KTM 125 DUKE Manual

MODELS

This document is valid for the following models:
125 DUKE EU (F4003X1, F4003X2)
125 DUKE B.D. EU (F4003X3, F4003X4)
125 DUKE JP (F4086X3, F4086X4)
125 DUKE UK (F4022X3, F4022X4)

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 information with more details or tips.
»	Indicates the result of a testing step.
	Indicates a voltage measurement.
	Indicates a current measurement.
	Indicates a resistance measurement.

Formats used

The typographical formats used in this document are explained below.

Proprietary name	Indicates a proprietary name.
Underlined terms	Refer to technical details of the vehicle or indicate technical terms, which are explained in the glossary.

SETUP

Transport mode

This vehicle was blocked for transport in the software.
To operate the vehicle, the vehicle electronics must be enabled.
This process is conducted during initial setup in KTMDealer.net.
Enabling ensures that the initial setup in KTMDealer.net is documented.
Enabling can be performed either temporarily, e.g. for a test ride, or permanently for vehicle handover.

Info
Make sure that the vehicle is permanently enabled before handing it over to the customer.

Diagnostics connector

Diagnostics connector is located under the passenger seat.

Unpacking and setting up the product

Preliminary work

• Remove the box.

Main work

• Remove the straps, lid and pallet wall.
• Remove the adhesive tape in the upper area of the motorcycle.

• Roll down the film at the sides.

Info
To avoid damaging the motorcycle during unpacking, leave the other films on the vehicle until you have finished work on the vehicle.

• Remove the separate enclosure and unpack it. Check the separate enclosure for completeness.
• Check the vehicle for transport damage.

• Position all controls in their exact positions on the handlebar. Tighten all screws.
  

• Make sure that the clutch cable is attached to the clutch release lever and secured.
  
• Check the clutch lever play. (see "Checking the clutch lever play")
• Mount and tighten the rear mirror on both sides.
• Carefully loosen and remove the tension belt over the link fork.
  Info
  An assistant prevents the motorcycle from falling over.
• Carefully loosen and remove the tension belts around the lower triple clamp.
  The vehicle is released at the front.
• Together with an assistant, take the vehicle off the pallet.
• Remove the passenger seat. (see "Removing the passenger seat")
• Remove the front rider's seat. (see "Removing the front rider's seat")
• Remove the tool set from the separate enclosure and position it next to the battery compartment.
  
• Remove spare key and KEYCODECARD from under the seat and keep in a safe place for the handover.

Risk of injury
Battery acid and battery gases cause serious chemical burns.

• Keep 12 V batteries out of the reach of children.
• Wear suitable protective clothing and safety glasses.
• Avoid contact with battery acid and battery gases.
• Keep sparks or open flames away from the 12 V battery.
• Only charge 12 V batteries in well-ventilated rooms.
• Rinse the affected area immediately with plenty of water in the event of contact with the skin.
• Rinse eyes with water for at least 15 minutes and consult a doctor immediately if battery acid and battery gases get into the eyes.

• Fill the 12 V battery.
  Info
  Read the notes in the 12 V battery accessory pack.
• Charge the 12-V battery. (see "Charging the 12-V battery")
• Install the 12-V battery. (see "Connecting the negative cable of the 12-V battery")
• Remove the remaining film, padding, the corrugated cardboard, and the other packaging material.
• Mount the front rider's seat. (see "Mounting the front rider's seat")
• Mount the passenger seat. (see "Mounting the passenger seat")
• Refuel. (see "Refueling")
• Check the headlight setting. (see "Checking the headlight setting")
• Prepare the vehicle according to the specifications in the KTMDealer.net for handover to the customer.

Info
Transport mode must be deactivated to be able to start the motorcycle.

WORK

Checking the clutch lever play

Note
Clutch damage
If there is no free travel by the clutch lever, the clutch will begin to slip.

• Check the free travel of the clutch lever each time before using the motorcycle.
• Adjust the free travel of the clutch lever when necessary in accordance with the specification.

• Check the clutch lever for smooth operation.
• Move the handlebar to the straight-ahead position.
• Pull the clutch lever until resistance is perceptible, and determine the play in the clutch lever .

Clutch lever play

1... 3 mm (0.04... 0.12 in)

» If the clutch lever play does not meet the specified value:

• Adjust play in the clutch lever. (see "Adjusting play in the clutch lever")

• Move the handlebar to the front over the entire steering range.
  The clutch lever play must not change.
  » If the clutch lever play changes:
  • Check the routing of the clutch cable.

Adjusting play in the clutch lever

• Move the handlebar to the straight-ahead position.
• Push back sleeve .
• Loosen lock nut .
• Adjust the play in the clutch level A by turning adjusting screw .

Guideline
Clutch lever play	1... 3 mm (0.04... 0.12 in)

• Tighten lock nut .
• Position bellows .

Removing the passenger seat

• Insert the ignition key in seat lock and turn it clockwise.
• Lift the front of the seat and push it towards the fuel tank.
• Remove the ignition key from the seat lock.

Mounting the passenger seat

• Attach hooks on the passenger seat to hangers on the subframe, and push it to the rear.
• Press the passenger seat downward until it clicks into place.

Danger of accidents
The seat can come loose from the anchoring if it is not mounted correctly.

• After assembly, check whether the seat is correctly locked and cannot be pulled up.

• Finally, check that the passenger seat is correctly mounted.

Removing the front rider's seat

Preparatory work

• Remove the passenger seat. (see "Removing the passenger seat")

Main work

• Raise the rear of the front rider's seat, pull it towards the rear, and remove it upwards.
  

Mounting the front rider's seat

Main work

• Attach the front rider's seat in area and lower at the rear.
  
• Finally, check that the front rider's seat is correctly mounted.

Finishing work

• Mount the passenger seat. (see "Mounting the passenger seat")

Charging the 12-V battery

Risk of injury
Battery acid and battery gases cause serious chemical burns.

• Keep 12 V batteries out of the reach of children.
• Wear suitable protective clothing and safety glasses.
• Avoid contact with battery acid and battery gases.
• Keep sparks or open flames away from the 12 V battery.
• Only charge 12 V batteries in well-ventilated rooms.
• Rinse the affected area immediately with plenty of water in the event of contact with the skin.
• Rinse eyes with water for at least 15 minutes and consult a doctor immediately if battery acid and battery gases get into the eyes.

Note
Danger of damage
An incorrectly selected charging mode will damage the 12-V battery.

• Always select a charging mode that is compatible with the type of battery.

Note
Environmental hazard
12 V batteries contain environmentally hazardous materials.

• Do not dispose of 12 V batteries as household waste.
• Dispose of 12 V batteries at a collection point for used batteries.

Note
Environmental hazard
Hazardous substances cause environmental damage.

• Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations.

Info
Even when there is no load on the 12-V battery, it discharges steadily each day.
The charging level and the method of charging are very important for the service life of the 12-V battery.
Rapid recharging with a high charging current shortens the service life of the battery.
If the charging current, charging voltage, or charging time is exceeded, electrolyte escapes through the safety valves.
This reduces the capacity of the 12-V battery. If the 12-V battery is discharged by repeated starting, charge the 12-V battery immediately.
If the 12-V battery is left in a discharged state for an extended period, it will become deeply discharged and sulfating occurs, thus destroying the battery.
The 12-V battery is maintenance-free. The acid level does not have to be checked.

Preparatory work

• Remove the passenger seat. (see "Removing the passenger seat")
• Remove the front rider's seat. (see "Removing the front rider's seat")
• Disconnect the negative cable of the 12-V battery. (see "Disconnecting the negative cable of the 12-V battery")

Main work

• Connect a battery charger to the 12-V battery. Adjust the battery charger.
  

EU battery charger XCharge‑professional (00029095050)
Alternative 1
US battery charger XCharge‑professional (00029095051)
Alternative 2
UK battery charger XCharge‑professional (00029095052)

Info
Follow the instructions of the charger and the manual.

• Disconnect the battery charger after charging the 12-V battery. Guideline

The charging current, charging voltage, and charging time must not be exceeded.
Recharge the 12-V battery regularly when the motorcycle is not being used	6 months

Finishing work

• Connect the negative cable of the 12-V battery. (see "Connecting the negative cable of the 12-V battery")
• Mount the front rider's seat. (see "Mounting the front rider's seat")
• Mount the passenger seat. (see "Mounting the passenger seat")
• Set time and date. (see "Setting the time and date")

Disconnecting the negative cable of the 12-V battery

Preparatory work

• Remove the passenger seat. (see "Removing the passenger seat")
• Remove the front rider's seat. (see "Removing the front rider's seat")

Main work

• Remove battery cover .
  
• Disconnect negative cables of the 12-V battery.

Connecting the negative cable of the 12-V battery

Main work

• Connect negative cables of the 12-V battery.
  
• Install battery cover .
  

Finishing work

• Mount the front rider's seat. (see "Mounting the front rider's seat")
• Mount the passenger seat. (see "Mounting the passenger seat")
• Set time and date. (see "Setting the time and date")

Installing the 12-V battery

Main work

• Position the 12-V battery in the battery compartment.
  12-V battery (ETZ-9-BS)
• Position positive cable and mount and tighten the screw.
• Position positive terminal cover .
• Position negative cable and mount and tighten the screw.
• Mount battery cover .
  

Finishing work

• Mount the front rider's seat. (see "Mounting the front rider's seat")
• Mount the passenger seat. (see "Mounting the passenger seat")
• Set time and date. (see "Setting the time and date")

Setting the time and date

Condition
The motorcycle is stationary.

• Press the SET button when the menu is closed.
• Press UP or DOWN button until Settings appears. Press the SET button to open the menu.
• Press the UP or DOWN button until Clock & Date is highlighted. Press the SET button to open the submenu.
  

Setting the clock

• Press UP or DOWN button until Set Clock is highlighted.
• Press the SET button to open the menu.
• Press the UP or DOWN button until the current hour is set. Press the SET button to select the hour.
• Press the UP or DOWN button until the current minute is set. Press the SET button to select the minute.
• Press the BACK button to exit the menu.

Setting the date

• Press UP or DOWN button until Set Date is highlighted.
• Press the SET button to open the menu.
• Press the UP or DOWN button until the current day is set. Press the SET button to select the day.
• Press the UP or DOWN button until the current month is set. Press the SET button to select the month.
• Press the UP or DOWN button until the current year is set. Press the SET button to select the year.
• Press the BACK button to exit the menu.

Opening fuel tank filler cap

Fire hazard
Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.

• Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.
• Switch off the engine for refueling.
• Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
• If any fuel is spilled, wipe it off immediately.
• Observe the specifications for refueling.

Danger of poisoning
Fuel is harmful to health.

• Avoid skin, eye and clothing contact with fuel.
• Immediately consult a doctor if you swallow fuel.
• Do not inhale fuel vapors.
• Rinse the affected area immediately with plenty of water in the event of contact with the skin.
• Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
• Change your clothing if fuel spills on them.
• Keep fuels correctly in a suitable canister, and out of the reach of children

Note
Environmental hazard
Improper handling of fuel is a danger to the environment.

• Do not allow fuel to enter the groundwater, the soil, or the sewage system.

• Lift cover of the fuel tank filler cap and insert the ignition key into the lock.

Note
Danger of damage
The ignition key may break if overloaded.
Damaged ignition keys must be replaced.

• Push down on the fuel tank filler cap to take pressure off the ignition key.

• Turn the ignition key 90° clockwise.
• Lift the fuel tank filler cap.
• Remove the ignition key.

Closing the fuel tank filler cap

Fire hazard
Fuel is highly flammable and a health hazard.

• Check that the fuel tank filler cap is locked correctly after closing.
• Change your clothing if fuel spills on them.
• Rinse the affected area immediately with plenty of water in the event of contact with the skin.

• Close the fuel tank filler cap.
  
• Push down the fuel tank filler cap until the lock engages.
  

Refueling

Fire hazard
Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.

• Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.
• Switch off the engine for refueling.
• Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
• If any fuel is spilled, wipe it off immediately.
• Observe the specifications for refueling.

Danger of poisoning
Fuel is harmful to health.

• Avoid skin, eye and clothing contact with fuel.
• Immediately consult a doctor if you swallow fuel.
• Do not inhale fuel vapors.
• Rinse the affected area immediately with plenty of water in the event of contact with the skin.
• Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
• Change your clothing if fuel spills on them.

Note
Material damage
Inadequate fuel quality causes the fuel filter to quickly become clogged.
In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the fuel system.

• Refuel only with clean fuel that meets the specified standards.

Note
Environmental hazard
Improper handling of fuel is a danger to the environment.

• Do not allow fuel to enter the groundwater, the soil, or the sewage system.

• Switch off the engine.
• Open the fuel tank filler cap. (see "Opening fuel tank filler cap")
• Fill the fuel tank with fuel up to the lower edge of the fuel filler.

Total fuel tank capacity, approx.

15 l (4 US gal)

Super unleaded (ROZ 95)

• Close the fuel tank filler cap. (see "Closing the fuel tank filler cap")

Checking the headlight setting

• Park the vehicle on a horizontal surface in front of a lightcolored wall and make a mark at the height of the center of the low beam headlight.
• Make another mark at a distance under the first marking.

Guideline
Distance	5 cm (2 in)

• Position the vehicle vertical to the wall at distance from the wall and switch on the low beam.

Guideline
Distance	5 m (16 ft)

• The rider now mounts the motorcycle with luggage and passenger if applicable.
• Check the headlight setting.
  The light-dark boundary must be exactly on the lower marking when the motorcycle is ready to be operated with the rider mounted along with any luggage and a passenger if applicable.
  » If the boundary between light and dark does not meet specifications:
  • Adjust the headlight range. (see "Adjusting the headlight setting")

Adjusting the headlight range

Preparatory work

• Check the headlight setting. (see "Checking the headlight setting")

Main work

• Turn adjusting screw to adjust the headlight range.
  

Info
Turn clockwise to increase the headlight range; turn counterclockwise to reduce the headlight range.
If you have a payload, you may have to correct the headlight range.
Screw also secures the headlight. Ensure the screw is always screwed in far enough.

• Set the headlight to marking .
  Guideline
  The light-dark boundary must lie exactly on lower marking when the motorcycle is ready to operate with the rider mounted along with any luggage and a passenger if applicable.
  

TECHNICAL SPECIFICATIONS

Chassis tightening torques

SUBSTANCES

Super unleaded (ROZ 95)
Standard/classification

• DIN EN 228 (ROZ 95)

Guideline

• Only use super unleaded fuel that matches or is equivalent to the specified standard.
• Fuel with an ethanol content of up to 10% (E10 fuel) is safe to use.

Info
Do not use fuel containing methanol (e.g., M15, M85, M100) or more than 10% ethanol (e.g., E15, E25, E85, E100).

KTM Sportmotorcycle GmbH
5230 Mattighofen/Austria
KTM.COM

Documents / Resources

References

• Redirecting
• KTM - READY TO RACE | United States

Download manual

Here you can download full pdf version of manual, it may contain additional safety instructions, warranty information, FCC rules, etc.

Download KTM 125 DUKE Manual