Related Manuals for KTM 2013 200 DUKE
Summarization of Contents
Means of Representation
Symbols Used in Manual
Explains the meaning of specific symbols used in the manual for clear communication.
Document Formats Explained
Details the typographical formats used within the repair manual for consistency.
Safety Advice and Work Rules
Repair Manual Guidance
Provides instructions on reading the repair manual carefully before starting work.
Vehicle Operating Safety
Outlines important safety instructions for operating the vehicle safely.
Risk Degrees and Symbols
Defines danger symbols and their associated risks and appropriate measures.
Essential Work Rules
Specifies essential work rules, including using special tools and replacing non-reusable parts.
Important Information and Serial Numbers
Guarantee and Warranty Conditions
Details warranty conditions and voiding circumstances for repairs.
Operating and Auxiliary Substances
Warns about environmental hazards from fuel and specifies correct substance usage.
Spare Parts and Accessories
Advises using only approved KTM spare parts and accessories for safety.
Chassis Number and Type Label Location
Identifies the location of the chassis number and type label on the vehicle.
Key Number Identification
Explains where to find the key number and the importance of the KEYCODECARD.
Engine Number Location
Specifies the location of the engine number stamped on the engine.
Motorcycle Operations
Raising Motorcycle with Rear Wheel Stand
Provides steps and safety notes for lifting the motorcycle using a rear wheel stand.
Removing Motorcycle from Rear Wheel Stand
Details the procedure for safely removing the motorcycle from a rear wheel stand.
Raising Motorcycle with Front Wheel Stand
Outlines preparatory steps and conditions for raising the motorcycle with a front wheel stand.
Motorcycle Front Wheel Stand Removal
Provides safety notes and steps for safely removing the motorcycle from a front wheel stand.
Raising Motorcycle with Work Stand
Details preparatory work and the first step for raising the motorcycle with a work stand.
Motorcycle Removal from Work Stand
Provides safety notes and steps for safely removing the motorcycle from a work stand.
Work Stand Screw Tightening
Details mounting and tightening screws for the engine bearer on the frame.
Safe Motorcycle Starting Procedure
Explains safe starting procedures, including dangers of exhaust gases and battery.
Starting Motorcycle for Checks
Provides safety advice on exhaust gases and steps to start the motorcycle for checks.
Fork and Triple Clamp Maintenance
Cleaning Fork Leg Dust Boots
Details how to push down dust boots on fork legs and clean them.
Removing Front Fork Legs
Outlines preparatory work and main steps for removing fork legs, including brake caliper handling.
Installing Front Fork Legs
Details tightening screws for triple clamps and mounting the wheel speed sensor.
Fork Leg Installation Checks
Covers checking wheel bearings and greasing seal rings and contact surfaces.
Front Fork Leg Reassembly Steps
Describes cleaning the wheel spindle, mounting brake calipers, and tightening fork stub screws.
Fork Leg Installation: Triple Clamps
Details pushing fork legs into triple clamps and aligning them for Duke EU/MAL models.
Front Wheel Bearing and Seal Greasing
Details checking wheel bearings, greasing seals, and mounting the wheel spindle.
Front Fork Straightening Procedure
Describes positioning brake calipers, tightening them, and pulling the front brake to straighten fork legs.
Disassembling Fork Legs
Provides general information that operations are the same for both fork legs and condition for disassembly.
Fork Leg Disassembly Steps
Details unclamping the inner tube, draining oil, and removing dust boot and lock ring.
Checking Fork Leg Condition
Describes checking inner and outer tubes for damage and measuring diameters.
Assembling Fork Legs
Provides general information that assembly operations are the same for both fork legs.
Fork Leg Assembly Steps
Details mounting lock rings, installing dust boots, and filling with fork oil.
Removing Lower Triple Clamp
Outlines preparatory work and main steps for removing the lower triple clamp.
Lower Triple Clamp Removal Details
Details removing screws, headlight mask, and upper triple clamp.
Installing Lower Triple Clamp
Outlines main work and alternative 1 for installing the lower triple clamp with a new bearing.
Lower Triple Clamp Installation Options
Details alternative 2 for installing the lower triple clamp with an existing bearing and securing cables.
Lower Triple Clamp Final Tightening
Covers mounting the upper triple clamp with the handlebar and tightening screws.
Checking Steering Head Bearing Play
Warns about unstable handling due to incorrect bearing play and outlines checking procedure.
Adjusting Steering Head Bearing Play
Details preparatory work and main work for adjusting steering head bearing play.
Steering Head Bearing Adjustment Tightening
Covers tightening screws and finishing work after adjusting steering head bearing play.
Handlebar and Controls Checks
Checking Throttle Cable Play
Explains how to check throttle grip smooth operation and cable play.
Adjusting Throttle Cable Play
Details steps for adjusting throttle cable play by turning the adjusting screw.
Checking Clutch Lever Play
Explains how to check clutch lever smooth operation and play.
Adjusting Clutch Cable Play
Details steps for adjusting clutch cable play by turning the adjusting screw.
Shock Absorber and Swingarm Maintenance
Adjusting Shock Absorber Spring Preload
Warns about suspension changes affecting ride behavior and how to adjust spring preload.
Removing the Shock Absorber
Outlines preparatory work and main steps for removing the shock absorber.
Installing the Shock Absorber
Details lifting the link fork and positioning the shock absorber for installation.
Removing the Shock Absorber Spring
Describes clamping the shock absorber and removing the spring using special tools.
Installing the Shock Absorber Spring
Details mounting the spring and releasing it after compressor removal.
Exhaust System Maintenance
Removing the Exhaust Manifold
Warns about hot exhaust components and outlines preparatory and main steps for removal.
Installing the Exhaust Manifold
Details positioning the exhaust manifold and mounting nuts and exhaust clamp.
Removing the Main Silencer
Outlines preparatory work and main steps for removing the main silencer.
Installing the Main Silencer
Details positioning the main silencer and mounting screws.
Air Filter System
Removing the Air Filter
Warns about engine failure from unfiltered air and outlines preparatory and main steps for removal.
Installing the Air Filter
Details positioning the air filter and mounting the air filter box lid.
Fuel Tank, Seat, and Trim
Opening the Fuel Filler Cap
Warns about fire and poisoning hazards of fuel and provides steps to open the filler cap.
Closing the Fuel Filler Cap
Warns about fuel hazards and details closing the filler cap until it locks.
Removing the Motorcycle Seat
Outlines preparatory work and main steps for removing the seat.
Mounting the Motorcycle Seat
Details attaching seat recesses and mounting/tightening screws for the seat.
Removing the Passenger Seat
Provides steps for removing the passenger seat using the ignition key.
Mounting the Passenger Seat
Details attaching hooks and pressing down the passenger seat until it clicks.
Removing the Fuel Tank Cover
Warns about fuel hazards and describes creating a special tool for removing the fuel tank cover.
Fuel Tank Cover Removal Steps
Details removing screws, filler cap, and other components to lift the fuel tank cover.
Fuel Tank Cover Detachment
Describes lifting the fuel tank cover, detaching side covers, and removing the vent hose.
Installing the Fuel Tank Cover
Warns about fuel hazards and describes removing the plug as the main work.
Fuel Tank Cover Reinstallation
Details mounting the vent hose, positioning the fuel tank cover, and tightening screws.
Removing the Fuel Tank
Warns about fuel hazards and outlines preparatory steps for fuel tank removal.
Fuel Tank Removal Procedure
Details removing screws, hanging the EFI control unit, and detaching the fuel line.
Installing the Fuel Tank
Warns about fuel hazards and describes connecting the fuel line and positioning the fuel tank.
Removing the Front Spoiler
Details removing screws and taking off the front spoiler.
Fitting the Front Spoiler
Describes positioning the front spoiler and mounting screws without tightening.
Dismounting the Front Fender
Provides steps for removing the front fender for Duke COL and Duke EU/MAL models.
Installing the Front Fender
Details positioning and mounting the front fender for Duke COL and Duke EU/MAL models.
Checking Fuel Pressure
Warns about fuel hazards and describes checking fuel pressure with a closed and open filler cap.
Changing the Fuel Filter
Warns about fuel hazards and outlines preparatory work and main steps for changing the fuel filter.
Replacing the Fuel Pump
Warns about fuel hazards and outlines preparatory work and main steps for replacing the fuel pump.
Fuel Pump Reinstallation
Details positioning the fuel pump with gasket and installing screws.
Wheels and Tires
Checking Tire Air Pressure
Provides information on correct tire pressure for optimal riding comfort and tire life.
Checking Tire Condition
Warns about hazards of flat or worn tires and outlines checking tread depth and tire age.
Checking Front Brake Discs
Warns about reduced braking efficiency due to worn discs and how to check thickness.
Removing the Front Wheel
Outlines preparatory work and main steps for removing the front wheel.
Installing the Front Wheel
Outlines main work for installing the front wheel, including checking wheel bearings.
Front Wheel Installation Procedure
Details cleaning threads, positioning wheel, mounting and tightening screws for front wheel installation.
Removing Front Brake Disc
Outlines preparatory work and main steps for removing the front brake disc.
Installing Front Brake Disc
Details cleaning contact surfaces and installing the front brake disc.
Removing the Rear Wheel
Outlines preparatory work and main steps for removing the rear wheel.
Rear Wheel Removal Steps
Details removing nut, chain adjuster, and wheel spindle for rear wheel removal.
Installing the Rear Wheel
Outlines main work for installing the rear wheel, including checking hub rubber dampers.
Rear Wheel Installation Procedure
Details checking wheel bearings and installing spacers for rear wheel installation.
Removing Rear Brake Disc
Outlines preparatory work and main steps for removing the rear brake disc.
Installing Rear Brake Disc
Details cleaning contact surfaces and installing the rear brake disc and ABS sensor wheel.
Checking Chain Tension
Warns about incorrect chain tension and outlines the procedure for checking chain tension.
Adjusting Chain Tension
Warns about incorrect chain tension and details adjusting it by turning screws.
Checking Chain, Sprockets, and Wear
Describes checking the chain, rear sprocket, and engine sprocket for wear and damage.
Cleaning the Drive Chain
Warns about oil/grease on tires and brake discs and describes cleaning the chain.
Checking Rear Hub Rubber Dampers
Explains the function of rubber dampers and how to check their wear and play.
Wiring Harness and Battery
Removing the Motorcycle Battery
Warns about battery acid and gases and outlines steps for removing the battery.
Installing the Motorcycle Battery
Details positioning the battery and connecting terminals and covers.
Disconnecting Negative Battery Cable
Outlines preparatory work and main steps for disconnecting the negative battery cable.
Reconnecting Negative Battery Cable
Details main work for connecting the negative battery cable and finishing work.
Recharging the Motorcycle Battery
Warns about battery acid hazards and provides guidelines for charging and battery care.
Checking Charging Voltage
Outlines conditions and main work for checking the charging voltage.
Changing Fuses for Power Consumers
Explains fuse box location and how to remove and replace defective fuses.
Fuse Assignments (Duke EU/MAL)
Lists fuse assignments for Duke EU/MAL and provides warnings about using correct fuses.
Brake System Checks and Maintenance
Checking Front Brake Linings
Warns about reduced braking efficiency due to worn linings and how to check minimum thickness.
Changing Front Brake Linings
Warns about skin irritation from brake fluid and reduced braking from old fluid or oil on discs.
Front Brake Fluid Reservoir Access
Details moving the brake fluid reservoir and removing screws and cover.
Front Brake Caliper Disassembly
Describes removing locking clips, pins, springs, and brake linings, and cleaning the caliper.
Front Brake Linings and Springs Installation
Details positioning brake linings, springs, and pin, and activating the brake lever.
Checking Front Brake Fluid Level
Warns about brake system failure if fluid level is low and how to check it.
Front Brake Fluid Level Check Procedure
Describes moving the reservoir and checking the brake fluid level in the viewer.
Adding Front Brake Fluid
Warns about brake system failure and skin irritation from brake fluid.
Front Brake Fluid Top-Up Process
Details moving the reservoir, removing cover, and adding brake fluid to the correct level.
Changing Front Brake Fluid
Warns about skin irritation and hazards of old brake fluid and environmental damage.
Front Brake Fluid Change Procedure
Details covering painted parts, removing cover, and drawing out old fluid for rear brake fluid change.
Front Brake Fluid Bleeding
Describes connecting bleeding device, opening bleeder screw, and draining fluid until no bubbles.
Checking Rear Brake Linings
Warns about reduced braking efficiency due to worn linings and how to check minimum thickness.
Changing Rear Brake Linings
Warns about skin irritation and hazards of old brake fluid and oil on discs.
Checking Foot Brake Lever Free Travel
Warns about brake system failure due to no free travel and how to check it.
Adjusting Foot Brake Lever Free Travel
Warns about brake system failure and how to adjust free travel by releasing and using screws.
Checking Rear Brake Fluid Level
Warns about brake system failure if fluid level is low and how to check it.
Rear Brake Fluid Level Check Procedure
Describes checking the rear brake fluid level in the reservoir for Duke COL and Duke EU/MAL.
Adding Rear Brake Fluid
Warns about brake system failure and skin irritation from brake fluid.
Rear Brake Fluid Change Procedure
Warns about skin irritation and hazards of old brake fluid and environmental damage.
Rear Brake Fluid Bleeding
Describes covering painted parts, removing cover, and drawing out old fluid for rear brake fluid change.
Rear Brake Fluid Level Correction
Details connecting bleeding device, opening bleeder screw, and correcting brake fluid level.
Lighting System and Instruments
Setting Kilometers or Miles
Provides information on making country-specific settings for distance units.
Adjusting Shift Speed RPM 1
Explains how to set RPM 1 for the shift warning light.
Adjusting Shift Speed RPM 2
Explains how to set RPM 2 for the shift warning light.
Setting the Time Display
Details steps for setting the hours and minutes display.
Resetting Service Interval Display
Explains how to reset the service interval display.
Checking Headlight Alignment
Describes positioning the vehicle and checking the headlight beam pattern.
Adjusting Headlight Range
Explains how to adjust the beam distance of the headlight using a turning screw.
Changing Parking Light Bulb
Warns about reflector damage and grease and outlines steps for changing the parking light bulb.
Changing Headlight Bulb
Warns about reflector damage and grease and outlines steps for changing the headlight bulb.
Headlight Bulb Replacement Steps
Details taking off the protection cap, disconnecting the connector, and detaching the retaining clamp.
Engine Disassembly and Assembly
Removing the Engine
Outlines preparatory work and main steps for removing the engine.
Engine Removal Steps
Details removing screws, fittings, and engine fixing arms for engine removal.
Installing the Engine
Outlines main work for positioning the engine in the frame with assistance.
Engine Installation Procedure
Details positioning the ground wire, mounting fittings, and removing the floor jack.
Engine Installation: Radiator Pipe
Covers mounting the radiator pipe, tightening screws, and mounting the radiator hose.
Engine Installation: Radiator Hose
Details mounting the radiator hose, tightening fittings, and positioning the throttle valve body.
Engine Installation: Connectors and Cables
Covers plugging in connectors, mounting the engine sprocket, and installing the rear wheel.
Engine Installation: Spark Plug and Cables
Details mounting the spark plug connector, vent hose, and clutch cable.
Engine Disassembly Preparations
Outlines preparations for engine disassembly, including mounting special tools.
Draining Engine Oil (125 Duke)
Details removing the oil drain plug and oil screen to drain the engine oil.
Removing Chain Securing Guide (125 Duke)
Details removing screws and taking off the chain securing guide.
Removing Valve Cover (125 Duke)
Details removing screws and taking off the valve cover.
Removing Spark Plug (125 Duke)
Explains how to remove the spark plug using a special tool.
Removing Clutch Cover (125 Duke)
Details removing screws and taking off the clutch cover.
Setting Engine to TDC (125 Duke)
Explains how to turn the crankshaft and align markings to set TDC.
Removing Starter Motor (125 Duke)
Details removing screws and taking off the starter motor.
Removing Timing Chain Tensioner (125 Duke)
Details removing the screw and taking off the timing chain tensioner.
Removing Camshaft (125 Duke)
Details releasing screws, removing bearing bridge, and removing camshafts.
Removing Cylinder Head (125 Duke)
Details removing screws, washers, and taking off the cylinder head.
Cylinder Head Gasket Removal
Details taking off the cylinder head gasket, dowels, and timing chain guide rail.
Removing Piston (125 Duke)
Describes pushing the cylinder upward, removing piston pin retainer, and taking off the cylinder.
Removing Water Pump Wheel (125 Duke)
Details removing screws and water pump cover, and removing locating pins.
Water Pump Wheel Removal Steps
Describes locking clutch basket and primary gear, removing nut, and taking off water pump wheel.
Removing Alternator Cover (125 Duke)
Details removing screws and taking off the alternator cover.
Alternator Cover Gasket Removal
Details removing dowels and taking off the alternator cover gasket.
Removing Rotor (125 Duke)
Describes locking clutch basket and primary gear, and removing the rotor.
Removing Starter Drive (125 Duke)
Details removing screws and retaining bracket, and hanging the ignition pulse generator.
Starter Drive Component Removal
Describes removing freewheel gear, torque limiter, and starter idler gear.
Removing Balancer Shaft Drive Wheel (125 Duke)
Describes locking clutch basket and primary gear using a special tool.
Removing Gear Position Sensor (125 Duke)
Details removing screws, retaining bracket, and the gear position sensor.
Removing Spacer (125 Duke)
Describes removing the spacer from the countershaft.
Removing Clutch Basket (125 Duke)
Details locking clutch basket/primary gear, removing screws and springs, and removing inner clutch hub.
Removing Primary Gear (125 Duke)
Details removing timing chain sprocket and taking off the primary gear.
Primary Gear Removal Steps
Describes removing spring washer and taking off spacer ring.
Removing Oil Pump (125 Duke)
Details removing lock ring and taking off the oil pump gear.
Removing Shift Shaft (125 Duke)
Describes pushing sliding plate and removing shift shaft.
Removing Shift Drum Locating (125 Duke)
Details removing screw, pressing locking lever, and taking off shift drum locating.
Removing Locking Lever (125 Duke)
Describes removing screw and taking off the locking lever.
Removing Oil Filter (125 Duke)
Details removing screws and the oil filter cover.
Oil Filter Removal Steps
Describes pulling oil filter out of housing using circlip pliers.
Removing Left Engine Case (125 Duke)
Details removing screws and swinging up the left engine case.
Left Engine Case Separation
Describes mounting special tools and separating the engine case section.
Left Engine Case Removal
Details removing dowels, engine case gasket, and the left engine case.
Removing Shift Rails (125 Duke)
Describes removing shift rails with springs.
Removing Shift Drum (125 Duke)
Details swinging shift forks and removing the shift drum.
Removing Shift Forks (125 Duke)
Describes removing the shift forks.
Removing Transmission Shafts (125 Duke)
Details pulling out the transmission shafts.
Removing Balancer Shaft (125 Duke)
Describes removing screw, lock washer, and balancer shaft.
Removing Crankshaft (125 Duke)
Details mounting special tools and pressing out the crankshaft.
Work on Left Engine Case Section (125 Duke)
Outlines steps for working on the left section of the engine case, including bearing installation.
Work on Right Engine Case Section (125 Duke)
Outlines steps for working on the right section of the engine case, including bearing installation.
Changing Water Pump Shaft Seal Ring (125 Duke)
Details removing and pressing in shaft seal rings and mounting lock rings.
Removing Main Bearing (125 Duke)
Describes mounting special tools for removing the main bearing.
Checking Conrod Bearing Radial Play (125 Duke)
Details clamping the connecting rod and checking conrod bearing radial play using Plastigauge.
Changing Conrod Bearing (125 Duke)
Describes clamping the connecting rod, removing nuts, and changing bearing shells.
Changing Balancer Shaft Bearing (125 Duke)
Details mounting special tools and pressing out/on the balancer shaft bearing.
Changing Camshaft Bearing (125 Duke)
Describes clamping the camshaft and changing the camshaft bearing.
Work on Cylinder Head (125 Duke)
Details folding the cam lever, taking out shims, and pretensioning valve springs.
Cylinder Head Inspection
Describes checking valve guides, sealing areas, and valve seats.
Checking/Measuring Cylinder (125 Duke)
Details checking cylinder bearing surface and measuring cylinder diameter.
Checking Piston Ring End Gap (125 Duke)
Describes checking piston ring end gap and mounting the piston ring.
Checking/Measuring Piston (125 Duke)
Details checking piston bearing surface, rings, and piston pin.
Checking Piston/Cylinder Clearance (125 Duke)
Describes checking cylinder and piston and calculating mounting clearance.
Checking Oil Pump (125 Duke)
Details checking play between rotors and axial play of the oil pump.
Checking Oil Pressure Regulator Valve (125 Duke)
Describes removing washer/spring and measuring spring length.
Checking Clutch (125 Duke)
Details checking bearing, clutch springs, inner clutch hub, and pressure cap.
Clutch Disc Thickness Check
Covers checking clutch facing discs, contact surfaces, and intermediate discs.
Preassembling Clutch (125 Duke)
Details lubricating clutch discs and assembling components onto the inner clutch hub.
Checking Shift Mechanism (125 Duke)
Describes checking shift forks, shift drum grooves, and bearings.
Shift Mechanism Inspection Details
Details checking shift rail, sliding plate, and guide pin for wear and damage.
Preassembling Shift Shaft (125 Duke)
Describes fixing the shift shaft and mounting sliding plate and springs.
Disassembling Main Shaft (125 Duke)
Details fixing the main shaft and removing various gears and disks.
Dismantling Countershaft (125 Duke)
Details fixing the countershaft and removing various gears and disks.
Checking Transmission (125 Duke)
Describes checking collar bushings, pivot points, and tooth profiles of gears.
Transmission Inspection Details
Describes checking shift dogs, sliding gears, and stop disks for wear and smooth operation.
Assembling Main Shaft (125 Duke)
Provides information on using new lock rings and assembling the main shaft.
Assembling Countershaft (125 Duke)
Provides information on using new lock rings and assembling the countershaft.
Checking Timing Assembly (125 Duke)
Details checking timing chain, guide rail, tensioning rail, and sprockets.
Timing Assembly Checks (Continued)
Covers checking camshaft gears and bearings.
Changing Stator (125 Duke)
Details removing screws and the cable retainer for stator replacement.
Stator Replacement Steps
Describes removing the stator and mounting/tightening screws for the new stator.
Checking Electric Starter Drive (125 Duke)
Details checking starter idler gear, torque limiter, and freewheel gear.
Checking Freewheel (125 Duke)
Describes inserting and checking the locking action of the freewheel gear.
Work on Left Engine Case (200 Duke)
Outlines steps for working on the left engine case, including removing dowels and lock rings.
Left Engine Case Work Steps
Details removing shaft seal rings, oil nozzles, and cleaning the engine case.
Work on Right Engine Case (200 Duke)
Outlines steps for working on the right engine case, including bearing installation.
Changing Water Pump Shaft Seal Ring (200 Duke)
Details removing and pressing in shaft seal rings and mounting lock rings.
Removing Main Bearing (200 Duke)
Describes mounting special tools for removing the main bearing.
Checking Conrod Bearing Radial Play (200 Duke)
Details clamping the connecting rod and checking conrod bearing radial play using Plastigauge.
Changing Conrod Bearing (200 Duke)
Describes clamping the connecting rod, removing screws, and changing bearing shells.
Changing Balancer Shaft Bearing (200 Duke)
Details mounting special tools and pressing out/on the balancer shaft bearing.
Changing Camshaft Bearing (200 Duke)
Describes clamping the camshaft and changing the camshaft bearing.
Work on Cylinder Head (200 Duke)
Details folding the cam lever, taking out shims, and pretensioning valve springs.
Cylinder Head Inspection (200 Duke)
Describes checking valve guides, sealing areas, and valve seats.
Checking/Measuring Cylinder (200 Duke)
Details checking cylinder bearing surface and measuring cylinder diameter.
Checking Piston Ring End Gap (200 Duke)
Describes checking piston ring end gap and mounting the piston ring.
Checking/Measuring Piston (200 Duke)
Details checking piston bearing surface, rings, and piston pin.
Checking Piston/Cylinder Clearance (200 Duke)
Describes checking cylinder and piston and calculating mounting clearance.
Checking Oil Pump (200 Duke)
Details checking play between rotors and axial play of the oil pump.
Checking Oil Pressure Regulator Valve (200 Duke)
Describes removing washer/spring and measuring spring length.
Checking Clutch (200 Duke)
Details checking bearing, clutch springs, inner clutch hub, and pressure cap.
Clutch Disc Thickness Check
Covers checking clutch facing discs, contact surfaces, and intermediate discs.
Preassembling Clutch (200 Duke)
Details lubricating clutch discs and assembling components onto the inner clutch hub.
Checking Shift Mechanism (200 Duke)
Describes checking shift forks, shift drum grooves, and bearings.
Shift Mechanism Inspection Details
Details checking shift rail, sliding plate, and guide pin for wear and damage.
Installing Shift Shaft (200 Duke)
Describes sliding shift shaft into bearing seat and engaging sliding plate.
Installing Oil Pump (200 Duke)
Details positioning rotors, checking oil holes, mounting dowels, and installing oil pump.
Installing Primary Gear (200 Duke)
Describes positioning spacer ring, mounting spring washer, and installing primary gear.
Installing Clutch Basket (200 Duke)
Details mounting collar sleeve and sliding clutch basket onto main shaft.
Installing Spacer (200 Duke)
Describes greasing shaft seal ring and mounting the spacer.
Installing Gear Position Sensor (200 Duke)
Details mounting contact springs and bolt, and installing the gear position sensor.
Installing Balancer Shaft Drive Wheel (200 Duke)
Describes mounting spring washer, drive wheel, and balancer shaft gear.
Installing Starter Drive (200 Duke)
Details mounting starter idler gear, torque limiter, and freewheel gear.
Installing Rotor (200 Duke)
Describes mounting spring washer, rotor, and tightening screws.
Installing Alternator Cover (200 Duke)
Details mounting dowels, sealing cable guide, and installing the alternator cover.
Installing Water Pump Cover (200 Duke)
Describes mounting water pump impeller and tightening nut.
Installing Piston (200 Duke)
Details shifting piston rings and pushing piston into cylinder.
Installing Cylinder Head (200 Duke)
Details mounting dowels, cylinder head gasket, and the cylinder head.
Installing Camshafts (200 Duke)
Describes turning crankshaft and installing camshafts.
Installing Timing Chain Tensioner (200 Duke)
Details turning tensioner screw, mounting tensioner with gasket, and checking tension.
Checking Valve Clearance (200 Duke)
Describes cranking engine and checking valve clearance at camshaft and cam lever.
Adjusting Valve Clearance (200 Duke)
Outlines removing camshaft, correcting shims, and reinstalling components.
Installing Starter Motor (200 Duke)
Details greasing O-ring, positioning starter motor, and mounting screws.
Installing Clutch Cover (200 Duke)
Details mounting dowel and gasket, positioning cover, and tightening screws.
Installing Spark Plug (200 Duke)
Explains how to mount and tighten the spark plug using a special tool.
Installing Valve Cover (200 Duke)
Details degreasing sealing areas, positioning gasket, and mounting valve cover.
Installing Chain Securing Guide (200 Duke)
Describes positioning the chain securing guide and mounting screws.
Installing Oil Screen (200 Duke)
Details mounting the oil screen with the O-ring.
Shift Mechanism Adjustment
Adjusting the Shift Lever
Explains how to adjust the shift lever by turning the shift rod.
Water Pump and Cooling System
Draining the Coolant
Warns about hot coolant and poisoning hazards, and outlines steps for draining.
Filling and Bleeding Cooling System
Warns about coolant poisoning hazards and describes filling until no bubbles appear.
Checking Antifreeze and Coolant Level
Warns about coolant hazards and describes checking level in radiator and compensating tank.
Checking Coolant Level
Describes checking coolant level in compensating tank and radiator.
Lubrication System
Oil Circuit Overview
Illustrates the engine's oil circuit components.
Checking Engine Oil Level
Explains how to check the engine oil level when the engine is at operating temperature.
Checking Engine Oil Pressure
Warns about hot oil and exhaust gas hazards and details checking oil pressure.
Changing Engine Oil and Oil Filter
Warns about hot oil and environmental hazards and outlines steps for oil and filter change.
Adding Engine Oil
Warns about engine wear from low or poor-quality oil and provides steps for adding oil.
Ignition System
Alternator Stator Winding Checks
Details checking stator winding resistance and short circuit to ground.
Technical Data
Engine Specifications (125 Duke)
Lists engine design, displacement, bore, stroke, and control specifications.
Engine Specifications (200 Duke)
Lists engine design, displacement, bore, stroke, and control specifications.
Engine Tolerances and Wear Limits (125 Duke)
Provides specifications for valve clearance, cylinder, piston, and connecting rod measurements.
Engine Tolerances and Wear Limits (200 Duke)
Provides specifications for valve clearance, cylinder, piston, and connecting rod measurements.
Engine Tightening Torques
Lists various engine component screws with their torque specifications.
Engine Oil Capacities
Specifies engine oil capacities for first fill and after oil change based on temperature.
Coolant and Fuel Capacities
Lists coolant capacity and total fuel tank capacity.
Chassis Specifications
Details frame, fork, shock absorber, brake system, suspension, and tire data.
Electrical System Components
Lists battery types, fuse ratings, headlight specifications, and other electrical components.
Tire Specifications
Provides front and rear tire sizes and additional information source.
Fork Specifications
Lists fork part number, type, length, and oil specifications.
Shock Absorber Specifications
Lists shock absorber part number, type, spring preload, and sag measurements.
Chassis Tightening Torques
Lists chassis component screws with their torque specifications.
Cleaning and Protective Treatment
Cleaning the Motorcycle
Warns about high-pressure cleaning damage and environmental hazards, and outlines cleaning steps.
Winter Operation Maintenance Steps
Provides precautions for road salt corrosion and steps for cleaning brakes and chains.
Storage and Preparation
Motorcycle Storage Procedures
Details steps for long-term storage, including refueling and battery removal.
Preparing Motorcycle After Storage
Outlines steps for preparing the motorcycle for use after a storage period.
Service Schedule
Scheduled Maintenance Intervals
Provides a schedule for maintenance tasks at different mileage/time intervals.
Wiring Diagram
Wiring Diagram Page 1 (Duke EU/MAL)
Shows electrical connections for EFI control unit, alarm system, and vehicle control unit.
Wiring Diagram Page 2 (Duke EU/MAL)
Illustrates connections for power relays, fuel pump relay, and radiator fan relay.
Wiring Diagram Page 3 (Duke EU/MAL)
Depicts connections for fuses, alternator, and voltage regulator.
Wiring Diagram Page 4 (Duke EU/MAL)
Shows connections for sensors, ignition components, and combination instrument.
Wiring Diagram Page 5 (Duke EU/MAL)
Illustrates connections for vehicle control unit, turn signals, and lights.
Wiring Diagram Page 6 (Duke EU/MAL)
Depicts connections for vehicle control unit, brake light switches, and combination instrument.
Wiring Diagram Page 7 (Duke EU/MAL)
Shows connections for vehicle control unit, turn signals, and lights.
Wiring Diagram Page 8 (Duke EU/MAL)
Illustrates connections for EFI control unit, vehicle control unit, and combination instrument.
Wiring Diagram Page 9 (Duke EU/MAL)
Depicts connections for EFI control unit, vehicle control unit, and alarm system.
Wiring Diagram Page 1 (Duke COL)
Shows electrical connections for EFI control unit, alarm system, and vehicle control unit.
Wiring Diagram Page 2 (Duke COL)
Illustrates connections for power relays, fuel pump relay, and radiator fan relay.
Wiring Diagram Page 3 (Duke COL)
Depicts connections for fuses, alternator, and voltage regulator.
Wiring Diagram Page 4 (Duke COL)
Shows connections for sensors, ignition components, and combination instrument.
Wiring Diagram Page 5 (Duke COL)
Illustrates connections for vehicle control unit, turn signals, and lights.
Wiring Diagram Page 6 (Duke COL)
Depicts connections for vehicle control unit, brake light switches, and combination instrument.
Wiring Diagram Page 7 (Duke COL)
Shows connections for vehicle control unit, turn signals, and lights.
Wiring Diagram Page 8 (Duke COL)
Illustrates connections for EFI control unit, vehicle control unit, and combination instrument.
Special Tools
Bleeder Cover Set
Lists the article number for the bleeder cover set.
Brake Bleeding Device
Lists the article number for the brake bleeding device.
Bleed Syringe
Lists the article number for the bleed syringe.
Circlip Pliers Reverse
Lists the article number for circlip pliers reverse.
Valve Spring Compressor
Lists the article number for the valve spring compressor.
Feeler Gauge Set
Lists the article number for the feeler gauge set.
Plastigauge Measuring Strips
Lists the article number for Plastigauge measuring strips.
Wheel Stand Adapters
Lists article numbers for adapters used with wheel stands.
Rear Wheel Stand
Lists the article number for the rear wheel stand.
Front Wheel Stand
Lists the article number for the front wheel stand.
Testing Hose
Lists the article number for the testing hose.
Pressure Testing Tool
Lists the article number for the pressure testing tool.
Adapter for Pressure Testing
Lists the article number for the adapter used with pressure testing.
Engine Assembly Stand
Lists the article number for the engine assembly stand.
Work Stand
Lists the article number for the work stand.
Floor Jack Attachment
Lists the article number for the floor jack attachment.
Oil Pressure Adapter
Lists the article number for the oil pressure adapter.
Separator Plate
Lists the article number for the separator plate.
Spark Plug Wrench
Lists the article number for the spark plug wrench.
Engine Fixing Arm (for engine assembly)
Lists the article number for the engine fixing arm.
Engine Fixing Arm (alternate)
Lists the article number for the engine fixing arm.
Mounting Sleeve
Lists the article number for the mounting sleeve.
Extractor Tool
Lists the article number for the extractor tool.
Holding Spanner
Lists the article number for the holding spanner.
Puller for Main Bearing
Lists the article number for the puller for main bearing.
Protecting Sleeve
Lists the article number for the protecting sleeve.
Pressure Screw for Crankshaft
Lists the article number for the pressure screw for crankshaft.
Castle Nut Wrench (1/2" Drive)
Lists the article number for the castle nut wrench.
Castle Nut Wrench (1/2" Drive, Alternate)
Lists the article number for the castle nut wrench.
Limit Plug Gauge
Lists the article number for the limit plug gauge.
Insertion for Piston Ring Lock
Lists the article number for the insertion tool for piston ring lock.
Mounting Sleeve for Piston Rings
Lists the article number for the mounting sleeve for piston rings.
Case Separating Tool
Lists the article number for the case separating tool.
Castle Nut Wrench (1/2" Drive, for Piston)
Lists the article number for the castle nut wrench.
Castle Nut Wrench (1/2" Drive, for Steering Head)
Lists the article number for the castle nut wrench.
Key for Steering Head Bearing
Lists the article number for the key for steering head bearing.
Disassembly Tool, Balancer Shaft Bearing
Lists the article number for the disassembly tool for balancer shaft bearing.
Insert for Valve Spring Lever
Lists the article number for the insert for valve spring lever.
Gear Segment Tool
Lists the article number for the gear segment tool.
Hook Wrench
Lists the article number for the hook wrench.
Spring Compressor
Lists the article number for the spring compressor.
Mounting Tool
Lists the article number for the mounting tool.
Clamping Stand
Lists the article number for the clamping stand.
Standards Information
JASO T903 MA Standard Explanation
Explains the JASO T903 MA Standard for 4-stroke motorcycle oils.
SAE Viscosity Classification
Defines SAE viscosity classes and their meaning for oil classification.
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