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KTM Manuals
Motorcycle
2013 125 DUKE
Repair manual
KTM 125 Duke 2013 Repair Manual
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:
Owner's manual
(185 pages)
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Table Of Contents
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Contents
Table of Contents
Bookmarks
Table of Contents
Table of Contents
Means of Representation
Symbols Used
Formats Used
Safety Advice
Repair Manual
Degrees of Risk and Symbols
Work Rules
Important Information
Guarantee, Warranty
Operating and Auxiliary Substances
Spare Parts, Accessories
Figures
Serial Numbers
Chassis Number/Type Label
Key Number
Engine Number
Motorcycle
Raising the Motorcycle with the Rear Wheel Stand
Taking the Motorcycle off of the Rear Wheel Stand
Raising the Motorcycle with the Front Wheel Stand
Taking the Motorcycle off of the Front Wheel Stand
Raising the Motorcycle with the Work Stand
Removing the Motorcycle from the Work Stand
Starting
Starting the Motorcycle to Make Checks
Fork, Triple Clamp
Cleaning the Dust Boots of the Fork Legs
Removing Fork Legs
Installing the Fork Legs
Disassembling the Fork Legs
Checking the Fork Legs
Assembling the Fork Legs
Removing the Lower Triple Clamp
Installing the Lower Triple Clamp
Checking the Steering Head Bearing Play
Adjusting the Steering Head Bearing Play
Handlebar, Controls
Checking the Play in the Throttle Cable
Adjusting the Play in the Throttle Cable
Checking the Clutch Lever Play
Adjusting the Clutch Cable Play
Shock Absorber, Swingarm
Adjusting the Spring Preload of the Shock Absorber
Removing the Shock Absorber
Installing the Shock Absorber
Removing the Spring
Installing the Spring
Exhaust
Removing the Exhaust Manifold
Installing the Exhaust Manifold
Removing the Main Silencer
Installing the Main Silencer
Air Filter
Removing the Air Filter
Installing the Air Filter
Fuel Tank, Seat, Trim
Opening the Filler Cap
Closing the Filler Cap
Removing the Seat
Mounting the Seat
Removing the Passenger Seat
Mounting the Passenger Seat
Removing the Fuel Tank Cover
Installing the Fuel Tank Cover
Removing the Fuel Tank
Installing the Fuel Tank
Removing the Front Spoiler
Fitting Front Spoiler
Dismounting the Front Fender
Installing the Front Fender
Checking the Fuel Pressure
Changing the Fuel Filter
Replacing the Fuel Pump
Wheels
Checking the Tire Air Pressure
Checking the Tire Condition
Checking the Brake Discs
Front Wheel
Removing the Front Wheel
Installing the Front Wheel
Removing the Brake Disc of the Front Brake
Installing the Brake Disc of the Front Brake
Rear Wheel
Removing the Rear Wheel
Installing the Rear Wheel
Removing the Brake Disc of the Rear Brake
Installing the Brake Disc of the Rear Brake
Checking the Chain Tension
Adjusting the Chain Tension
Checking the Chain, Rear Sprocket, and Engine Sprocket
Cleaning the Chain
Checking the Rear Hub Rubber Dampers
Wiring Harness, Battery
Removing the Battery
Installing the Battery
Disconnecting the Negative Cable of the Battery
Reconnecting the Negative Cable of the Battery
Recharging the Battery
Checking the Charging Voltage
Changing the Fuses of Individual Power Consumers
Brake System
Checking the Front Brake Linings
Changing the Front Brake Linings
Checking the Brake Fluid Level of the Front Brake
Adding Front Brake Fluid
Changing the Front Brake Fluid
Checking the Rear Brake Linings
Changing the Rear Brake Linings
Checking the Free Travel of Foot Brake Lever
Adjusting the Free Travel of the Foot Brake Lever
Checking the Rear Brake Fluid Level
Adding Rear Brake Fluid
Changing the Rear Brake Fluid
Lighting System, Instruments
Setting Kilometers or Miles
Adjusting the Shift Speed RPM 1
Adjusting the Shift Speed RPM 2
Setting the Time
Resetting the Service Interval Display
Checking the Headlight Setting
Adjusting the Headlight Range
Changing the Parking Light Bulb
Changing the Headlight Bulb
Engine
Removing the Engine
Installing the Engine
Engine Disassembly
Preparations (125 Duke)
Draining the Engine Oil (125 Duke)
Removing the Chain Securing Guide
Duke)
Removing the Valve Cover (125 Duke)
Removing the Spark Plug (125 Duke)
Removing the Clutch Cover (125 Duke)
Setting the Engine to Ignition Top Dead Center (125 Duke)
Removing the Starter Motor (125 Duke)
Removing the Timing Chain Tensioner
Duke)
Removing the Camshaft (125 Duke)
Removing the Cylinder Head (125 Duke)
Removing the Piston (125 Duke)
Removing the Water Pump Wheel
Duke)
Removing the Alternator Cover
Duke)
Removing the Rotor (125 Duke)
Removing the Starter Drive (125 Duke)
Removing the Balancer Shaft Drive Wheel (125 Duke)
Removing the Gear Position Sensor
Duke)
Removing the Spacer (125 Duke)
Removing the Clutch Basket (125 Duke)
Removing the Primary Gear (125 Duke)
Removing the Oil Pump (125 Duke)
Removing the Shift Shaft (125 Duke)
Removing the Shift Drum Locating
Duke)
Removing the Locking Lever (125 Duke)
Removing the Oil Filter (125 Duke)
Removing the Left Engine Case
Duke)
Removing the Shift Rails (125 Duke)
Removing the Shift Drum (125 Duke)
Removing the Shift Forks (125 Duke)
Removing the Transmission Shafts
Duke)
Removing the Balancer Shaft (125 Duke)
Removing the Crankshaft (125 Duke)
Preparations (200 Duke)
Draining the Engine Oil (200 Duke)
Removing the Chain Securing Guide
Duke)
Removing the Valve Cover (200 Duke)
Removing the Spark Plug (200 Duke)
Removing the Clutch Cover (200 Duke)
Setting the Engine to Ignition Top Dead Center (200 Duke)
Removing the Starter Motor (200 Duke)
Removing the Timing Chain Tensioner
Duke)
Removing the Camshaft (200 Duke)
Removing the Cylinder Head (200 Duke)
Removing the Piston (200 Duke)
Removing the Water Pump Wheel
Duke)
Removing the Alternator Cover
Duke)
Removing the Rotor (200 Duke)
Removing the Starter Drive (200 Duke)
Removing the Balancer Shaft Drive Wheel (200 Duke)
Duke)
Removing the Spacer (200 Duke)
Removing the Clutch Basket (200 Duke)
Removing the Primary Gear (200 Duke)
Removing the Oil Pump (200 Duke)
Removing the Shift Shaft (200 Duke)
Removing the Shift Drum Locating
Duke)
Removing the Locking Lever (200 Duke)
Removing the Oil Filter (200 Duke)
Removing the Left Engine Case
Duke)
Removing the Shift Rails (200 Duke)
Removing the Shift Drum (200 Duke)
Removing the Shift Forks (200 Duke)
Removing the Transmission Shafts
Duke)
Removing the Balancer Shaft (200 Duke)
Removing the Crankshaft (200 Duke)
Work on Individual Parts
Work on the Left Section of the Engine Case (125 Duke)
Work on the Right Section of the Engine Case (125 Duke)
Changing the Shaft Seal Ring of the Water Pump (125 Duke)
Removing the Main Bearing (125 Duke)
Checking the Radial Play of the Lower Conrod Bearing (125 Duke)
Changing the Conrod Bearing (125 Duke)
Changing the Balancer Shaft Bearing
Duke)
Changing the Camshaft Bearing
Work on the Cylinder Head (125 Duke)
Checking the Cylinder Head (125 Duke)
Checking/Measuring the Cylinder
Duke)
Checking the Piston Ring End Gap
Duke)
Checking/Measuring the Piston
Checking the Piston/Cylinder Mounting Clearance (125 Duke)
Checking the Oil Pump (125 Duke)
Checking the Oil Pressure Regulator Valve (125 Duke)
Checking the Clutch (125 Duke)
Preassembling the Clutch (125 Duke)
Checking the Shift Mechanism
Duke)
Preassembling the Shift Shaft (125 Duke)
Disassembling the Main Shaft
Duke)
Dismantling the Countershaft (125 Duke)
Checking the Transmission (125 Duke)
Assembling the Main Shaft (125 Duke)
Assembling the Countershaft (125 Duke)
Checking the Timing Assembly
Duke)
Changing the Stator (125 Duke)
Checking the Electric Starter Drive
Duke)
Checking the Freewheel (125 Duke)
Work on the Left Section of the Engine Case (200 Duke)
Work on the Right Section of the Engine Case (200 Duke)
Changing the Shaft Seal Ring of the Water Pump (200 Duke)
Removing the Main Bearing (200 Duke)
Checking the Radial Play of the Lower
Conrod Bearing (200 Duke)
Changing the Conrod Bearing (200 Duke)
Changing the Balancer Shaft Bearing
Duke)
Changing the Camshaft Bearing
Work on the Cylinder Head (200 Duke)
Checking the Cylinder Head (200 Duke)
Checking/Measuring the Cylinder
Duke)
Checking the Piston Ring End Gap
Duke)
Checking/Measuring the Piston
Checking the Piston/Cylinder Mounting Clearance (200 Duke)
Checking the Oil Pump (200 Duke)
Checking the Oil Pressure Regulator Valve (200 Duke)
Checking the Clutch (200 Duke)
Preassembling the Clutch (200 Duke)
Checking the Shift Mechanism
Duke)
Preassembling the Shift Shaft (200 Duke)
Disassembling the Main Shaft
Duke)
Dismantling the Countershaft (200 Duke)
Checking the Transmission (200 Duke)
Assembling the Main Shaft (200 Duke)
Assembling the Countershaft (200 Duke)
Checking the Timing Assembly
Duke)
Changing the Stator (200 Duke)
Checking the Electric Starter Drive
Duke)
Checking the Freewheel (200 Duke)
Engine Assembly
Installing the Crankshaft (125 Duke)
Installing the Balancer Shaft (125 Duke)
Duke)
Installing the Shift Forks (125 Duke)
Installing the Shift Drum (125 Duke)
Installing the Shift Rails (125 Duke)
Installing the Left Engine Case
Duke)
Installing the Oil Filter (125 Duke)
Installing the Locking Lever (125 Duke)
Installing the Shift Drum Locating
Duke)
Installing the Shift Shaft (125 Duke)
Installing the Oil Pump (125 Duke)
Installing the Primary Gear (125 Duke)
Installing the Clutch Basket (125 Duke)
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REPAIR MANUAL
2013
125 Duke EU
200 Duke EU
200 Duke MAL
200 Duke 2014 COL
Art. no. 3206162en
Table of
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This manual is also suitable for:
200 duke 2013
200 duke 2014
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