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KTM 125 Duke 2013 Repair Manual

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REPAIR MANUAL
2013
125 Duke EU
200 Duke EU
200 Duke MAL
200 Duke 2014 COL
Art. no. 3206162en

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Summary of Contents for KTM 125 Duke 2013

  • Page 1 REPAIR MANUAL 2013 125 Duke EU 200 Duke EU 200 Duke MAL 200 Duke 2014 COL Art. no. 3206162en...
  • Page 3 KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as misprints and other errors.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS 11 FUEL TANK, SEAT, TRIM ........... 45 TABLE OF CONTENTS MEANS OF REPRESENTATION ........6 11.1 Opening the filler cap........45 Symbols used ........... 6 11.2 Closing the filler cap ........45 Formats used............ 6 11.3 Removing the seat .......... 45 SAFETY ADVICE............
  • Page 5 TABLE OF CONTENTS 14.11 Adding rear brake fluid ........90 16.3.37 Removing the valve cover (200 Duke) ..123 14.12 Changing the rear brake fluid ......91 16.3.38 Removing the spark plug (200 Duke)..123 15 LIGHTING SYSTEM, INSTRUMENTS ......94 16.3.39 Removing the clutch cover (200 Duke) ..
  • Page 6 TABLE OF CONTENTS 16.4.15 Checking the oil pump (125 Duke) ..... 145 16.5 Engine assembly ........... 176 16.4.16 Checking the oil pressure regulator valve 16.5.1 Installing the crankshaft (125 Duke) ..176 (125 Duke) ..........145 16.5.2 Installing the balancer shaft (125 Duke) ..176 16.4.17 Checking the clutch (125 Duke)....
  • Page 7 TABLE OF CONTENTS 16.5.50 Installing the gear position sensor (200 22.2 Checks and maintenance steps for winter Duke) ............199 operation............230 16.5.51 Installing the balancer shaft drive wheel 23 STORAGE ..............231 (200 Duke) ..........200 23.1 Storage ............231 16.5.52 Installing the starter drive (200 Duke) ..

  • Page 8: Means Of Representation

    MEANS OF REPRESENTATION Symbols used The meaning of specific symbols is described below. Indicates an expected reaction (e.g. of a work step or a function). Indicates an unexpected reaction (e.g. of a work step or a function). Indicates a page reference (more information is provided on the specified page). Indicates information with more details or tips.

  • Page 9: Safety Advice

    Read this Repair Manual carefully and thoroughly before beginning work. It contains useful information and tips that will help you repair and maintain your vehicle. This manual assumes that the necessary special KTM tools and KTM workplace and workshop equipment are available. Safety advice A number of safety instructions need to be followed to operate the vehicle safely.

  • Page 10: Important Information

    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 consid- ered for damage resulting from manipulations and/or alterations to the vehicle.

  • Page 11: Serial Numbers

    SERIAL NUMBERS Chassis number/type label The chassis number is stamped on the right of the steering head. The type label is on the right of the frame behind the steering head. B00699-10 Key number can be found on the KEYCODECARD. The key number Info You need the key number to order a spare key.

  • Page 12: Motorcycle

    MOTORCYCLE 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 support of the wheel stand. –...

  • Page 13: Taking The Motorcycle Off Of The Front Wheel Stand

    MOTORCYCLE – Move the handlebar to the straight-ahead position. Attach the lifting gear to the steering stem. Adapter (61029955620) ( p. 274) Front wheel stand (61029055500) ( p. 273) Info Always raise the rear of the motorcycle first. – Raise the front of the motorcycle. C00197-01 Taking the motorcycle off of the front wheel stand Note...

  • Page 14: Removing The Motorcycle From The Work Stand

    MOTORCYCLE – Mount special tool on the right side of the vehicle. Work stand (62529055000) ( p. 274) 307318-10 – Remove screw 307319-10 – Mount special tool on the left side of the vehicle. Work stand (62529055000) ( p. 274) 307320-10 –...

  • Page 15: Starting

    MOTORCYCLE – Mount and tighten screws Guideline Screw, engine bearer on frame 30 Nm (22.1 lbf ft) 307322-10 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 16: Starting The Motorcycle To Make Checks

    MOTORCYCLE Switching off ABS (Duke EU/MAL) 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 The ABS warning lamp starts flashing; ABS is deactivated.

  • Page 17: Fork, Triple Clamp

    FORK, TRIPLE CLAMP Cleaning the dust boots of the fork legs (Duke COL) – Push dust boot of both fork legs downwards. Info The dust boots should remove dust and coarse dirt particles from the fork tubes. Over time, dirt can penetrate behind the dust boots. If this dirt is not removed, the oil seals behind can start to leak.
  • Page 18 FORK, TRIPLE CLAMP – Loosen screws and screw – Unscrew screw about six turns and press your hand on the screw to push the wheel spindle out of the axle clamp. Remove screw Warning Danger of accidents Reduced braking effect caused by damaged brake discs.

  • Page 19: Installing The Fork Legs

    FORK, TRIPLE CLAMP – Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of the fork. – Loosen screws . Remove the fork legs from the bottom. 307313-10 Installing the fork legs Warning Danger of accidents Modifications to the suspension settings can seriously alter the vehicle's ride behavior. –...
  • Page 20 FORK, TRIPLE CLAMP – Clean screw and the wheel spindle. – Lift the front wheel into the fork, position it, and insert the wheel spindle. – Mount and tighten screw Guideline Screw, front wheel spindle 30 Nm (22.1 lbf ft) 304858-11 –...
  • Page 21 FORK, TRIPLE CLAMP – 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 contact surfaces of the spacers. Long-life grease ( p.

  • Page 22: Disassembling The Fork Legs

    FORK, TRIPLE CLAMP Disassembling the fork legs Info These operations are the same on both fork legs. Condition The fork legs have been removed. – Clamp the fork leg in the area of the lower triple clamp. Clamping stand (T612S) ( p.
  • Page 23 FORK, TRIPLE CLAMP – Detach the outer tube from the inner tube. Info Place a container underneath to catch any oil that may run out. 201510-10 – Unclamp the inner tube. Drain the oil. 201511-10 – Clamp the outer tube in the area of the lower triple clamp. Clamping stand (T612S) ( p.

  • Page 24: Checking The Fork Legs

    FORK, TRIPLE CLAMP Checking the fork legs Condition The fork legs have been disassembled. – Check the inner tube and the axle clamp for damage. » If damage is found: – Change the fork leg. 201516-10 – Measure the outside diameter of the inner tube in several places. External diameter of inner tube 42.975…...

  • Page 25: Assembling The Fork Legs

    FORK, TRIPLE CLAMP Assembling the fork legs Info These operations are the same on both fork legs. Preparatory work – Check the fork legs. ( p. 22) Main work – Clamp in the inner tube with the axle clamp. Guideline Use soft jaws.

  • Page 26: Removing The Lower Triple Clamp

    FORK, TRIPLE CLAMP – Mount lock ring Info The lock ring must engage audibly. 202095-10 – Install dust boot 202096-10 – Mount screw cap onto the piston rod. Info must be turned all the way down. – Hold the screw cap and tighten the nut. Guideline Nut, piston rod on screw cap M12x1...
  • Page 27 FORK, TRIPLE CLAMP Main work – Remove expanding rivets 307323-10 – Remove screws – Lift the headlight mask slightly and swing forward. 307324-10 – Detach connectors 307325-10 – Detach connectors 307326-10 – Remove the connector holder. – Disconnect connector 307327-10 –...
  • Page 28 FORK, TRIPLE CLAMP – Remove screws – Remove the headlight mask. 307329-10 – Remove screw 307330-10 – Remove the upper triple clamp with the handlebar and set aside. Info Protect the vehicle and its attachments from damage by covering them. 307331-10 –...

  • Page 29: Installing The Lower Triple Clamp

    FORK, TRIPLE CLAMP Installing the lower triple clamp Main work – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 270) – Insert the lower triple clamp with the steering stem. – Mount the upper steering head bearing –...
  • Page 30 FORK, TRIPLE CLAMP – Mount screw with the washer but do not tighten it yet. Guideline Screw, top steering head M16x1.5 52 Nm (38.4 lbf ft) Holding lugs reach into the drilled holes. 307330-11 – Position the headlight mask. – Mount and tighten screw Guideline Screw, headlight mask...

  • Page 31: Checking The Steering Head Bearing Play

    FORK, TRIPLE CLAMP – Mount expanding rivets on both sides. – Install the fork legs. ( p. 17) 307323-11 – Loosen screws – Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains. – Tighten screw Guideline Screw, top steering head M16x1.5...

  • Page 32: Adjusting The Steering Head Bearing Play

    FORK, TRIPLE CLAMP 6.10 Adjusting the steering head bearing play Preparatory work – Raise the motorcycle with the work stand. ( p. 11) Main work (Duke COL) – Loosen screws – Loosen screw 304855-10 – Tighten nut with the special tool until there is no play in the steering head bearing.
  • Page 33 FORK, TRIPLE CLAMP – Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains. – Tighten screw Guideline Screw, top steering head M16x1.5 52 Nm (38.4 lbf ft) – Tighten screws Guideline Screw, top triple clamp 11 Nm 307352-10 (8.1 lbf ft)

  • Page 34: Handlebar, Controls

    HANDLEBAR, CONTROLS 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- wards and forwards to ascertain the play in the throttle cable. Throttle cable play 3…...

  • Page 35: Adjusting The Clutch Cable Play

    HANDLEBAR, CONTROLS Adjusting the clutch cable play – Move the handlebar to the straight-ahead position. – Push back sleeve – Loosen lock nut – Adjust the play in the clutch level by turning adjusting screw Guideline Clutch lever play 1… 3 mm (0.04… 0.12 in) –...

  • Page 36: Shock Absorber, Swingarm

    SHOCK ABSORBER, SWINGARM 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 37: Installing The Shock Absorber

    SHOCK ABSORBER, SWINGARM – Remove fitting – Lift the link fork and take out the shock absorber toward the rear. 307336-10 Installing the shock absorber Main work (Duke COL) – Lift the link fork and position shock absorber – Mount fitting but do not tighten yet.

  • Page 38: Removing The Spring

    SHOCK ABSORBER, SWINGARM Removing the spring Condition The shock absorber has been removed. – Clamp the shock absorber in the vise using soft jaws for protection. – Note the position of the spring preload. – Loosen adjusting ring using the special tool. Hook wrench (T106S) ( p.
  • Page 39 SHOCK ABSORBER, SWINGARM – Tension the spring to the position measured during dismantling by turning the adjusting ring.

  • Page 40: Exhaust

    EXHAUST Removing the exhaust manifold Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. – Allow the exhaust system to cool down. Do not touch hot components. Preparatory work – Remove the passenger seat. ( p.

  • Page 41: Installing The Exhaust Manifold

    EXHAUST – Remove the nuts 307342-10 – Remove the exhaust manifold toward the front. 307343-10 Installing the exhaust manifold Main work – Position the exhaust manifold. 307343-10 – Mount nuts but do not tighten them yet. Guideline Nut, exhaust flange (125 Duke) 22 Nm (16.2 lbf ft) Nut, exhaust flange (200 Duke)

  • Page 42: Removing The Main Silencer

    EXHAUST – Press the side cover aside. – Plug in connector – Secure the connector with a cable binder. 307339-11 – Position the side cover. – Mount and tighten screws Guideline Remaining nuts, chassis 3 Nm (2.2 lbf ft) 307338-11 –...
  • Page 43 EXHAUST – Remove screw Info Do not misplace the sleeves. 304851-10 – Remove the main silencer toward the bottom. 304852-10 (Duke EU/MAL) – Remove screw with washers. 307344-10 – Remove screw with the sleeve. – Hang the brake fluid reservoir to one side. Info Ensure that brake fluid does not escape.

  • Page 44: Installing The Main Silencer

    EXHAUST – Remove the main silencer toward the bottom. 307347-10 Installing the main silencer Main work (Duke COL) – Position the main silencer. 304852-10 – Mount and tighten screw Guideline Screw, main silencer 23 Nm (17 lbf ft) Info Make sure the sleeves are seated correctly. 304851-11 –...
  • Page 45 EXHAUST – Mount and tighten screw Guideline Screw, main silencer 23 Nm (17 lbf ft) Info Make sure the sleeves are seated correctly. 307346-11 – Mount and tighten screw with the washers. Guideline Screw, main silencer 11 Nm (8.1 lbf ft) 307353-11 –...

  • Page 46: Air Filter

    AIR FILTER 10.1 Removing the air filter Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine. – Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear. Preparatory work –...

  • Page 47: Fuel Tank, Seat, Trim

    FUEL TANK, SEAT, TRIM 11.1 Opening the filler cap Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. –...

  • Page 48: Mounting The Seat

    FUEL TANK, SEAT, TRIM 11.4 Mounting the seat Main work – Attach seat recesses at screws and lower at the rear. – Mount and tighten screws Guideline Screw, seat 11 Nm (8.1 lbf ft) B00727-10 Finishing work – Mount the passenger seat. ( p.
  • Page 49 FUEL TANK, SEAT, TRIM 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.
  • Page 50 FUEL TANK, SEAT, TRIM – Remove screw – Mount and tighten another special screw – Open the filler cap. ( p. 45) 304824-10 – Remove filler cap 304825-10 – Remove screws with the washers. 304826-10 – Remove screws – Remove screws 304827-10 –...

  • Page 51: Installing The Fuel Tank Cover

    FUEL TANK, SEAT, TRIM – Lift the fuel tank cover. – Detach the side covers on both sides. 304830-10 – Push back hose clamp – Pull off the vent hose. – Remove the fuel tank cover. 304831-10 – Close the fuel tank with a suitable plug. 304832-10 11.8 Installing the fuel tank cover...
  • Page 52 FUEL TANK, SEAT, TRIM – Mount the vent hose. – Position hose clamp 304831-11 – Position the fuel tank cover. – Attach the side cover on both sides. 304830-10 – Mount and tighten screws Guideline Remaining screws, chassis 5 Nm (3.7 lbf ft) 304829-11 –...

  • Page 53: Removing The Fuel Tank

    FUEL TANK, SEAT, TRIM – Mount plug of the compensating tank. 304835-10 – Mount and tighten screws with the washer. Guideline Screw, fuel tank 11 Nm (8.1 lbf ft) 304836-10 – Mount and tighten screws Guideline Screw, fuel tank trim 5 Nm (3.7 lbf ft) –...
  • Page 54 FUEL TANK, SEAT, TRIM Main work – Remove screw – Hang the EFI control unit to one side. Info Protect the frame and attachments from damage. 304878-10 – Remove screws 304879-10 – Take off the holder 304880-10 – Detach connector 304881-10 –...

  • Page 55: Installing The Fuel Tank

    FUEL TANK, SEAT, TRIM 11.10 Installing the fuel tank Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. –...

  • Page 56: Removing The Front Spoiler

    FUEL TANK, SEAT, TRIM – Mount and tighten screws Guideline Screw, fuel tank 11 Nm (8.1 lbf ft) 304879-11 – Position the EFI control unit. – Mount and tighten screws Guideline Screw, EFI control unit 4 Nm (3 lbf ft) 304878-11 Finishing work –...

  • Page 57: Dismounting The Front Fender

    FUEL TANK, SEAT, TRIM – Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) – Tighten screw Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) B00771-10 11.13 Dismounting the front fender (Duke COL) – Remove screws .

  • Page 58: Checking The Fuel Pressure

    FUEL TANK, SEAT, TRIM 11.15 Checking the fuel pressure Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. –...

  • Page 59: Changing The Fuel Filter

    FUEL TANK, SEAT, TRIM – Stop the "Function test of fuel pump control" actuator test by pressing the "Quit" but- ton. – Remove the special tools. – Connect the fuel line and position hose clamp – Remove the tool. 304895-10 11.16 Changing the fuel filter Danger...

  • Page 60: Replacing The Fuel Pump

    FUEL TANK, SEAT, TRIM – Position the fuel filter. Connection faces to the left. – Position the fuel hoses and mount hose clamp – Position hose clamps 304890-10 – Position fuel filter in the holder. 304887-10 Finishing work – Install the fuel tank. ( p.
  • Page 61 FUEL TANK, SEAT, TRIM – Position gasket 304891-10 – Position the fuel pump with the gasket. – Install the screws and tighten them diagonally. Guideline Screw, fuel pump 5 Nm (3.7 lbf ft) 304889-10 Finishing work – Install the fuel tank. ( p.

  • Page 62: Wheels

    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. Info The type, condition and air pressure of the tires all have a major impact on the riding behavior of the motorcycle.

  • Page 63: Checking The Brake Discs

    WHEELS » If a tire is more than 5 years old: – Change the tires. 12.3 Checking the brake discs Warning Danger of accidents Reduced braking efficiency due to worn brake disc(s). – Change the worn brake disc(s) without delay. – Check the thickness of the front and rear brake discs at several places on the disk to see if it conforms to measurement Info...

  • Page 64: Installing The Front Wheel

    WHEELS (Duke EU/MAL) – Remove screws and push the fender to the side. – Remove screw and pull wheel speed sensor out of the hole. – Loosen screws and screw – Unscrew screw about six turns and press your hand on the screw to push the wheel spindle out of the axle clamp.

  • Page 65: Removing The Brake Disc Of The Front Brake

    WHEELS (Duke EU/MAL) – 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. Long-life grease ( p.

  • Page 66: Installing The Brake Disc Of The Front Brake

    WHEELS 12.4.4 Installing the brake disc of the front brake Main work (Duke COL) – Clean the contact surface of the brake disc. – Position the brake disc with the label facing outward. – Mount and tighten screws Guideline Screw, front brake disc 30 Nm Loctite ®...

  • Page 67: Installing The Rear Wheel

    WHEELS – Remove nut and the washer. Remove chain adjuster – Holding the rear wheel, withdraw wheel spindle with the washer and chain adjuster. – Push the rear wheel forward as far as possible and take the chain off the rear sprocket.

  • Page 68: Removing The Brake Disc Of The Rear Brake

    WHEELS – Pull the rear wheel back and mount wheel spindle with the washer and chain adjuster Info 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 tighten nut Guideline In order for the rear wheel to be correctly aligned, the markings on the left...

  • Page 69: Installing The Brake Disc Of The Rear Brake

    WHEELS Main work (Duke COL) – Remove screws – Remove the brake disc. 304805-10 (Duke EU/MAL) – Remove screws – Take off the ABS sensor wheel. 307350-10 – Remove screws – Remove the brake disc. 307351-10 12.5.4 Installing the brake disc of the rear brake Main work (Duke COL) –...

  • Page 70: Checking The Chain Tension

    WHEELS Finishing work – Install the rear wheel. ( p. 65) – Take the motorcycle off of the rear wheel stand. ( p. 10) 12.5.5 Checking 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, bear- ings in the transmission and in the rear wheel) will be under additional load.

  • Page 71: Checking The Chain, Rear Sprocket, And Engine Sprocket

    WHEELS Main work (Duke COL) – 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) Turn adjusting screws on the left and right so that the markings on the left and right chain adjuster are in the same position in relation to reference marks...
  • Page 72 WHEELS – 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 Chain wear is not always even, so you should repeat this measurement 0 0 A at different chain positions.
  • Page 73 WHEELS – Position the chain guard and tighten screw Guideline Screw, chain guard EJOT PT ® 4 Nm (3 lbf ft) – Tighten screw Guideline EJOT PT ® Screw, chain guard 4 Nm (3 lbf ft) – Tighten screw Guideline Remaining screws, chassis 5 Nm (3.7 lbf ft) C00198-10...

  • Page 74: Cleaning The Chain

    WHEELS – Remove screws and release screw . Push the chain guard aside. B01416-10 – Check the chain sliding guard for wear. » If drill hole becomes visible on the chain sliding guard in area – Change the chain sliding guard. –...

  • Page 75: Checking The Rear Hub Rubber Dampers

    WHEELS Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. Info The service life of the chain depends largely on its maintenance. – Clean the chain regularly. –...

  • Page 76: Wiring Harness, Battery

    WIRING HARNESS, BATTERY 13.1 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 77: Disconnecting The Negative Cable Of The Battery

    – Do not discard batteries with the household waste. Dispose of faulty batteries in an environmentally compatible 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 still loses power steadily.

  • Page 78: Checking The Charging Voltage

    WIRING HARNESS, BATTERY Preparatory work – Switch off all power consumers and switch off the engine. – Remove the passenger seat. ( p. 46) – Remove the seat. ( p. 45) – Disconnect the negative cable of the battery to avoid damage to the motorcycle's electronics.

  • Page 79: Changing The Fuses Of Individual Power Consumers

    WIRING HARNESS, BATTERY 13.7 Changing the fuses of individual power consumers Info The fuse box with the main fuse and the fuses of the individual power consumers is located under the passenger seat. Preparatory work – Switch off all power consumers and switch off the engine. –...
  • Page 80 WIRING HARNESS, BATTERY 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, tail light, license plate lamp...

  • Page 81: Brake System

    Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc- tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi- nal license.
  • Page 82 BRAKE SYSTEM (Duke COL) – Move the brake fluid reservoir mounted on the handlebar to a horizontal posi- tion. – Remove screws – Remove cover with membrane 307304-10 – Remove locking clip 304812-10 – Remove pin – Take off springs 304813-10 –...
  • Page 83 BRAKE SYSTEM – Position springs The arrow on the spring points in the direction of travel. – Mount pin Info Make sure the springs are seated correctly. – Activate the hand brake lever until there is a firm pressure point. 304813-10 –...

  • Page 84: Checking The Brake Fluid Level Of The Front Brake

    BRAKE SYSTEM – Press the brake piston back to its basic position and make sure that no brake fluid overflows from the brake fluid reservoir. Suction it off if necessary. Info Protect the components against damage. 307308-10 – Position brake linings Info Always change the brake linings in pairs.

  • Page 85: Adding Front Brake Fluid

    BRAKE SYSTEM 14.4 Adding front brake fluid Warning Danger of accidents Failure of the brake system. – 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. Warning Skin irritation Brake fluid can cause skin irritation on contact.
  • Page 86 BRAKE SYSTEM (Duke COL) – Move the brake fluid reservoir mounted on the handlebar to a horizontal posi- tion. – Cover painted parts. – Remove screws – Remove cover with the membrane. – Draw the old brake fluid out of the brake fluid reservoir using a syringe and fill with fresh brake fluid.
  • Page 87 BRAKE SYSTEM – Check the hand brake lever for a firm pressure point. (Duke EU/MAL) – Move the brake fluid reservoir mounted on the handlebar to a horizontal posi- tion. – Cover painted parts. – Remove screws – Remove cover with the membrane.

  • Page 88: Checking The Rear Brake Linings

    Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc- tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi- nal license.
  • Page 89 BRAKE SYSTEM (Duke COL) – Stand the vehicle upright. – Remove screw cap and membrane – Push the brake caliper toward the brake disc with your hand to push back the brake piston; ensure that brake fluid does not runs out of the brake fluid reser- voir, removing it if it does.
  • Page 90 BRAKE SYSTEM (Duke EU/MAL) – Stand the vehicle upright. – Remove screw cap and membrane – Push the brake caliper toward the brake disc with your hand to push back the brake piston; ensure that brake fluid does not runs out of the brake fluid reser- voir, removing it if it does.

  • Page 91: Checking The Free Travel Of Foot Brake Lever

    BRAKE SYSTEM 14.8 Checking the free travel of foot brake lever Warning Danger of accidents Brake system failure. – If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to overheating.

  • Page 92: Checking The Rear Brake Fluid Level

    BRAKE SYSTEM 14.10 Checking the rear brake fluid level Warning Danger of accidents Failure of the brake system. – 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.

  • Page 93: Changing The Rear Brake Fluid

    BRAKE SYSTEM (Duke COL) – Stand the vehicle upright. – Remove screw cap with membrane – Add brake fluid to level Brake fluid DOT 4 / DOT 5.1 ( p. 268) – Refit screw cap with membrane. Info C00203-10 Clean up overflowed or spilt brake fluid immediately with water. (Duke EU/MAL) –...
  • Page 94 BRAKE SYSTEM – Open shut-off valve Info Follow the operating instructions of the bleeding device. – Ensure that the filling pressure is set on pressure gauge . Correct the filling pressure on pressure regulator if necessary. Guideline Filling pressure 2… 2.5 bar (29… 36 psi) 201494-11 –...
  • Page 95 BRAKE SYSTEM – Open shut-off valve Info Follow the operating instructions of the bleeding device. – Ensure that the filling pressure is set on pressure gauge . Correct the filling pressure on pressure regulator if necessary. Guideline Filling pressure 2… 2.5 bar (29… 36 psi) 201494-11 –...

  • Page 96: Lighting System, Instruments

    LIGHTING SYSTEM, INSTRUMENTS 15.1 Setting kilometers or miles Info Make the country-specific setting. Condition The ignition is on. 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.

  • Page 97: Setting The Time

    LIGHTING SYSTEM, INSTRUMENTS – Do not activate the two buttons for approx. 15 seconds. The display RPM 2 goes out and the set speed is stored. 15.4 Setting the time Condition The ignition is on. The motorcycle is stationary. – Press the MODE button briefly and repeatedly until ODO appears on the display.

  • Page 98: Adjusting The Headlight Range

    LIGHTING SYSTEM, INSTRUMENTS 15.7 Adjusting the headlight range Main work – Remove expanding rivets 601915-10 – Remove screws – Lift the headlight mask slightly and swing forward. 601914-10 – 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 99: Changing The Parking Light Bulb

    LIGHTING SYSTEM, INSTRUMENTS 15.8 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 100: Changing The Headlight Bulb

    LIGHTING SYSTEM, INSTRUMENTS – Position cover – Mount and tighten screws B00762-10 – Fold the headlight mask up. – Mount and tighten screws Guideline Screw, headlight mask 11 Nm (8.1 lbf ft) 307324-10 – Mount expanding rivets on both sides. –...
  • Page 101 LIGHTING SYSTEM, INSTRUMENTS – Take off protection cap – Disconnect plug-in connector B00760-10 – Detach retaining clamp – Remove headlight bulb – Position the new headlight bulb in the headlight housing. Headlight (H4/socket P43t) ( p. 225) Info Insert the headlight bulb so that the catches latch into the recesses. –...

  • Page 102: Engine

    ENGINE 16.1 Removing the engine Preparatory work – Raise the motorcycle with the rear wheel stand. ( p. 10) – Remove the front spoiler. ( p. 54) – Remove the passenger seat. ( p. 46) – Remove the seat. ( p.
  • Page 103 ENGINE – Remove screws – Remove screw – Take off the engine sprocket cover. 304901-10 – Remove screws and take off the lock washer. 304902-10 – Remove nut with washer. – Remove chain adjuster – Push the rear wheel into the foremost position. 304903-10 –...
  • Page 104 ENGINE – Expose the cable and detach connectors 304907-10 – Expose the cable and detach connector 304908-10 – Loosen hose clip – Push the throttle valve body upward out of the intake flange. 304909-10 – Remove screws – Remove fitting –...

  • Page 105: Installing The Engine

    ENGINE – Remove screws – Pull off the radiator pipe and hang it to one side. 304913-10 – Position the floor jack under the engine and fix it using the special tool. Floor jack attachment (75029055000) ( p. 275) 304914-10 –...
  • Page 106 ENGINE Main work – Position the engine in the frame. Info Watch out for clutch lever You should have an assistant for this step. Protect the frame and attachments from damage. 304916-11 – Position the ground wire – Mount fitting but do not tighten yet.
  • Page 107 ENGINE – Mount the radiator hose. – Position hose clamp 304911-11 – Tighten fitting Guideline Fitting, engine mounting bracket 55 Nm (40.6 lbf ft) 304917-10 – Position both engine fixing arms. – Mount and tighten screws Guideline Screw, engine bearer on frame 30 Nm (22.1 lbf ft) –...
  • Page 108 ENGINE – Mount and tighten nut with the washer. Guideline Remaining nuts, chassis 3 Nm (2.2 lbf ft) – Position the rubber cap. 304906-11 – Position the shift linkage. – Mount and tighten screw Guideline Screw, shift activation 11 Nm Loctite ®...
  • Page 109 ENGINE – Mount spark plug connector 304900-11 – Mount the vent hose. – Position hose clamp 304899-11 – Plug in connector 304898-11 – Attach the clutch cable. – Secure the clutch cable with lock washer 304897-11 – Mount and tighten nut with the washers.

  • Page 110: Engine Disassembly

    – Fit the front spoiler. ( p. 54) – Take a short test ride. – Read out the fault memory using the KTM diagnostics tool. – Check the engine for leakage. – Check the engine oil level. ( p. 216) –...

  • Page 111: Removing The Chain Securing Guide

    ENGINE 16.3.3 Removing the chain securing guide (125 Duke) – Remove screws – Take off the chain securing guide. 304422-10 16.3.4 Removing the valve cover (125 Duke) – Remove screws with the gasket. – Take off the valve cover with the valve cover seal. 304729-10 16.3.5 Removing the spark plug (125 Duke)

  • Page 112: Setting The Engine To Ignition Top Dead Center (125 Duke)

    ENGINE – Remove dowels – Take off clutch cover gasket 304733-10 16.3.7 Setting the engine to ignition top dead center (125 Duke) – Remove screw plug 304734-10 – Turn the crankshaft counterclockwise until markings align with the edge of the cylinder head.

  • Page 113: Removing The Timing Chain Tensioner

    ENGINE 16.3.9 Removing the timing chain tensioner (125 Duke) – Remove screw with the O-ring. 305040-10 – Turn the timing chain tensioner screw clockwise. The timing chain tensioner is locked. – Remove screw – Remove the timing chain tensioner with the gasket. 305039-10 16.3.10 Removing the camshaft (125 Duke) –...

  • Page 114: Removing The Cylinder Head (125 Duke)

    ENGINE 16.3.11 Removing the cylinder head (125 Duke) – Remove screws 304444-10 – Release screws in a crisscross pattern and remove them with the washers. – Take off the cylinder head. 304739-10 – Take off the cylinder head gasket – Remove dowels 304740-10 –...

  • Page 115: Removing The Water Pump Wheel

    ENGINE – Take off cylinder base gasket – Remove dowels 304744-10 – Slip out timing chain Info If the timing chain is to be reused, mark the direction of travel. 304745-10 – Remove screw – Take off the timing chain tensioning rail from above. 304746-10 16.3.13 Removing the water pump wheel (125 Duke) –...

  • Page 116: Removing The Alternator Cover

    ENGINE 16.3.14 Removing the alternator cover (125 Duke) – Remove screws – Take off the alternator cover. 304754-10 – Remove dowels – Take off alternator cover gasket 304755-10 16.3.15 Removing the rotor (125 Duke) – Lock the clutch basket and primary gear using special tool Gear segment (90129081100) ( p.

  • Page 117: Removing The Starter Drive (125 Duke)

    ENGINE 16.3.16 Removing the starter drive (125 Duke) – Remove screw – Remove the retaining bracket. 304759-10 – Remove screws – Hang the ignition pulse generator to one side. 304760-10 – Remove freewheel gear 304761-10 – Take off torque limiter –...

  • Page 118: Removing The Gear Position Sensor

    ENGINE – Remove nut with washer. Castle nut wrench; ½" drive (90129022000) ( p. 277) 304763-10 – Remove screw with the washer. 304764-10 – Remove balancer shaft gear with a wedge. – Take off drive wheel of the balancer shaft. –...

  • Page 119: Removing The Spacer (125 Duke)

    ENGINE 16.3.19 Removing the spacer (125 Duke) – Remove the spacer of the countershaft. 304773-10 16.3.20 Removing the clutch basket (125 Duke) – Lock the clutch basket and primary gear using special tool Gear segment (90129081100) ( p. 279) – Remove screws –...

  • Page 120: Removing The Primary Gear (125 Duke)

    ENGINE – Remove collar sleeve 304778-10 16.3.21 Removing the primary gear (125 Duke) – Remove timing chain sprocket 304781-10 – Take off primary gear 304782-10 – Remove spring washer – Take off spacer ring 304783-10 16.3.22 Removing the oil pump (125 Duke) –...

  • Page 121: Removing The Shift Shaft (125 Duke)

    ENGINE – Remove screws – Take off oil pump – Remove dowels. 304785-10 16.3.23 Removing the shift shaft (125 Duke) – Push sliding plate away from the shift drum locating . Remove shift shaft with the washer. 304786-10 16.3.24 Removing the shift drum locating (125 Duke) –...

  • Page 122: Removing The Left Engine Case

    ENGINE – Pull oil filter out of the oil filter housing. Circlip pliers reverse (51012011000) ( p. 272) 304492-10 16.3.27 Removing the left engine case (125 Duke) 304790-10 – Remove screws – Swing the left section of the engine case up and remove the fitting of the engine fixing arm. –...

  • Page 123: Removing The Shift Rails (125 Duke)

    ENGINE – Remove dowels – Remove the engine case gasket. 305903-10 16.3.28 Removing the shift rails (125 Duke) – Remove shift rail together with upper spring and the lower spring. – Remove shift rail 305904-10 16.3.29 Removing the shift drum (125 Duke) –...

  • Page 124: Removing The Balancer Shaft (125 Duke)

    ENGINE 16.3.32 Removing the balancer shaft (125 Duke) – Remove screw – Take off the lock washer. – Remove balancer shaft 304799-10 16.3.33 Removing the crankshaft (125 Duke) – Mount special tool Protecting sleeve (90129019000) ( p. 277) – Position the section of the engine case in a press. –...

  • Page 125: Removing The Chain Securing Guide

    ENGINE 16.3.36 Removing the chain securing guide (200 Duke) – Remove screws – Take off the chain securing guide. 305803-10 16.3.37 Removing the valve cover (200 Duke) – Remove screws with the gasket. – Take off the valve cover with the valve cover seal. 305804-10 16.3.38 Removing the spark plug (200 Duke) –...

  • Page 126: Setting The Engine To Ignition Top Dead Center (200 Duke)

    ENGINE – Remove dowels – Take off clutch cover gasket 305809-10 16.3.40 Setting the engine to ignition top dead center (200 Duke) – Remove screw plug 305810-10 – Turn the crankshaft counterclockwise until markings align with the edge of the cylinder head.

  • Page 127: Removing The Timing Chain Tensioner

    ENGINE 16.3.42 Removing the timing chain tensioner (200 Duke) – Remove screw with the O-ring. 305813-10 – Turn the timing chain tensioner screw clockwise. The timing chain tensioner is locked. – Remove screw – Remove the timing chain tensioner with the gasket. 305814-10 16.3.43 Removing the camshaft (200 Duke) –...

  • Page 128: Removing The Cylinder Head (200 Duke)

    ENGINE 16.3.44 Removing the cylinder head (200 Duke) – Remove screws 305825-10 – Release screws in a crisscross pattern and remove them with the washers. – Take off the cylinder head. 305826-10 – Take off the cylinder head gasket – Remove dowels 305827-10 –...

  • Page 129: Removing The Water Pump Wheel

    ENGINE – Take off cylinder base gasket – Remove dowels 305831-10 – Slip out timing chain Info If the timing chain is to be reused, mark the direction of travel. 305832-10 – Remove screw – Take off the timing chain tensioning rail from above. 305833-10 16.3.46 Removing the water pump wheel (200 Duke) –...

  • Page 130: Removing The Alternator Cover

    ENGINE 16.3.47 Removing the alternator cover (200 Duke) – Remove screws – Take off the alternator cover. 305840-10 – Remove dowels – Take off alternator cover gasket 305841-10 16.3.48 Removing the rotor (200 Duke) – Lock the clutch basket and primary gear using special tool Gear segment (90129081100) ( p.

  • Page 131: Removing The Starter Drive (200 Duke)

    ENGINE 16.3.49 Removing the starter drive (200 Duke) – Remove screw – Remove the retaining bracket. 305845-10 – Remove screws – Hang the ignition pulse generator to one side. 305846-10 – Remove freewheel gear 305847-10 – Take off torque limiter –...

  • Page 132: Duke)

    ENGINE – Remove nut with washer. Castle nut wrench; ½" drive (90129022000) ( p. 277) 305850-10 – Remove screw with the washer. 305851-10 – Remove balancer shaft gear with a wedge. – Take off drive wheel of the balancer shaft. –...

  • Page 133: Removing The Spacer (200 Duke)

    ENGINE 16.3.52 Removing the spacer (200 Duke) – Remove the spacer of the countershaft. 305857-10 16.3.53 Removing the clutch basket (200 Duke) – Lock the clutch basket and primary gear using special tool Gear segment (90129081100) ( p. 279) – Remove screws –...

  • Page 134: Removing The Primary Gear (200 Duke)

    ENGINE – Remove collar sleeve 305862-10 16.3.54 Removing the primary gear (200 Duke) – Remove timing chain sprocket 305865-10 – Take off primary gear 305866-10 – Remove spring washer – Take off spacer ring 305867-10 16.3.55 Removing the oil pump (200 Duke) –...

  • Page 135: Removing The Shift Shaft (200 Duke)

    ENGINE – Remove screws – Take off oil pump – Remove dowels. 305869-10 16.3.56 Removing the shift shaft (200 Duke) – Push sliding plate away from the shift drum locating . Remove shift shaft with the washer. 305872-10 16.3.57 Removing the shift drum locating (200 Duke) –...

  • Page 136: Removing The Left Engine Case

    ENGINE – Pull oil filter out of the oil filter housing. Circlip pliers reverse (51012011000) ( p. 272) 305877-10 16.3.60 Removing the left engine case (200 Duke) 305878-10 – Remove screws – Swing the left section of the engine case up and remove the fitting of the engine fixing arm. –...

  • Page 137: Removing The Shift Rails (200 Duke)

    ENGINE – Remove dowels – Remove the engine case gasket. 305881-10 16.3.61 Removing the shift rails (200 Duke) – Remove shift rail together with upper spring and the lower spring. – Remove shift rail 305882-10 16.3.62 Removing the shift drum (200 Duke) –...

  • Page 138: Removing The Balancer Shaft (200 Duke)

    ENGINE 16.3.65 Removing the balancer shaft (200 Duke) – Remove screw – Take off the lock washer. – Remove balancer shaft 305887-10 16.3.66 Removing the crankshaft (200 Duke) – Mount special tool Protecting sleeve (90129019000) ( p. 277) – Position the section of the engine case in a press. –...

  • Page 139: Work On The Right Section Of The Engine Case (125 Duke)

    ENGINE – Press in shaft seal ring of the shift shaft with the open side facing inward so that it is flush. – Press in shaft seal ring of the countershaft with the open side facing inward so that it is flush. –...

  • Page 140: Removing The Main Bearing (125 Duke)

    ENGINE – Remove shaft seal ring 304543-10 – Remove shaft seal ring – Press the new shaft seal ring in all the way with the open side facing inward. Mounting sleeve (90129043000) ( p. 278) 304544-10 – Press shaft seal ring all the way in with the open side facing outward.

  • Page 141: Checking The Radial Play Of The Lower Conrod Bearing (125 Duke)

    ENGINE – Clamp the crankshaft. – Mount special tool Pressure screw for crankshaft (90129020000) ( p. 277) 304524-10 – Mount special tool Puller for main bearing (90129018000) ( p. 276) Holding arms engage in the outer bearing race. – Tension the holding arms by turning nut –...

  • Page 142: Changing The Conrod Bearing (125 Duke)

    ENGINE 16.4.6 Changing the conrod bearing (125 Duke) – Clamp the connecting rod with soft jaws. – Remove the nuts – Remove the conrod bearing cover and crankshaft. Remove the bearing shells. 304561-10 – Measure the crank pin diameter. Guideline Crankshaft –...

  • Page 143: Changing The Balancer Shaft Bearing

    ENGINE 16.4.7 Changing the balancer shaft bearing (125 Duke) – Mount special tools Disassembly tool, balancer shaft bearing (90129056000) ( p. 279) 304566-10 – Position the balancer shaft with special tool in the press. Separator plate (77229032000) ( p. 275) –...

  • Page 144: Work On The Cylinder Head (125 Duke)

    ENGINE – Remove the spacer – Take off bearing – Oil the new bearing and slide it onto the camshaft. Lubricated with engine oil – Mount the spacer. 304547-10 – Mount camshaft gear Holding lug engages in the recess of the camshaft. –...

  • Page 145: Checking The Cylinder Head (125 Duke)

    ENGINE – Pretension the valve spring using the special tool. Valve spring compressor (59029019000) ( p. 272) Insert for valve spring lever (90129060000) ( p. 279) – Mount valve keys. Relax the valve spring. Info When mounting the valve keys, check that they are seated correctly; prefer- ably, fix the valve keys to the valve with a little grease.

  • Page 146: Checking The Piston Ring End Gap

    ENGINE – Check the sealing area of the cylinder head for distortion using a straight edge and the special tool. Feeler gauge (59029041100) ( p. 273) ≤ 0.10 mm (≤ 0.0039 in) Cylinder/cylinder head - distortion of sealing area » If the measured value does not equal the specified value: –...

  • Page 147: Checking The Piston/Cylinder Mounting Clearance (125 Duke)

    ENGINE – Measure the piston at the piston skirt, at right angles to the piston pin, at a distance Guideline Distance 9 mm (0.35 in) Piston - diameter 57.963… 57.975 mm (2.282… 2.28248 in) 304538-10 16.4.14 Checking the piston/cylinder mounting clearance (125 Duke) –...

  • Page 148: Checking The Clutch (125 Duke)

    ENGINE » If there is damage or wear: – Change the control piston. – Check the control piston bore in the oil pump housing for damage and wear. » If there is damage or wear: – Change the oil pump housing. –...

  • Page 149: Preassembling The Clutch (125 Duke)

    ENGINE » If there is discoloration or scoring: – Change all clutch lining discs. – Check the thickness of clutch facing discs Clutch facing discs – thickness of total package ≥ 21.30 mm (≥ 0.8386 in) » If the clutch facing discs do not meet specifications: –...

  • Page 150: Checking The Shift Mechanism

    ENGINE 16.4.19 Checking the shift mechanism (125 Duke) 304513-10 – Check the shift forks (see ) for damage and wear (visual check). » If there is damage or wear: – Change the shift fork and gear wheel pair. – Check shift grooves of shift drum for wear.

  • Page 151: Preassembling The Shift Shaft (125 Duke)

    ENGINE – Preassemble the shift shaft. ( p. 149) – Check the play between the sliding plate and the shift quadrant. Shift shaft – play in sliding plate/shift 0.15… 0.45 mm (0.0059… quadrant 0.0177 in) » If the measured value does not equal the specified value: –...

  • Page 152: Dismantling The Countershaft (125 Duke)

    ENGINE 16.4.22 Dismantling the countershaft (125 Duke) 305900-10 – Fix the countershaft in the vise with the geared end facing downward. Guideline Use soft jaws – Remove stop disk and the 1st-gear idler gear – Remove collar bushing – Remove the 6th-gear sliding gear –...

  • Page 153: Assembling The Main Shaft (125 Duke)

    ENGINE 305902-10 – Check collar bushings for damage and wear. » If there is damage or wear: – Change the collar bushings. – Check the pivot points of main shaft and countershaft for damage and wear. » If there is damage or wear: –...

  • Page 154: Assembling The Countershaft (125 Duke)

    ENGINE Preparatory work – Oil all parts carefully before assembling. – Check the transmission. ( p. 150) 305899-11 Main work – Fix the main shaft in the vise with the geared end facing downward. Guideline Use soft jaws – Mount stop disk –...
  • Page 155 ENGINE 305901-10 Main work – Fix the countershaft in the vise with the geared end facing downward. Guideline Use soft jaws – Install lock ring and stop disk – Mount 2nd-gear idler gear – Mount collar bushing – Mount lock ring –...

  • Page 156: Checking The Timing Assembly

    ENGINE 16.4.26 Checking the timing assembly (125 Duke) 304529-10 – Check timing chain for damage and wear. » If there is damage or wear: – Change the timing chain. – Let the timing chain hang down freely. Check that the timing chain links move easily. »...

  • Page 157: Checking The Electric Starter Drive

    ENGINE – Remove screws – Remove the stator. 304554-10 – Position the new stator. – Mount and tighten screws Guideline Screw, stator 8 Nm Loctite ® 243™ (5.9 lbf ft) – Position cable guide in the alternator cover. 304555-10 – Position the cable retainer.

  • Page 158: Checking The Freewheel (125 Duke)

    ENGINE » If there is damage or wear: – Replace the freewheel gear and/or the bearing. – Check toothing of the starter motor for damage and wear. » If there is damage or wear: – Replace the starter motor. – Replace the O-ring of the starter motor.

  • Page 159: Work On The Right Section Of The Engine Case (200 Duke)

    ENGINE – Press in shaft seal ring of the countershaft with the open side facing inward so that it is flush. – Mount lock ring – Mount and tighten oil nozzle Guideline Oil nozzle 6 Nm Loctite ® 243™ (4.4 lbf ft) –...

  • Page 160: Removing The Main Bearing (200 Duke)

    ENGINE – Remove shaft seal ring 304543-10 – Remove shaft seal ring – Press the new shaft seal ring in all the way with the open side facing inward. Mounting sleeve (90129043000) ( p. 278) 304544-10 – Press shaft seal ring all the way in with the open side facing outward.

  • Page 161: Checking The Radial Play Of The Lower

    ENGINE – Clamp the crankshaft. – Mount special tool Pressure screw for crankshaft (90129020000) ( p. 277) 305892-10 – Mount special tool Puller for main bearing (90129018000) ( p. 276) Holding arms engage in the outer bearing race. – Tension the holding arms by turning nut –...

  • Page 162: Changing The Conrod Bearing (200 Duke)

    ENGINE 16.4.35 Changing the conrod bearing (200 Duke) – Clamp the connecting rod with soft jaws. – Remove screws – Remove the conrod bearing cover and crankshaft. Remove the bearing shells. 305894-10 – Measure the crank pin diameter. Guideline Crankshaft – diameter, crank pin Crankshaft classification A 29.995…...

  • Page 163: Changing The Balancer Shaft Bearing

    ENGINE 16.4.36 Changing the balancer shaft bearing (200 Duke) – Mount special tools Disassembly tool, balancer shaft bearing (90129056000) ( p. 279) 304566-10 – Position the balancer shaft with special tool in the press. Separator plate (77229032000) ( p. 275) –...

  • Page 164: Work On The Cylinder Head (200 Duke)

    ENGINE – Remove the spacer – Take off bearing – Oil the new bearing and slide it onto the camshaft. Lubricated with engine oil – Mount the spacer. 304547-10 – Mount camshaft gear Holding lug engages in the recess of the camshaft. –...

  • Page 165: Checking The Cylinder Head (200 Duke)

    ENGINE – Pretension the valve spring using the special tool. Valve spring compressor (59029019000) ( p. 272) Insert for valve spring lever (90129060000) ( p. 279) – Mount valve keys. Relax the valve spring. Info When mounting the valve keys, check that they are seated correctly; prefer- ably, fix the valve keys to the valve with a little grease.

  • Page 166: Checking The Piston Ring End Gap

    ENGINE – Check the sealing area of the cylinder head for distortion using a straight edge and the special tool. Feeler gauge (59029041100) ( p. 273) ≤ 0.10 mm (≤ 0.0039 in) Cylinder/cylinder head - distortion of sealing area » If the measured value does not equal the specified value: –...

  • Page 167: Checking The Piston/Cylinder Mounting Clearance (200 Duke)

    ENGINE – Measure the piston at the piston skirt, at right angles to the piston pin, at a distance Guideline Distance 9 mm (0.35 in) Piston - diameter 71.965… 71.977 mm (2.83326… 2.83373 in) 304538-10 16.4.43 Checking the piston/cylinder mounting clearance (200 Duke) –...

  • Page 168: Checking The Clutch (200 Duke)

    ENGINE » If there is damage or wear: – Change the control piston. – Check the control piston bore in the oil pump housing for damage and wear. » If there is damage or wear: – Change the oil pump housing. –...

  • Page 169: Preassembling The Clutch (200 Duke)

    ENGINE » If there is discoloration or scoring: – Change all clutch lining discs. – Check the thickness of clutch facing discs Clutch facing discs – thickness of total package ≥ 27.00 mm (≥ 1.063 in) » If the clutch facing discs do not meet specifications: –...

  • Page 170: Checking The Shift Mechanism

    ENGINE 16.4.48 Checking the shift mechanism (200 Duke) 304513-10 – Check the shift forks (see ) for damage and wear (visual check). » If there is damage or wear: – Change the shift fork and gear wheel pair. – Check shift grooves of shift drum for wear.

  • Page 171: Preassembling The Shift Shaft (200 Duke)

    ENGINE – Preassemble the shift shaft. ( p. 169) – Check the play between the sliding plate and the shift quadrant. Shift shaft – play in sliding plate/shift 0.15… 0.45 mm (0.0059… quadrant 0.0177 in) » If the measured value does not equal the specified value: –...

  • Page 172: Dismantling The Countershaft (200 Duke)

    ENGINE 16.4.51 Dismantling the countershaft (200 Duke) 305900-10 – Fix the countershaft in the vise with the geared end facing downward. Guideline Use soft jaws – Remove stop disk and the 1st-gear idler gear – Remove collar bushing – Remove the 6th-gear sliding gear –...

  • Page 173: Assembling The Main Shaft (200 Duke)

    ENGINE 305902-10 – Check collar bushings for damage and wear. » If there is damage or wear: – Change the collar bushings. – Check the pivot points of main shaft and countershaft for damage and wear. » If there is damage or wear: –...

  • Page 174: Assembling The Countershaft (200 Duke)

    ENGINE Preparatory work – Oil all parts carefully before assembling. – Check the transmission. ( p. 170) 305899-11 Main work – Fix the main shaft in the vise with the geared end facing downward. Guideline Use soft jaws – Mount stop disk –...
  • Page 175 ENGINE 305901-10 Main work – Fix the countershaft in the vise with the geared end facing downward. Guideline Use soft jaws – Install lock ring and stop disk – Mount 2nd-gear idler gear – Mount collar bushing – Mount lock ring –...

  • Page 176: Checking The Timing Assembly

    ENGINE 16.4.55 Checking the timing assembly (200 Duke) 304529-10 – Check timing chain for damage and wear. » If there is damage or wear: – Change the timing chain. – Let the timing chain hang down freely. Check that the timing chain links move easily. »...

  • Page 177: Checking The Electric Starter Drive

    ENGINE – Remove screws – Remove the stator. 304554-10 – Position the new stator. – Mount and tighten screws Guideline Screw, stator 8 Nm Loctite ® 243™ (5.9 lbf ft) – Position cable guide in the alternator cover. 304555-10 – Position the cable retainer.

  • Page 178: Checking The Freewheel (200 Duke)

    ENGINE » If there is damage or wear: – Replace the freewheel gear and/or the bearing. – Check toothing of the starter motor for damage and wear. » If there is damage or wear: – Replace the starter motor. – Replace the O-ring of the starter motor.

  • Page 179: Duke)

    ENGINE – Mount balancer shaft with the bearing. Info If necessary, heat the engine case. – Position the retaining bracket. – Mount and tighten screw Guideline Screw, bearing retainer 12 Nm Loctite ® 243™ 304799-11 (8.9 lbf ft) – Remove the special tool. Mounting sleeve (90129005000) ( p.

  • Page 180: Installing The Shift Rails (125 Duke)

    ENGINE 16.5.6 Installing the shift rails (125 Duke) – Oil all parts carefully before assembling. – Mount shift rail together with upper spring and the lower spring. – Mount shift rail 305904-10 16.5.7 Installing the left engine case (125 Duke) –...

  • Page 181: Installing The Oil Filter (125 Duke)

    ENGINE – Mount the fitting of the engine fixing arm. 16.5.8 Installing the oil filter (125 Duke) – Tilt the engine sideways and fill the oil filter housing approx. ⅓ full with engine oil. – Fill oil filter with engine oil and insert it in the oil filter housing. 304492-11 –...

  • Page 182: Installing The Shift Shaft (125 Duke)

    ENGINE 16.5.11 Installing the shift shaft (125 Duke) – Slide shift shaft with the washer into the bearing seat. – Push sliding plate away from the shift drum locating . Insert the shift shaft all the way. – Let the sliding plate engage in the shift drum locating. –...

  • Page 183: Installing The Primary Gear (125 Duke)

    ENGINE 16.5.13 Installing the primary gear (125 Duke) – Position spacer ring – Mount spring washer 304783-11 – Mount primary gear 304782-11 – Mount timing chain sprocket 304781-11 16.5.14 Installing the clutch basket (125 Duke) – Mount collar sleeve 304778-11 –...

  • Page 184: Installing The Spacer (125 Duke)

    ENGINE – Lock the clutch basket and primary gear using special tool Gear segment (90129081100) ( p. 279) – Mount and tighten nut with the washer. Guideline Nut, primary gear 55 Nm (40.6 lbf ft) Castle nut wrench; ½" drive (90129021000) ( p.

  • Page 185: Installing The Balancer Shaft Drive Wheel (125 Duke)

    ENGINE – Install the gear position sensor. – Mount and tighten screws Guideline Screw, gear sensor 6 Nm Loctite ® 243™ (4.4 lbf ft) – Position the cable guide in the engine case. – Position the retaining bracket. Info 304771-11 Ensure that the cable is correctly routed.

  • Page 186: Installing The Starter Drive (125 Duke)

    ENGINE – Mount and tighten nut Guideline Nut, drive wheel for balancer shaft 60 Nm (44.3 lbf ft) Castle nut wrench; ½" drive (90129022000) ( p. 277) – Remove the special tool. Gear segment (90129081100) ( p. 279) 304763-11 16.5.18 Installing the starter drive (125 Duke) –...

  • Page 187: Installing The Rotor (125 Duke)

    ENGINE 16.5.19 Installing the rotor (125 Duke) – Lock the clutch basket and primary gear using special tool Gear segment (90129081100) ( p. 279) 304756-10 – Mount the spring washer. – Mount the rotor. Info Turn the freewheel gear counterclockwise to simplify assembly. –...

  • Page 188: Installing The Piston (125 Duke)

    ENGINE – Mount locating pins 304748-11 – Mount the water pump cover with the seal ring. – Install the screws and tighten them diagonally. Guideline Screw, water pump cover 12 Nm (8.9 lbf ft) 304747-11 16.5.22 Installing the piston (125 Duke) –...

  • Page 189: Installing The Cylinder Head (125 Duke)

    ENGINE – Mount dowels and cylinder base gasket 304744-11 – Thread the timing chain through the chain shaft. Mount piston pin 304743-11 – Cover the engine case opening with a cloth. – Position piston pin retainer – Insert the special tool and firmly press it toward the piston. Insertion for piston ring lock (90129030000) ( p.

  • Page 190: Installing The Camshafts (125 Duke)

    ENGINE – Mount dowels – Put on cylinder head gasket – Mount the cylinder head. 304740-11 – Mount screws with the washer and tighten in a crisscross pattern. Guideline Cylinder head screw Step 1 Thread is oiled, head flat is 20 Nm (14.8 lbf ft) greased...

  • Page 191: Installing The Timing Chain Tensioner

    ENGINE – Clean all oil nozzles thoroughly and blow out with compressed air. – Mount the dowels. – Position the camshaft bearing bridge. – Mount screws and tighten from the inside to the outside. Guideline Screw, camshaft bearing bridge 11 Nm (8.1 lbf ft) 304735-11 16.5.25 Installing the timing chain tensioner (125 Duke) –...

  • Page 192: Checking The Valve Clearance (125 Duke)

    ENGINE 16.5.26 Checking the valve clearance (125 Duke) – Crank the engine several times. Castle nut wrench; ½" drive (90129021000) ( p. 277) – Set the engine to ignition top dead center. ( p. 110) 304431-10 – Check the valve clearance at all valves between the camshaft and cam lever. Guideline Valve clearance, exhaust, cold 0.13…...

  • Page 193: Installing The Clutch Cover (125 Duke)

    ENGINE 16.5.29 Installing the clutch cover (125 Duke) – Mount dowel and clutch cover gasket 304733-11 – Position the clutch cover. Info Pivot the clutch lever. 304732-10 – Mount and tighten screws Guideline Screw, clutch cover 12 Nm (8.9 lbf ft) 304731-11 16.5.30 Installing the spark plug (125 Duke) –...

  • Page 194: Installing The Valve Cover (125 Duke)

    ENGINE 16.5.31 Installing the valve cover (125 Duke) – Degrease the sealing areas and thinly coat with sealant in areas Loctite ® 5910 – Position the gasket in the valve cover. 304803-10 – Position the valve cover with the gasket. –...

  • Page 195: Removing The Engine From The Engine Assembly Stand (125 Duke)

    ENGINE – Mount and tighten oil drain plug with the O-ring. Guideline Oil drain plug M24x1.5 15 Nm (11.1 lbf ft) 304420-11 16.5.34 Removing the engine from the engine assembly stand (125 Duke) – Remove the fitting from special tools Engine fixing arm (90129002060) ( p.

  • Page 196: Installing The Transmission Shafts

    ENGINE – Mount balancer shaft with the bearing. Info If necessary, heat the engine case. – Position the retaining bracket. – Mount and tighten screw Guideline Screw, bearing retainer 12 Nm Loctite ® 243™ 305887-11 (8.9 lbf ft) – Remove the special tool. Mounting sleeve (90129005000) ( p.

  • Page 197: Installing The Shift Rails (200 Duke)

    ENGINE 16.5.40 Installing the shift rails (200 Duke) – Oil all parts carefully before assembling. – Mount shift rail together with upper spring and the lower spring. – Mount shift rail 305882-10 16.5.41 Installing the left engine case (200 Duke) –...

  • Page 198: Installing The Oil Filter (200 Duke)

    ENGINE – Mount the fitting of the engine fixing arm. 16.5.42 Installing the oil filter (200 Duke) – Tilt the engine sideways and fill the oil filter housing approx. ⅓ full with engine oil. – Fill oil filter with engine oil and insert it in the oil filter housing. 305877-11 –...

  • Page 199: Installing The Shift Shaft (200 Duke)

    ENGINE 16.5.45 Installing the shift shaft (200 Duke) – Slide shift shaft with the washer into the bearing seat. – Push sliding plate away from the shift drum locating . Insert the shift shaft all the way. – Let the sliding plate engage in the shift drum locating. –...

  • Page 200: Installing The Primary Gear (200 Duke)

    ENGINE 16.5.47 Installing the primary gear (200 Duke) – Position spacer ring – Mount spring washer 305867-11 – Mount primary gear 305866-11 – Mount timing chain sprocket 305865-11 16.5.48 Installing the clutch basket (200 Duke) – Mount collar sleeve 305862-11 –...

  • Page 201: Installing The Spacer (200 Duke)

    ENGINE – Lock the clutch basket and primary gear using special tool Gear segment (90129081100) ( p. 279) – Mount and tighten nut with the washer. Guideline Nut, primary gear 55 Nm (40.6 lbf ft) Castle nut wrench; ½" drive (90129021000) ( p.

  • Page 202: Installing The Balancer Shaft Drive Wheel (200 Duke)

    ENGINE – Install the gear position sensor. – Mount and tighten screws Guideline Screw, gear sensor 6 Nm Loctite ® 243™ (4.4 lbf ft) – Position the cable guide in the engine case. – Position the retaining bracket. Info 305855-11 Ensure that the cable is correctly routed.

  • Page 203: Installing The Starter Drive (200 Duke)

    ENGINE – Mount and tighten nut Guideline Nut, drive wheel for balancer shaft 60 Nm (44.3 lbf ft) Castle nut wrench; ½" drive (90129022000) ( p. 277) – Remove the special tool. Gear segment (90129081100) ( p. 279) 305850-11 16.5.52 Installing the starter drive (200 Duke) –...

  • Page 204: Installing The Rotor (200 Duke)

    ENGINE 16.5.53 Installing the rotor (200 Duke) – Lock the clutch basket and primary gear using special tool Gear segment (90129081100) ( p. 279) 305842-10 – Mount the spring washer. – Mount the rotor. Info Turn the freewheel gear counterclockwise to simplify assembly. –...

  • Page 205: Installing The Piston (200 Duke)

    ENGINE – Mount locating pins 305838-11 – Mount the water pump cover with the seal ring. – Install the screws and tighten them diagonally. Guideline Screw, water pump cover 12 Nm (8.9 lbf ft) 305837-11 16.5.56 Installing the piston (200 Duke) –...

  • Page 206: Installing The Cylinder Head (200 Duke)

    ENGINE – Mount dowels and cylinder base gasket 305831-11 – Thread the timing chain through the chain shaft. Mount piston pin 305830-11 – Cover the engine case opening with a cloth. – Position piston pin retainer – Insert the special tool and firmly press it toward the piston. Insertion for piston ring lock (90129030000) ( p.

  • Page 207: Installing The Camshafts (200 Duke)

    ENGINE – Mount dowels – Put on cylinder head gasket – Mount the cylinder head. 305827-11 – Mount screws with the washer and tighten in a crisscross pattern. Guideline Cylinder head screw Step 1 Thread is oiled, head flat is 20 Nm (14.8 lbf ft) greased...

  • Page 208: Installing The Timing Chain Tensioner (200 Duke)

    ENGINE – Clean all oil nozzles thoroughly and blow out with compressed air. – Mount the dowels. – Position the camshaft bearing bridge. – Mount screws and tighten from the inside to the outside. Guideline Screw, camshaft bearing bridge 11 Nm (8.1 lbf ft) 305820-11 16.5.59 Installing the timing chain tensioner (200 Duke) –...

  • Page 209: Checking The Valve Clearance (200 Duke)

    ENGINE 16.5.60 Checking the valve clearance (200 Duke) – Crank the engine several times. Castle nut wrench; ½" drive (90129021000) ( p. 277) – Set the engine to ignition top dead center. ( p. 124) 305816-10 – Check the valve clearance at all valves between the camshaft and cam lever. Guideline Valve clearance, exhaust, cold 0.13…...

  • Page 210: Installing The Clutch Cover (200 Duke)

    ENGINE 16.5.63 Installing the clutch cover (200 Duke) – Mount dowel and clutch cover gasket 305809-11 – Position the clutch cover. Info Pivot the clutch lever. 305808-10 – Mount and tighten screws Guideline Screw, clutch cover 12 Nm (8.9 lbf ft) 305807-11 16.5.64 Installing the spark plug (200 Duke) –...

  • Page 211: Installing The Valve Cover (200 Duke)

    ENGINE 16.5.65 Installing the valve cover (200 Duke) – Degrease the sealing areas and thinly coat with sealant in areas Loctite ® 5910 – Position the gasket in the valve cover. 305805-10 – Position the valve cover with the gasket. –...

  • Page 212: Removing The Engine From The Engine Assembly Stand (200 Duke)

    ENGINE – Mount and tighten oil drain plug with the O-ring. Guideline Oil drain plug M24x1.5 15 Nm (11.1 lbf ft) 305801-11 16.5.68 Removing the engine from the engine assembly stand (200 Duke) – Remove the fitting from special tools Engine fixing arm (90129002060) ( p.

  • Page 213: Shift Mechanism

    SHIFT MECHANISM 17.1 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 Shift rod adjustment range 100… 112 mm (3.94… 4.41 in) Info Make the same adjustments on both sides.

  • Page 214: Water Pump, Cooling System

    WATER PUMP, COOLING SYSTEM 18.1 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 215: Checking The Antifreeze And Coolant Level

    WATER PUMP, COOLING SYSTEM – Fill the radiator completely with coolant. Mount the radiator cap. – Rest the vehicle on the side stand. 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 ventila- tion, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.

  • Page 216: Checking The Coolant Level

    WATER PUMP, COOLING SYSTEM – Remove radiator cap – Check the coolant antifreeze. −25… −45 °C (−13… −49 °F) » If the coolant antifreeze does not meet specifications: – Correct the coolant antifreeze. – Check the coolant level in the radiator. The radiator must be completely filled.
  • Page 217 WATER PUMP, COOLING SYSTEM » If you had to add more coolant than the specified amount: > 0.20 l (> 0.21 qt.) – Fill/bleed the cooling system. ( p. 212) – Mount the radiator cap.

  • Page 218: Lubrication System

    LUBRICATION SYSTEM 19.1 Oil circuit 304938-60 Oil drain plug and oil screen Oil pump Oil filter Oil pressure regulator valve Oil pressure sensor Oil nozzle for piston cooling Oil nozzle for cam follower lubrication Oil nozzle, clutch 19.2 Checking the engine oil level Condition The engine is at operating temperature.
  • Page 219 LUBRICATION SYSTEM Main work – Place a suitable container under the engine. – Remove screws . Take off the oil filter cover with the O-ring. 304892-10 – Remove oil filter Circlip pliers reverse (51012011000) ( p. 272) 304893-10 – Position the special tool with the O-ring. Mount and tighten the screws. Guideline Screw, oil filter cover (125 Duke) 8 Nm (5.9 lbf ft)

  • Page 220: Changing The Engine Oil And Oil Filter, Cleaning The Oil Screen

    LUBRICATION SYSTEM – Oil the O-ring of the oil filter cover. Mount the oil filter cover. – Mount and tighten the screws. Guideline Screw, oil filter cover (125 Duke) 8 Nm (5.9 lbf ft) Screw, oil filter cover (200 Duke) 8 Nm (5.9 lbf ft) Finishing work –...

  • Page 221: Adding Engine Oil

    LUBRICATION SYSTEM – Remove the oil filler plug with the O-ring from the clutch cover and fill up with engine oil. Engine oil After oil 1.2 l (1.3 qt.) External temper- Engine oil change ature: 0… 50 °C (SAE 15W/50) approx.

  • Page 222: Ignition System

    IGNITION SYSTEM 20.1 Alternator - checking the stator winding Stator winding, measurement I - check the resistance – Measure the resistance between the specified points. Stator, connector HB pin 1 – Stator, connector HB pin 2 Alternator ≤ 1 Ω Resistance of stator winding at: 20 °C (68 °F) »...

  • Page 223: 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 224: Engine Tolerance, Wear Limits

    TECHNICAL DATA Piston rings 1 L-ring, 1 tapered compression piston ring, 1 oil scraper ring Engine lubrication Pressure circulation lubrication with one rotary pump Primary transmission 22:72 Clutch Clutch in oil bath/mechanically activated Transmission 6-gear, claw shifted Transmission ratio 1st gear 12:34 2nd gear 15:31...

  • Page 225: 200 Duke

    TECHNICAL DATA 21.2.2 200 Duke Valve - sealing seat width Intake 0.90… 1.10 mm (0.0354… 0.0433 in) Exhaust 0.90… 1.10 mm (0.0354… 0.0433 in) ≤ 0.10 mm (≤ 0.0039 in) Cylinder/cylinder head - distortion of sealing area Cylinder - bore diameter 72.016…...

  • Page 226: Capacities

    TECHNICAL DATA ® Screw, oil pump 12 Nm (8.9 lbf ft) Loctite 243™ ® Screw, retaining bracket, shaft seal 11 Nm (8.1 lbf ft) Loctite 243™ ring, clutch cover ® Screw, shift drum locating 12 Nm (8.9 lbf ft) Loctite 243™...

  • Page 227: Chassis

    TECHNICAL DATA Fuel reserve, approx. 1.5 l (1.6 qt.) 21.5 Chassis Frame Lattice frame of steel tubes, powder-coated Fork WP Suspension Shock absorber WP Suspension Brake system Front Disc brake with four-pot brake caliper Rear Disc brake with single-piston brake caliper, floating Suspension travel Front 150 mm (5.91 in)

  • Page 228: 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 21.8 Fork Fork part number 90101000044 Fork WP Suspension Fork length 736 mm (28.98 in)
  • Page 229 TECHNICAL DATA – Screw, brake fluid reservoir of rear 9 Nm (6.6 lbf ft) brake ® Screw, cable holder, side stand switch 9 Nm (6.6 lbf ft) Loctite 243™ ® Screw, chain sliding guard 9 Nm (6.6 lbf ft) Loctite 243™...
  • Page 230 TECHNICAL DATA – Nut, rear wheel spindle M14x1.5 90 Nm (66.4 lbf ft) – Nut, swingarm pivot M14x1.5 140 Nm (103.3 lbf ft) – Screw, top steering head M16x1.5 52 Nm (38.4 lbf ft) Lambda sensor M18x1.5 40… 60 Nm (29.5… Lubricant (T152) 44.3 lbf ft) p.

  • Page 231: Cleaning/Protective Treatment

    CLEANING/PROTECTIVE TREATMENT 22.1 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 pressure can cause malfunctions or destroy these parts.

  • Page 232: Checks And Maintenance Steps For Winter Operation

    CLEANING/PROTECTIVE TREATMENT 22.2 Checks and maintenance steps for winter operation Info If the motorcycle is used in the winter, salt can be expected on the roads. Precautions need to be taken against road salt corro- sion. If the vehicle was operated in road salt, clean it with cold water after riding. Warm water would enhance the corrosive effects of salt.

  • Page 233: Storage

    – Store the vehicle in a dry location that is not subject to large fluctuations in tem- perature. Info KTM recommends jacking up the motorcycle. – Raise the motorcycle with the rear wheel stand. ( p. 10) –...

  • Page 234: Service Schedule

    Final check: Check the vehicle for roadworthiness and take a test ride. ○ ● ● Read out the fault memory using the KTM diagnostics tool after a test ride. ○ ● ● Make the service entry in KTM DEALER.NET and in the service record.

  • Page 236: Wiring Diagram

    WIRING DIAGRAM 25.1 Page 1 of 9 (Duke EU/MAL) bl-ye ye-rd wh-bl ye-bu ye-bu wh-gn wh-gn ye-rd ye-rd wh-or ye-rd bu-gr rd-gr wh-or gn-rd wh-br wh-gn wh-or gn-rd gn-rd bl-ye gn-rd gn-rd bu-gr wh-or bu-gr bu-gr wh-or wh-or 308061-01...
  • Page 237 WIRING DIAGRAM Components: EFI control unit Alarm system (optional) Vehicle control unit Fuse Fuse Battery Start auxiliary relay 1 Start auxiliary relay 2 Start auxiliary relay 3 Starter relay Starter motor Emergency OFF switch, electric starter button...

  • Page 238: Duke Eu/Mal)

    WIRING DIAGRAM 25.2 Page 2 of 9 (Duke EU/MAL) wh-rd wh-bl wh-rd bu-gn bu-gn wh-rd wh-br wh-br wh-br wh-bu wh-bu wh-rd bu-or bl-ye bu-or wh-bl wh-br gn-pk gn-pk ye-gr bl-ye ye-gr wh-bl wh-bl bu-br bu-br bu-br ye-rd bu-br ye-rd bl-ye 308062-01...
  • Page 239 WIRING DIAGRAM Components: EFI control unit Alarm system (optional) Fuse Fuse Fuse Fuse Power relay Fuel pump relay Radiator fan relay Fuel pump Radiator fan Ignition/steering lock X293 Connector for accessory ground ACC 2 (not assigned) X294 Connector for accessory plug terminal 15 ACC 2 (not assigned)

  • Page 240: Duke Eu/Mal)

    WIRING DIAGRAM 25.3 Page 3 of 9 (Duke EU/MAL) wh-bl wh-bl wh-bl HC/3 HB/3 bl-ye ye-bu ye-bu bu-gn bu-gn bl-ye bl-ye 308063-01...
  • Page 241 WIRING DIAGRAM Components: EFI control unit Alarm system (optional) Alarm system switch (optional) Fuse Alternator Combination instrument Voltage regulator X295 Diagnostics connector...

  • Page 242: Duke Eu/Mal)

    WIRING DIAGRAM 25.4 Page 4 of 9 (Duke EU/MAL) wh-bl wh-bl wh-br wh-br wh-br bu-rd bu-rd ye-bu ye-bu wh-br bl-gn bl-gn bl-gn ye-gn ye-gn bl-rd bl-rd bl-ye bl-ye bu-rd bu-rd br-gn br-gn bl-ye bl-ye bu-rd bu-rd wh-rd wh-rd bl-ye bl-ye gn-rd gn-rd gn-rd...
  • Page 243 WIRING DIAGRAM Components: EFI control unit Throttle position sensor circuit A Rollover sensor Side stand switch Fuel tank sensor Temperature and manifold absolute pressure sensor Lambda sensor (cylinder 1) Injection valve (cylinder 1) Combination instrument...

  • Page 244: Duke Eu/Mal)

    WIRING DIAGRAM 25.5 Page 5 of 9 (Duke EU/MAL) wh-or wh-or ye-gn ye-gn gn-rd gn-rd wh-gr wh-gr bl-bu bl-bu wh-rd wh-rd bl-ye bl-ye wh-ye bu-pk bu-pk ye-gn wh-ye wh-ye wh-gn wh-ye wh-bu wh-bu wh-gn bl-ye ye-gn ye-gn 308065-01...
  • Page 245 WIRING DIAGRAM Components: EFI control unit Vehicle control unit Coolant temperature sensor (cylinder 1) Gear position sensor Ignition pulse generator Clutch switch Idle speed actuator Combination instrument Ignition coil (cylinder 1)

  • Page 246: Duke Eu/Mal)

    WIRING DIAGRAM 25.6 Page 6 of 9 (Duke EU/MAL) bl-ye wh-br ye-rd bl-rd bl-rd bl-rd bl-rd bl-rd ye-rd ye-rd bl-ye ye-rd bl-ye bl-rd bl-ye bl-ye bl-ye bl-ye wh-br FG/1 FG/1 bl-ye bl-ye bl-ye 308066-01...
  • Page 247 WIRING DIAGRAM Components: Vehicle control unit Brake light switch, front Brake light switch, rear Low beam, high beam License plate lamp Combination instrument Horn Parking light Brake/tail light Emergency OFF switch, electric starter button Light switch, horn button, high beam flasher button, turn signal switch...

  • Page 248: Duke Eu/Mal)

    WIRING DIAGRAM 25.7 Page 7 of 9 (Duke EU/MAL) bl-ye bl-ye bl-ye bl-ye bl-ye bl-ye bl-ye bl-ye bu-pk bu-pk pk-br pk-br 308067-01...
  • Page 249 WIRING DIAGRAM Components: Alarm system (optional) Vehicle control unit Oil pressure sensor Combination instrument Turn signal, front left Turn signal, front right Turn signal, rear left Turn signal, rear right Light switch, horn button, high beam flasher button, turn signal switch...

  • Page 250: Duke Eu/Mal)

    WIRING DIAGRAM 25.8 Page 8 of 9 (Duke EU/MAL) bl-ye bl-ye bl-ye bl-ye bl-ye bl-ye wh-gr wh-gr bl-ye bl-ye bl-ye bl-pu wh-ye bl-ye br-rd bu-or bl-ye bl-ye bl-ye bu-or br-rd bl-ye wh-ye bl-pu bl-ye bl-ye bl-ye bl-ye bl-ye bl-ye 308068-01...
  • Page 251 WIRING DIAGRAM Components: EFI control unit Alarm system (optional) Vehicle control unit Combination instrument...

  • Page 252: Duke Eu/Mal)

    WIRING DIAGRAM 25.9 Page 9 of 9 (Duke EU/MAL) gn-gr rd-gr ye-gr ye-gr rd-gr ye-gr ye-gr wh-bl wh-br wh-bu wh-bu wh-br wh-bl bl-ye bl-ye bl-ye bl-ye wh-rd wh-bu wh-bu gn-gr gn-gr wh-bl wh-bl bu-pk bu-pk wh-rd wh-rd bl-bu bl-bu wh-rd wh-rd 308069-01...
  • Page 253 WIRING DIAGRAM Components: EFI control unit ABS control unit Vehicle control unit Wheel speed sensor, front Wheel speed sensor, rear Fuse Fuse ABS fuse ABS fuse Combination instrument Cable colors: Black Brown Blue Green Gray Light blue Orange Pink Violet White Yellow...

  • Page 254: Duke Col)

    WIRING DIAGRAM 25.10 Page 1 of 8 (Duke COL) bl-ye ye-rd wh-bl ye-bu ye-bu wh-gn wh-gn ye-rd ye-rd wh-or ye-rd wh-or rd-gr rd-gr wh-or gn-rd wh-br wh-gn rd-gr wh-or gn-rd gn-rd bl-ye gn-rd gn-rd wh-or bu-gr bu-gr wh-or wh-or 202666-01...
  • Page 255 WIRING DIAGRAM Components: EFI control unit Alarm system (optional) Vehicle control unit Fuse Fuse Battery Start auxiliary relay 1 Start auxiliary relay 2 Start auxiliary relay 3 Starter relay Starter motor Combination instrument Emergency OFF switch, electric starter button...

  • Page 256: Duke Col)

    WIRING DIAGRAM 25.11 Page 2 of 8 (Duke COL) wh-rd wh-bl wh-rd bu-gn bu-gn wh-rd wh-br wh-br wh-br wh-bu wh-bu wh-rd bu-or bl-ye bu-or wh-bl wh-br gn-pk gn-pk ye-gr bl-ye ye-gr wh-bl wh-bl bu-br bu-br bu-br 202667-01...
  • Page 257 WIRING DIAGRAM Components: EFI control unit Alarm system (optional) Fuse Fuse Fuse Power relay Fuel pump relay Radiator fan relay Fuel pump Radiator fan Ignition/steering lock...

  • Page 258: Duke Col)

    WIRING DIAGRAM 25.12 Page 3 of 8 (Duke COL) wh-bl wh-bl wh-bl HC/3 HB/3 bl-ye ye-bu ye-bu bu-gn bu-gn bl-ye bl-ye 202668-01...
  • Page 259 WIRING DIAGRAM Components: EFI control unit Alarm system (optional) Alarm system switch (optional) Fuse Alternator Combination instrument CAN bus terminating resistor 1 Voltage regulator X295 Diagnostics connector...

  • Page 260: Duke Col)

    WIRING DIAGRAM 25.13 Page 4 of 8 (Duke COL) wh-bl wh-bl wh-br wh-br wh-br bu-br bu-br ye-bu ye-bu wh-br bl-gn bl-gn bl-gn ye-gn ye-gn bl-rd bl-rd bl-ye bl-ye bu-rd bu-rd br-gn br-gn bl-ye gn-gr gn-gr bl-ye bu-rd bu-rd wh-rd wh-rd bl-ye bl-ye gn-rd...
  • Page 261 WIRING DIAGRAM Components: EFI control unit Throttle position sensor circuit A Rollover sensor Side stand switch Fuel tank sensor Temperature and manifold absolute pressure sensor Lambda sensor (cylinder 1) Injection valve (cylinder 1) Combination instrument...

  • Page 262: Duke Col)

    WIRING DIAGRAM 25.14 Page 5 of 8 (Duke COL) wh-or wh-or ye-gn ye-gn gn-rd gn-rd wh-gr wh-gr bl-bu bl-bu wh-rd wh-rd bl-ye bl-ye wh-ye bu-pk bu-pk ye-gn wh-ye wh-ye wh-ye wh-bu wh-bu wh-bu wh-or wh-bu wh-bu bl-ye wh-bu bl-ye ye-gn ye-gn 202670-01...
  • Page 263 WIRING DIAGRAM Components: EFI control unit Vehicle control unit Coolant temperature sensor (cylinder 1) Gear position sensor Ignition pulse generator Clutch switch Wheel speed sensor, front Idle speed actuator Combination instrument Ignition coil (cylinder 1)

  • Page 264: Duke Col)

    WIRING DIAGRAM 25.15 Page 6 of 8 (Duke COL) bl-ye wh-br ye-rd bl-rd bl-rd bl-rd bl-rd bl-rd ye-rd ye-rd bl-ye ye-rd bl-ye bl-rd bl-ye bl-ye bl-ye wh-br FG/1 FG/1 bl-ye bl-ye bl-ye 202671-01...
  • Page 265 WIRING DIAGRAM Components: Vehicle control unit Brake light switch, front Brake light switch, rear Low beam, high beam License plate lamp Combination instrument Horn Parking light Brake/tail light Emergency OFF switch, electric starter button Light switch, horn button, high beam flasher button, turn signal switch...

  • Page 266: Duke Col)

    WIRING DIAGRAM 25.16 page 7 of 8 (Duke COL) bl-ye bl-ye bl-ye bl-ye bl-ye bl-ye bl-ye bl-ye bu-pk bu-pk gr-or gr-or 202672-01...
  • Page 267 WIRING DIAGRAM Components: Alarm system (optional) Vehicle control unit Oil pressure sensor Combination instrument Turn signal, front left Turn signal, front right Turn signal, rear left Turn signal, rear right Light switch, horn button, high beam flasher button, turn signal switch...

  • Page 268: Duke Col)

    WIRING DIAGRAM 25.17 Page 8 of 8 (Duke COL) bl-ye bl-ye bl-ye bl-ye wh-gn bl-ye bl-ye wh-gr wh-gr bl-ye bl-ye bl-ye bl-ye bl-ye bl-pu wh-ye bl-ye br-rd bu-or bl-ye bl-ye bl-ye bu-or br-rd bl-ye wh-ye bl-pu wh-gn bl-ye bl-ye bl-ye bl-ye bl-ye bl-ye...
  • Page 269 WIRING DIAGRAM Components: EFI control unit Alarm system (optional) Vehicle control unit Combination instrument Cable colors: Black Brown Blue Green Gray Light blue Orange Pink Violet White Yellow...

  • Page 270: Substances

    Brake fluid DOT 4 / DOT 5.1 According to – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that possesses the corre- sponding properties. KTM recommends Castrol and Motorex ® products. Supplier Castrol –...
  • Page 271 SUBSTANCES Fork oil (SAE 4) (48601166S1) According to – SAE ( p. 281) (SAE 4) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties. Super unleaded (ROZ 95/RON 95/PON 91) According to –...

  • Page 272: Auxiliary Substances

    AUXILIARY SUBSTANCES Chain cleaner Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Chain Clean Chain lube for road use Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Chainlube Road Cleaning and preserving materials for metal, rubber and plastic Guideline –...
  • Page 273 AUXILIARY SUBSTANCES Lubricant (T152) Guideline – KTM recommends Bel‑Ray ® products. Supplier Bel‑Ray ® – Molylube ® Anti‑Seize Motorcycle cleaner Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Moto Clean 900 Paint cleaner and polish for high-gloss and matte finishes, bare metal and plastic surfaces Guideline –...

  • Page 274: Special Tools

    SPECIAL TOOLS Bleeder cover Art. no.: 00029013000 201490-10 Bleeding device Art. no.: 00029013100 201491-10 Bleed syringe Art. no.: 50329050000 400058-01 Circlip pliers reverse Art. no.: 51012011000 400059-01 Valve spring compressor Art. no.: 59029019000 400101-01...
  • Page 275 SPECIAL TOOLS Feeler gauge Art. no.: 59029041100 400110-01 Plastigauge measuring strips Art. no.: 60029012000 400122-01 Adapter Art. no.: 61029055130 C00194-01 Rear wheel stand Art. no.: 61029055400 500077-01 Front wheel stand Art. no.: 61029055500 B00756-01...
  • Page 276 SPECIAL TOOLS Testing hose Art. no.: 61029093000 201314-01 Pressure testing tool Art. no.: 61029094000 400149-01 Adapter Art. no.: 61029955620 B00757-01 Engine assembly stand Art. no.: 61229001000 200306-01 Work stand Art. no.: 62529055000 400151-01...
  • Page 277 SPECIAL TOOLS Floor jack attachment Art. no.: 75029055000 400184-01 Oil pressure adapter Art. no.: 75029094000 400169-01 Separator plate Art. no.: 77229032000 302922-10 Spark plug wrench Art. no.: 77229172000 304549-10 Engine fixing arm Art. no.: 90129002050 304419-10...
  • Page 278 SPECIAL TOOLS Engine fixing arm Art. no.: 90129002060 304418-10 Mounting sleeve Art. no.: 90129005000 201612-01 Extractor Art. no.: 90129009000 304569-10 Holding spanner Art. no.: 90129012000 304548-10 Puller for main bearing Art. no.: 90129018000 304528-10...
  • Page 279 SPECIAL TOOLS Protecting sleeve Art. no.: 90129019000 304526-10 Pressure screw for crankshaft Art. no.: 90129020000 304527-10 Castle nut wrench; ½" drive Art. no.: 90129021000 304430-10 Castle nut wrench; ½" drive Art. no.: 90129022000 304469-10 Limit plug gauge Art. no.: 90129026000 305035-10...
  • Page 280 SPECIAL TOOLS Insertion for piston ring lock Art. no.: 90129030000 305036-10 Mounting sleeve Art. no.: 90129043000 304541-10 Case separating tool Art. no.: 90129048000 304570-10 Castle nut wrench; ½" drive Art. no.: 90129050000 305037-10 Castle nut wrench; ½" drive Art. no.: 90129050100 305037-10...
  • Page 281 SPECIAL TOOLS Key for steering head bearing Art. no.: 90129051000 304951-10 Disassembly tool, balancer shaft bearing Art. no.: 90129056000 304565-10 Insert for valve spring lever Art. no.: 90129060000 305038-10 Gear segment Art. no.: 90129081100 304453-10 Hook wrench Art. no.: T106S 301085-01...
  • Page 282 SPECIAL TOOLS Spring compressor Art. no.: T14050S 201648-10 Mounting tool Art. no.: T528S 200634-10 Clamping stand Art. no.: T612S 200638-10...

  • Page 283: 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 specifi- cation.

  • Page 284: Index

    INDEX Brake discs INDEX checking ....... . . 61 Accessories ........8 Brake fluid front brake, adding .
  • Page 285 INDEX piston, removing ..... . . 112, 126 Engine oil level preparations ......108, 122 checking .
  • Page 286 INDEX Kilometers or miles Shift speed RPM 1 adjusting ....... . . 94 adjusting .
  • Page 287 INDEX page 8 of 8 ......266 page 8 of 9 ......248 page 9 of 9 .
  • Page 288 *3206162en* 3206162en 07/2013 KTM-Sportmotorcycle AG 5230 Mattighofen/Austria Photo: Mitterbauer/KTM http://www.ktm.com...

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