) ...................................................... 145
16.4.41 Checking the piston ring end gap (200
Duke) ...................................................... 146
16.4.42 Checking/measuring the piston (200
Duke) ...................................................... 146
16.4.43 Checking the piston/cylinder mounting
clearance (200 Duke)................................ 147
16.4.44 Checking the oil pump (200 Duke) ............. 147
16.4.45 Checking the oil pressure regulator valve
(200 Duke) .............................................. 147
16.4.46 Checking the clutch (200 Duke)................. 148
16.4.47 Preassembling the clutch (200 Duke) ......... 149
16.4.48 Checking the shift mechanism (200
Duke) ...................................................... 150
16.4.49 Preassembling the shift shaft (200 Duke) ... 151
16.4.50 Disassembling the main shaft (200
Duke) ...................................................... 151
16.4.51 Dismantling the countershaft (200 Duke).... 152
16.4.52 Checking the transmission (200 Duke)........ 152
16.4.53 Assembling the main shaft (200 Duke) ....... 153
16.4.54 Assembling the countershaft (200 Duke) .... 154
16.4.55 Checking the timing assembly (200
Duke) ...................................................... 156
16.4.56 Changing the stator (200 Duke) ................. 156
16.4.57 Checking the electric starter drive (200
Duke) ...................................................... 157
16.4.58 Checking the freewheel (200 Duke) ............ 158
16.5 Assembling the engine .................................. 158
16.5.1 Installing the crankshaft (125 Duke) .......... 158
16.5.2 Installing the balancer shaft (125 Duke) ..... 158
16.5.3 Installing the transmission shafts (125
Duke) ...................................................... 159
16.5.4 Installing the shift forks (125 Duke) ........... 159
16.5.5 Installing the shift drum (125 Duke)........... 159
16.5.6 Installing the shift rails (125 Duke) ............ 160
16.5.7 Installing the left engine case (125
Duke) ...................................................... 160
16.5.8 Installing the oil filter (125 Duke) .............. 161
16.5.9 Installing the locking lever (125 Duke) ....... 161
16.5.10 Installing the shift drum locating (125
Duke) ...................................................... 161
16.5.11 Installing the shift shaft (125 Duke) ........... 162
16.5.12 Installing the oil pump (125 Duke)............. 162
16.5.13 Installing the primary gear (125 Duke)........ 163
16.5.14 Installing the clutch basket (125 Duke) ...... 163
16.5.15 Installing the spacer (125 Duke) ................ 164
16.5.16 Installing the gear position sensor (125
Duke) ...................................................... 164
16.5.17 Installing the balancer shaft drive wheel
(125 Duke) .............................................. 165
16.5.18 Installing the starter drive (125 Duke) ........ 166
16.5.19 Installing the rotor (125 Duke)................... 167
16.5.20 Installing the alternator cover (125 Duke) ... 167
16.5.21 Installing the water pump cover (125
Duke) ...................................................... 167
16.5.22 Installing the piston (125 Duke)................. 168
16.5.23 Installing the cylinder head (125 Duke) ...... 169
16.5.24 Installing the camshafts (125 Duke)........... 170
16.5.25 Installing the timing chain tensioner (125
Duke) ...................................................... 171
16.5.26 Checking the valve clearance (125 Duke).... 172
16.5.27 Adjusting the valve clearance (125 Duke) ... 172
16.5.28 Installing the starter motor (125 Duke) ....... 172
16.5.29 Installing the clutch cover (125 Duke) ........ 173
16.5.30 Installing the spark plug (125 Duke)........... 173
16.5.31 Installing the valve cover (125 Duke).......... 174
16.5.32 Installing the chain securing guide (125
Duke) ...................................................... 174
16.5.33 Installing the oil screen (125 Duke)............ 174
16.5.34 Removing the engine from the engine
assembly stand (125 Duke) ....................... 175
16.5.35 Installing the crankshaft (200 Duke) .......... 175
16.5.36 Installing the balancer shaft (200 Duke) ..... 175
16.5.37 Installing the transmission shafts (200
Duke) ...................................................... 176
16.5.38 Installing the shift forks (200 Duke) ........... 176
16.5.39 Installing the shift drum (200 Duke)........... 176
16.5.40 Installing the shift rails (200 Duke) ............ 177
16.5.41 Installing the left engine case (200
Duke) ...................................................... 177
16.5.42 Installing the oil filter (200 Duke) .............. 178
16.5.43 Installing the locking lever (200 Duke) ....... 178
16.5.44 Installing the shift drum locating (200
Duke) ...................................................... 178
16.5.45 Installing the shift shaft (200 Duke) ........... 179
16.5.46 Installing the oil pump (200 Duke)............. 179
16.5.47 Installing the primary gear (200 Duke)........ 180
16.5.48 Installing the clutch basket (200 Duke) ...... 180
16.5.49 Installing the spacer (200 Duke) ................ 181
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