Table Of Contents - KTM 125 Duke 2013 Repair Manual

TABLE OF CONTENTS

TABLE OF CONTENTS
1 MEANS OF REPRESENTATION ..................................... 6
1.1 Symbols used ................................................... 6
1.2 Formats used.................................................... 6
2 SAFETY ADVICE........................................................... 7
2.1 Repair Manual .................................................. 7
2.2 Safety advice.................................................... 7
2.3 Degrees of risk and symbols ............................... 7
2.4 Work rules........................................................ 7
3 IMPORTANT INFORMATION ......................................... 8
3.1 Guarantee, warranty .......................................... 8
3.2 Operating and auxiliary substances ..................... 8
3.3 Spare parts, accessories .................................... 8
3.4 Figures ............................................................ 8
4 SERIAL NUMBERS ...................................................... 9
4.1 Chassis number/type label ................................. 9
4.2 Key number...................................................... 9
4.3 Engine number ................................................. 9
5 MOTORCYCLE ........................................................... 10
5.1 Raising the motorcycle with the rear wheel
stand ............................................................. 10
5.2 Taking the motorcycle off of the rear wheel
stand ............................................................. 10
5.3 Raising the motorcycle with the front wheel
stand ............................................................. 10
5.4 Taking the motorcycle off of the front wheel
stand ............................................................. 11
5.5 Raising the motorcycle with the work stand ....... 11
5.6 Removing the motorcycle from the work stand ... 12
5.7 Starting.......................................................... 13
5.8 Starting the motorcycle to make checks ............ 14
6 FORK, TRIPLE CLAMP ............................................... 15
6.1 Cleaning the dust boots of the fork legs............. 15
6.2 Removing fork legs.......................................... 15
6.3 Installing the fork legs ..................................... 17
6.4 Disassembling the fork legs.............................. 20
6.5 Checking the fork legs ..................................... 22
6.6 Assembling the fork legs.................................. 23
6.7 Removing the lower triple clamp....................... 24
6.8 Installing the lower triple clamp ....................... 27
6.9 Checking the steering head bearing play............ 29
6.10 Adjusting the steering head bearing play ........... 30
7 HANDLEBAR, CONTROLS........................................... 32
7.1 Checking the play in the throttle cable .............. 32
7.2 Adjusting the play in the throttle cable.............. 32
7.3 Checking the clutch lever play.......................... 32
7.4 Adjusting the clutch cable play ........................ 33
8 SHOCK ABSORBER, SWINGARM ................................ 34
8.1 Adjusting the spring preload of the shock
absorber......................................................... 34
8.2 Removing the shock absorber ........................... 34
8.3 Installing the shock absorber............................ 35
8.4 Removing the spring........................................ 36
8.5 Installing the spring ........................................ 36
9 EXHAUST .................................................................. 38
9.1 Removing the exhaust manifold........................ 38
9.2 Installing the exhaust manifold ........................ 39
9.3 Removing the main silencer ............................. 40
9.4 Installing the main silencer.............................. 42
10 AIR FILTER ............................................................... 44
10.1 Removing the air filter ..................................... 44
10.2 Installing the air filter...................................... 44
11 FUEL TANK, SEAT, TRIM ........................................... 45
11.1 Opening the filler cap...................................... 45
11.2 Closing the filler cap ....................................... 45
11.3 Removing the seat .......................................... 45
11.4 Mounting the seat ........................................... 46
11.5 Removing the passenger seat ........................... 46
11.6 Mounting the passenger seat............................ 46
11.7 Removing the fuel tank cover ........................... 46
11.8 Installing the fuel tank cover ............................ 49
11.9 Removing the fuel tank.................................... 51
11.10 Installing the fuel tank .................................... 53
11.11 Removing the front spoiler ............................... 54
11.12 Fitting front spoiler ......................................... 54
11.13 Dismounting the front fender ........................... 55
11.14 Installing the front fender ................................ 55
11.15 Checking the fuel pressure............................... 56
11.16 Changing the fuel filter.................................... 57
11.17 Replacing the fuel pump ................................. 58
12 WHEELS ................................................................... 60
12.1 Checking the tire air pressure........................... 60
12.2 Checking the tire condition .............................. 60
12.3 Checking the brake discs ................................. 61
12.4 Front wheel .................................................... 61
12.4.1 Removing the front wheel ............................ 61
12.4.2 Installing the front wheel ............................. 62
12.4.3 Removing the brake disc of the front brake.... 63
12.4.4 Installing the brake disc of the front brake .... 64
12.5 Rear wheel ..................................................... 64
12.5.1 Removing the rear wheel ............................. 64
12.5.2 Installing the rear wheel .............................. 65
12.5.3 Removing the brake disc of the rear brake ..... 66
12.5.4 Installing the brake disc of the rear brake...... 67
12.5.5 Checking the chain tension.......................... 68
12.5.6 Adjusting the chain tension ......................... 68
12.5.7 Checking the chain, rear sprocket, and
engine sprocket .......................................... 69
12.5.8 Cleaning the chain ...................................... 72
12.5.9 Checking the rear hub rubber dampers.......... 73
13 WIRING HARNESS, BATTERY..................................... 74
13.1 Removing the battery ...................................... 74
13.2 Installing the battery ....................................... 74
13.3 Disconnecting the negative cable of the
battery ........................................................... 75
13.4 Reconnecting the negative cable of the
battery ........................................................... 75
13.5 Recharging the battery .................................... 75
13.6 Checking the charging voltage .......................... 76
13.7 Changing the fuses of individual power
consumers...................................................... 77
14 BRAKE SYSTEM ........................................................ 79
14.1 Checking the front brake linings ....................... 79
14.2 Changing the front brake linings ....................... 79
14.3 Checking the brake fluid level of the front
brake ............................................................. 82
14.4 Adding front brake fluid................................... 83
14.5 Changing the front brake fluid .......................... 83
14.6 Checking the rear brake linings ........................ 86
14.7 Changing the rear brake linings ........................ 86
14.8 Checking the free travel of foot brake lever ........ 89
14.9 Adjusting the free travel of the foot brake
lever .............................................................. 89
14.10 Checking the rear brake fluid level.................... 90
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