KTM 125 DUKE EU Owner's Manual
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KTM 125 DUKE EU Owner's Manual

2013
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See also: Repair Manual , Owner's Manual
2013
OWNER'S MANUAL
125 Duke EU
200 Duke EU
200 Duke MAL
Art. no. 3211963en

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Summary of Contents for KTM 125 DUKE EU

  • Page 1 2013 OWNER'S MANUAL 125 Duke EU 200 Duke EU 200 Duke MAL Art. no. 3211963en...
  • Page 3 KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as misprints and other errors.
  • Page 4 DEAR KTM CUSTOMER ISO 9001(12 100 6061) According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead to the maximum possible quality of the products. Issued by: TÜV Management Service KTM-Sportmotorcycle AG 5230 Mattighofen, Austria...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Hand brake lever..........22 TABLE OF CONTENTS MEANS OF REPRESENTATION ........7 Throttle grip ............23 Symbols used ............7 Horn button............23 Formats used............7 Light switch ............24 SAFETY ADVICE.............. 8 High beam flasher button ........24 Use definition............
  • Page 6 TABLE OF CONTENTS 6.11.18 Distance menu 1 TRIP 1 ........ 44 SERVICE SCHEDULE ............ 71 6.11.19 Distance menu 2 TRIP 2 ........ 45 Service schedule..........71 6.11.20 Setting kilometers or miles ......45 10 TUNING THE CHASSIS ..........73 6.11.21 Setting the time..........
  • Page 7 TABLE OF CONTENTS 12.3 Checking the brake fluid level of the front brake ... 94 15 COOLING SYSTEM ............132 15.1 Cooling system ..........132 12.4 Adding front brake fluid ......... 95 15.2 Checking the antifreeze and coolant level ... 133 12.5 Checking the front brake linings ......
  • Page 8 TABLE OF CONTENTS 21.3 Capacities ............163 21.3.1 Engine oil ........... 163 21.3.2 Coolant ............163 21.3.3 Fuel ............163 21.4 Chassis ............164 21.5 Electrical system..........165 21.6 Tires ............... 166 21.7 Fork..............166 21.8 Shock absorber ..........166 21.9 Chassis tightening torques ........

  • Page 9: Means Of Representation

    All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own safety, have these jobs performed by an authorized KTM workshop. There, your motorcycle will be optimally cared for by specially trained experts using the specialist tools required.

  • Page 10: Safety Advice

    SAFETY ADVICE Use definition KTM sport motorcycles are designed and constructed to meet the normal demands of regular road operation but not for use on race courses or offroad. Info The motorcycle is authorized for public road traffic in the homologous version only.

  • Page 11: Degrees Of Risk And Symbols

    SAFETY ADVICE Degrees of risk and symbols Danger Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken. Warning Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken. Caution Identifies a danger that may lead to minor injuries if the appropriate measures are not taken.

  • Page 12: Safe Operation

    Only operate the vehicle when it is in perfect technical condition, in accordance with its intended use, and in a safe and environmentally compatible manner. An appropriate driver's license is needed to ride the vehicle on public roads. Have malfunctions that impair safety promptly eliminated by an authorized KTM workshop. Adhere to the information and warning labels on the vehicle.

  • Page 13: Protective Clothing

    Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle. Always wear protective clothing that is in good condition and meets the legal requirements. In the interest of your own safety, KTM recommends that you only operate the vehicle while wearing protective clothing. Work rules Special tools are necessary for certain tasks.

  • Page 14: Owner's Manual

    Keep the Owner's Manual in an accessible place to enable you to refer to it as needed. If you would like to know more about the vehicle or have questions on the material you read, please contact an authorized KTM dealer.

  • Page 15: Important Notes

    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 considered for damage resulting from manipulations and/or alterations to the vehicle.

  • Page 16: Figures

    Please follow the instructions in the text. Customer service Your authorized KTM dealer will be happy to answer any questions you may have on your vehicle and KTM. A list of authorized KTM dealers can be found on the KTM website.

  • Page 18: View Of Vehicle

    VIEW OF VEHICLE View of vehicle, front left (example) B01385-10...
  • Page 19 VIEW OF VEHICLE Function buttons ( p. 32) Indicator lamps ( p. 33) Rear mirror Clutch lever ( p. 22) Seat Passenger seat Seat lock ( p. 50) Grab handles ( p. 51) Engine number ( p. 20) Side stand ( p.

  • Page 20: View Of Vehicle, Rear Right (Example)

    VIEW OF VEHICLE View of vehicle, rear right (example) B01386-10...
  • Page 21 VIEW OF VEHICLE Tool set ( p. 51) Light switch ( p. 24) High beam flasher button ( p. 24) Turn signal switch ( p. 25) Horn button ( p. 23) Ignition/steering lock ( p. 26) Emergency OFF switch ( p.

  • Page 22: 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 Engine number The engine number is stamped on the left side of the engine under the engine sprocket. B00700-10...

  • Page 23: Key Number

    SERIAL NUMBERS Key number The key number can be found on the KEYCODECARD. Info You need the key number to order a spare key. Keep the KEYCODECARD in a safe place. B00755-10...

  • Page 24: Controls

    CONTROLS Clutch lever The clutch lever is fitted on the left side of the handlebar. B00701-10 Hand brake lever The hand brake lever is fitted on the right side of the handlebar. The front brake is engaged using the hand brake lever. B00702-10...

  • Page 25: Throttle Grip

    CONTROLS Throttle grip The throttle grip is fitted on the right side of the handlebar. B00703-10 Horn button The horn button is fitted on the left side of the handlebar. Possible states • Horn button in neutral position pressed – The horn is operated in this position. •...

  • Page 26: Light Switch

    CONTROLS Light switch The light switch is fitted on the left side of the handlebar. Possible states Low beam on – Light switch is turned downward. In this position, the low beam and tail light are switched on. High beam on – Light switch is turned upward. In this position, the high beam and the tail light are switched on.

  • Page 27: Turn Signal Switch

    CONTROLS Turn signal switch The turn signal switch is fitted on the left side of the handlebar. Possible states Turn signal off Turn signal, left, on – Turn signal switch pressed to the left. The turn signal switch returns automatically to the central position after use. Turn signal, right, on –...

  • Page 28: Electric Starter Button

    CONTROLS Electric starter button The electric starter button is fitted on the right side of the handlebar. Possible states • Electric starter button in basic position pressed – In this position, the electric starter is actuated. • Electric starter button B00708-10 6.10 Ignition/steering lock...

  • Page 29: Combination Instrument

    CONTROLS 6.11 Combination instrument 6.11.1 Overview Display ( p. 34) Function buttons ( p. 32) Info display ( p. 38) Indicator lamps ( p. 33) 401685-10...

  • Page 30: Activation And Test

    CONTROLS 6.11.2 Activation and test Activation The combination instrument is activated when the ignition is switched on. Test The segments of the tachometer and the gear display light up and switch off in sequence. The speed display counts from 0 to 199 and back. The remaining display segments outside the info display light up briefly.

  • Page 31: Warning Notes

    CONTROLS 6.11.3 Warning notes Low Oil Pressure appears on the info display if the oil pressure is too low. 401309-01 Low Fuel Level appears on the info display if the fuel level reaches the reserve mark. 401310-01...
  • Page 32 CONTROLS High Coolant Temperature appears on the info display if the coolant temperature rises above the specified value. Coolant temperature 125 °C (257 °F) 401311-01 Side Stand Down appears on the info display if the side stand is folded down. 401312-01 Low Battery appears on the info display if the battery voltage falls below the specified value.
  • Page 33 CONTROLS Service Not Reset appears on the info display for 10 seconds when the ignition is switched on and the distance interval between service appointments has been exceeded or the service interval display was not reset during a service appointment. 401461-01...

  • Page 34: Function Buttons

    CONTROLS 6.11.4 Function buttons You can change the display mode with the MODE button Possible display modes are total distance traveled (TRIP 1), distance 1 (ODO) and distance 2 (TRIP 2). Pressing and holding the SET button resets the distance 1 (TRIP 1) and distance 2 (TRIP 2) functions to 0.0 and briefly pressing the SET button changes the info display to the next display mode.

  • Page 35: Indicator Lamps

    CONTROLS 6.11.5 Indicator lamps Possible states The turn signal indicator light flashes green simultaneously with the turn signal – The turn signal is switched on. The engine diagnosis warning lamp (MIL) lights up red – The OBD (on- board diagnosis) has detected an emission- or safety-critical error. The shift warning lights up/flashes red –...

  • Page 36: Display

    CONTROLS 6.11.6 Display The speed is shown in kilometers per hour km/h or in miles per hour mph. The tachometer shows the engine speed in revolutions per minute. The gear display shows the engaged gear. The coolant temperature appears in segment The time appears in segment The filling level in the fuel tank is displaced in segment The info display...

  • Page 37: Filling Level Display In Fuel Tank

    CONTROLS 6.11.7 Filling level display in fuel tank The filling level display consists of 9 bars. The more bars are lit, the more fuel is in the fuel tank. 401292-01...

  • Page 38: Trip F Display

    CONTROLS 6.11.8 TRIP F display If the fuel level drops to the reserve mark, the display mode automatically changes to TRIP F and starts to count from 0.0, regardless of the previous display mode. Info At the same time as the display mode TRIP F, the general warning lamp lights up and the warning note Low Fuel Level appears on the info display.

  • Page 39: Coolant Temperature Indicator

    CONTROLS 6.11.9 Coolant temperature indicator The temperature display consists of 13 bars. The more bars that light up, the hotter the coolant. When all bars light up, the following warning note appears on the info display: High Coolant Temperature. Possible states Engine cold –...

  • Page 40: Info Display

    CONTROLS 6.11.10 Info display Various warning notes appear on info display If the general warning lamp lights up, the corresponding warning note is shown on the info display. 401291-10...

  • Page 41: 6.11.11 Riding Time/Average Speed Menu

    CONTROLS 6.11.11 Riding time/average speed menu Condition Alternative 1 • The ignition is on. • The motorcycle is stationary. Alternative 2 • The ignition is on. • The motorcycle is moving. – Press the SET button briefly and repeatedly until the desired info display appears. The riding time and average speed are displayed in this menu.

  • Page 42: 6.11.13 Average Fuel Consumption 1/Average Fuel Consumption 2 Menu

    CONTROLS Info The average fuel consumption 1 is displayed after several 100 meters of travel after the ignition is switched on. If the ignition was switched off for over 60 minutes, the display of the average speed and average fuel consumption 1 is reset to 0. Press the SET button Next display mode on the info display briefly.

  • Page 43: 6.11.14 Average Fuel Consumption 2/Service Menu

    CONTROLS 6.11.14 Average fuel consumption 2/service menu Condition Alternative 1 • The ignition is on. • The motorcycle is stationary. Alternative 2 • The ignition is on. • The motorcycle is moving. – Press the SET button briefly and repeatedly until the desired info display appears. The average fuel consumption 2 in km/L (or miles/L) and the distance to the next service 401467-01 are displayed in this menu.

  • Page 44: 6.11.15 Service/Range Menu

    CONTROLS 6.11.15 Service/range menu Condition Alternative 1 • The ignition is on. • The motorcycle is stationary. Alternative 2 • The ignition is on. • The motorcycle is moving. – Press the SET button briefly and repeatedly until the desired info display appears. This menu shows the distance to the next service and the range.

  • Page 45: 6.11.16 Range/Riding Time Menu

    CONTROLS 6.11.16 Range/riding time menu Condition Alternative 1 • The ignition is on. • The motorcycle is stationary. Alternative 2 • The ignition is on. • The motorcycle is moving. – Press the SET button briefly and repeatedly until the desired info display appears. The range and the riding time are displayed in this menu.

  • Page 46: 6.11.17 Total Distance Menu Odo

    CONTROLS 6.11.17 Total distance menu ODO Condition Alternative 1 • The ignition is on. • The motorcycle is stationary. Alternative 2 • The ignition is on. • The motorcycle is moving. – Press the MODE button briefly and repeatedly until ODO appears on the display. ODO shows the total distance covered.

  • Page 47: Distance Menu 2 Trip 2

    CONTROLS Press the SET button Display of TRIP 1 is reset for 5 - 10 seconds. Press the MODE but- Next display mode on the display ton. 6.11.19 Distance menu 2 TRIP 2 Condition Alternative 1 • The ignition is on. •...

  • Page 48: 6.11.21 Setting The Time

    CONTROLS 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. 401303-01 6.11.21 Setting the time Condition...

  • Page 49: Adjusting The Shift Speed Rpm 1

    CONTROLS 6.11.22 Adjusting the shift speed RPM 1 Condition The ignition is on. The motorcycle is stationary. – Press the MODE button briefly and repeatedly until TRIP 2 appears on the display. – Press the MODE button for 5 - 10 seconds. The display RPM 1 appears.

  • Page 50: Opening The Filler Cap

    CONTROLS – Press the MODE button briefly and repeatedly until TRIP 2 appears on the display. – Press the SET button for 5 - 10 seconds. The display RPM 2 appears. Info The engine speed can be set at intervals of 50. RPM 2 is the engine speed above which the shift warning light lights up con- stantly.
  • Page 51 CONTROLS 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 52: Closing The Filler Cap

    CONTROLS 6.13 Closing the filler cap Warning Fire hazard Fuel is highly flammable, poisonous and harmful to your health. – After closing the filler cap, ensure that it is locked properly. Change cloth- ing that has been contaminated with fuel. Immediately clean contaminated areas on the skin with soap and water.

  • Page 53: Tool Set

    CONTROLS 6.15 Tool set The tool set is located under the passenger seat. B00758-10 6.16 Grab handles The grab handles are used for moving the motorcycle around. If you carry a passenger, the passenger can hold onto the grab handles during the trip. B00717-10...

  • Page 54: Passenger Footrests

    CONTROLS 6.17 Passenger footrests The passenger footrests can be folded in and out. Possible states Passenger footrests folded up – For operation without a passenger. • Passenger footrests folded down – For operation with a passenger. • B00713-01 6.18 Shift lever Shift lever is mounted on the left side of the engine.

  • Page 55: Foot Brake Lever

    CONTROLS The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. B00716-10 6.19 Foot brake lever Foot brake lever is located in front of the right footrest. The foot brake lever is used to activate the rear brake. B00718-10...

  • Page 56: Side Stand

    CONTROLS 6.20 Side stand The side stand is on the left side of the vehicle. The side stand is used to park the motorcycle. Info The side stand must be folded up during motorcycle use. Side stand is coupled with the safety start system; see the riding instructions. Possible states Side stand folded out –...

  • Page 57: Preparing For Use

    The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle. Warning 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. Warning Danger of accidents Reduced road grip with new tires. –...

  • Page 58: Running In The Engine

    PREPARING FOR USE – Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop. You receive a delivery certificate and the service record at vehicle handover. – Before your first trip, read the entire operating instructions carefully.

  • Page 59: Loading The Vehicle

    PREPARING FOR USE Loading the vehicle Warning Danger of accidents Unstable handling characteristics. – Do not exceed the maximum permitted weight and axle loads. The overall weight consists of: motorcycle operational and with a full tank, driver and passenger with protective clothing and helmet, baggage. Warning Danger of accidents Unstable handling characteristics due to incorrect mounting of suitcase and/or tank rucksack.
  • Page 60 PREPARING FOR USE – If you carry any baggage, make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight distribu- tion between the front and rear wheels. – Do not exceed the overall maximum permitted weight and the axle loads. Guideline Maximum permissible overall weight 335 kg (739 lb.)

  • Page 61: Riding Instructions

    RIDING INSTRUCTIONS Checks and maintenance when preparing for use Info Before every trip, check the condition of the vehicle and ensure that it is roadworthy. The vehicle must be in perfect technical condition when used. – Check the engine oil level. ( p.

  • Page 62: Starting

    RIDING INSTRUCTIONS 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 63 RIDING INSTRUCTIONS – Sit on the vehicle, take the weight off of the side stand, and move up all the way. – Turn the emergency OFF switch to the position – Switch on the ignition by turning the ignition key to the position After you switch on the ignition, you can hear the fuel pump working for about two seconds.

  • Page 64: Starting Off

    RIDING INSTRUCTIONS Switching off ABS 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 65 RIDING INSTRUCTIONS Warning Danger of accidents Malfunctions caused by incorrect ignition key position. – Do not change the ignition key position during a journey. Warning Danger of accidents Distraction from traffic activity by adjustments to the vehicle. – Make all adjustments when the vehicle is at a standstill. Warning Risk of injury Falling off of the passenger.
  • Page 66 If you continue with the coolant temperature warning lamp alight, you may have engine failure. Info If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized KTM workshop. – When conditions allow (incline, road situation, etc.), you can shift into a higher gear.

  • Page 67: Applying The Brakes

    Danger of accidents Reduced braking efficiency caused by spongy pressure point of front or rear brake. – Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Failure of brake system.
  • Page 68 RIDING INSTRUCTIONS Warning Danger of accidents Delayed brake action on salted roads. – There may be salt deposits on the brake discs. In order to restore the normal braking efficiency, you will need to remove the deposits from the discs by carefully applying the brakes. Warning Danger of accidents Greater stopping distance due to ABS.

  • Page 69: Stopping, Parking

    RIDING INSTRUCTIONS Stopping, parking Warning Risk of misappropriation Usage by unauthorized persons. – Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons. If you leave the vehicle, lock the steering and remove the ignition key. Warning Danger of burns Some vehicle components become very hot when the vehicle is operated.

  • Page 70: Transport

    RIDING INSTRUCTIONS – Switch off the ignition by turning the ignition key to the position Info If the engine is switched off with the emergency OFF switch and the ignition remains switched on at the ignition lock, power continues to flow to most power consumers and the battery will discharge. You should therefore always switch off the engine with the ignition key - the emergency OFF switch is intended for emergencies only.

  • Page 71: Refueling

    Material damage Premature clogging of the fuel filter. – In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the fuel system. (Your authorized KTM workshop will be glad to help.)
  • Page 72 RIDING INSTRUCTIONS – Only refuel with clean fuel that meets the specified standards. Warning Environmental hazard Improper handling of fuel is a danger to the environment. – Do not allow fuel to get into the ground water, the ground, or the sewage system. –...

  • Page 73: Service Schedule

    ○ ● ● Check the functioning of the electrical equipment. ○ ● ● Read out the fault memory using the KTM diagnostics tool. ○ ● ● Change the engine oil and oil filter, clean the oil screen. p. 144) ○...
  • Page 74 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 75: Tuning The Chassis

    TUNING THE CHASSIS 10.1 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 76: Adjusting The Shift Lever

    TUNING THE CHASSIS 10.2 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 77: Service Work On The Chassis

    SERVICE WORK ON THE CHASSIS 11.1 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 78: Raising The Motorcycle With The Front Wheel Stand

    SERVICE WORK ON THE CHASSIS – Secure the motorcycle against falling over. – Remove the rear wheel stand and lean the vehicle on the side stand – Remove the support of the wheel stand. B00714-10 11.3 Raising the motorcycle with the front wheel stand Note Danger of damage The parked vehicle may roll away or fall over.

  • Page 79: Taking The Motorcycle Off Of The Front Wheel Stand

    SERVICE WORK ON THE CHASSIS – Move the handlebar to the straight-ahead position. Attach the lifting gear to the steering stem. Adapter (61029955620) Front wheel stand (61029055500) Info Always raise the rear of the motorcycle first. – Raise the front of the motorcycle. C00197-01 11.4 Taking the motorcycle off of the front wheel stand...

  • Page 80: Removing The Passenger Seat

    SERVICE WORK ON THE CHASSIS – Mount cap C00196-10 11.5 Removing the passenger seat – Insert the ignition key in seat lock and turn it clockwise. – Raise the rear of the seat, push it towards the rear, and remove it upwards. –...

  • Page 81: Mounting The Passenger Seat

    SERVICE WORK ON THE CHASSIS 11.6 Mounting the passenger seat – Attach hooks on the passenger seat to brackets on the subframe, and lower it at the rear while pushing forward. – Press down the passenger seat until it clicks into place. Warning Danger of accidents The passenger seat can come loose from the anchoring if it is not mounted correctly.

  • Page 82: Mounting The Seat

    SERVICE WORK ON THE CHASSIS 11.8 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 83: Checking For Chain Dirt Accumulation

    SERVICE WORK ON THE CHASSIS 11.9 Checking for chain dirt accumulation – Check the chain for coarse dirt accumulation. » If the chain is very dirty: – Clean the chain. ( p. 81) 400678-01 11.10 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces their grip. –...

  • Page 84: Checking The Chain Tension

    SERVICE WORK ON THE CHASSIS Info The service life of the chain depends largely on its maintenance. – Clean the chain regularly. – Rinse off loose dirt with a soft jet of water. – Remove old grease remains with chain cleaner. Chain cleaner ( p.
  • Page 85 SERVICE WORK ON THE CHASSIS – Lean the motorcycle on the side stand. – Shift gear to neutral. – In the area of chain sliding guard, press the chain upward toward the swingarm and determine chain tension Info The upper chain section must be taut.

  • Page 86: Adjusting The Chain Tension

    SERVICE WORK ON THE CHASSIS 11.12 Adjusting 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, bearings in the transmission and in the rear wheel) will be under additional load.
  • Page 87 SERVICE WORK ON THE CHASSIS Main work – 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 88: Checking The Chain, Rear Sprocket, And Engine Sprocket

    SERVICE WORK ON THE CHASSIS 11.13 Checking the chain, rear sprocket, and engine sprocket – Check the rear sprocket and engine sprocket for wear. » If the rear sprocket and engine sprocket are worn: – Change the power set. Info The engine sprocket, rear sprocket, and chain should always be replaced together.
  • Page 89 SERVICE WORK ON THE CHASSIS – 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 at differ- 0 0 A...
  • Page 90 SERVICE WORK ON THE CHASSIS – 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 91 SERVICE WORK ON THE CHASSIS – Position the chain guard and tighten screw Guideline EJOT PT ® Screw, chain guard 4 Nm (3 lbf ft) – Tighten screw Guideline Screw, chain guard EJOT PT ® 4 Nm (3 lbf ft) –...

  • Page 92: Removing The Front Spoiler

    SERVICE WORK ON THE CHASSIS 11.14 Removing the front spoiler – Remove screws B00770-10 – Remove screws – Take off the front spoiler. B00771-10...

  • Page 93: Fitting Front Spoiler

    SERVICE WORK ON THE CHASSIS 11.15 Fitting front spoiler – Position the front spoiler. Mount screws but do not tighten yet. B00770-10 – 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...

  • Page 94: Brake System

    KTM. – Service work and repairs must be performed properly. (Your authorized KTM workshop will be glad to help.) The ABS is a safety system that prevents locking of the wheels when the vehicle is traveling straight ahead without the action of lateral forces.

  • Page 95: Checking The Brake Discs

    Danger of accidents Reduced braking efficiency due to worn brake disc(s). – Change the worn brake disc(s) without delay. (Your authorized KTM workshop will be glad to help.) – Check the thickness of the front and rear brake discs at several places on the disk to...

  • Page 96: Checking The Brake Fluid Level Of The Front Brake

    Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) – Move the brake fluid reservoir mounted on the handlebar to a horizontal position.

  • Page 97: Adding Front Brake Fluid X

    Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 98: Checking The Front Brake Linings

    Checking the front brake linings Warning Danger of accidents Reduced braking efficiency caused by worn brake linings. – Change worn brake linings immediately. (Your authorized KTM workshop will be glad to help.) Note Danger of accidents Reduced braking efficiency caused by damaged brake discs. –...

  • Page 99: Checking The Free Travel Of Foot Brake Lever

    BRAKE SYSTEM – Check the brake linings for minimum thickness ≥ 1 mm (≥ 0.04 in) Minimum thickness » If the minimum thickness is less than specified: – Change the front brake linings. – Check the brake linings for damage and cracking. »...

  • Page 100: Adjusting The Free Travel Of The Foot Brake Lever

    BRAKE SYSTEM – Disconnect spring – Move the foot brake lever back and forth between the end stop and the contact to the foot brake cylinder piston and check free travel Guideline Free travel at foot brake lever 3… 5 mm (0.12… 0.2 in) »...

  • Page 101: Checking The Rear Brake Fluid Level

    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. (Your authorized KTM workshop will be glad to help.)

  • Page 102: Adding Rear Brake Fluid X

    Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) – Stand the vehicle upright.
  • Page 103 Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 104: Checking The Rear Brake Linings

    Checking the rear brake linings Warning Danger of accidents Reduced braking efficiency caused by worn brake linings. – Change worn brake linings immediately. (Your authorized KTM workshop will be glad to help.) Note Danger of accidents Reduced braking efficiency caused by damaged brake discs. –...

  • Page 105: Wheels, Tires

    WHEELS, TIRES 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with the rear wheel stand. ( p. 75) – Raise the motorcycle with the front wheel stand. ( p. 76) Main work – Remove screws and push the fender to the side. –...

  • Page 106: Installing The Front Wheel

    WHEELS, TIRES 13.2 Installing the front wheel Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. – Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. Main work –...

  • Page 107: Removing The Rear Wheel X

    WHEELS, TIRES – Clean the thread of the wheel spindle and screw – Position the front wheel and insert the wheel spindle. The brake linings are correctly positioned. – Mount and tighten screw Guideline Screw, front wheel spindle 30 Nm (22.1 lbf ft) –...

  • Page 108: Installing The Rear Wheel X

    WHEELS, TIRES – 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. Warning Danger of accidents Reduced braking effect caused by damaged brake discs.
  • Page 109 WHEELS, TIRES Warning Danger of accidents No braking effect when operating the rear brake. – After installing the rear wheel, always operate the foot brake until the pressure point is reached. Main work – Check the rear hub rubber dampers. p. 108) –...

  • Page 110: Checking The Rear Hub Rubber Dampers

    WHEELS, TIRES – 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 Guideline In order for the rear wheel to be correctly aligned, the markings on the left and right chain adjusters must be in the same position relative to the reference marks...
  • Page 111 WHEELS, TIRES Preparatory work – Raise the motorcycle with the rear wheel stand. ( p. 75) – Remove the rear wheel. p. 105) Main work – Check bearing » If the bearing is damaged or worn: – Change the bearing. –...

  • Page 112: Checking The Tire Condition

    Danger of accidents Uncontrollable vehicle handling in the event of a flat tire. – In the interest of safety, replace damaged or worn tires immediately. (Your authorized KTM workshop will be glad to help.) Warning Danger of crashing Poor vehicle handling due to different tire tread patterns on front and rear wheels.

  • Page 113: Checking The Tire Air Pressure

    DOT marking. The first two digits refer to the week of manufacture and last two digits refer to the year of manufacture. KTM recommends that the tires are changed regardless of the actual wear, at the latest after 5 years.
  • Page 114 WHEELS, TIRES » If the tire air pressure does not meet specifications: – Correct the tire air pressure. – Mount the dust cap.

  • Page 115: Electrical System

    ELECTRICAL SYSTEM 14.1 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 116: Installing The Battery

    ELECTRICAL SYSTEM – Pull back the positive terminal cover – Disconnect the positive cable of the battery. – Detach rubber band – Pull the battery up and out of the battery holder. Info Never operate the motorcycle with a discharged battery or without a battery. In both cases, electrical components and safety devices can be damaged.

  • Page 117: Recharging The Battery

    ELECTRICAL SYSTEM – Connect the negative cable of the battery. – Position the negative terminal cover B00750-11 Finishing work – Mount the seat. ( p. 80) – Mount the passenger seat. ( p. 79) – Set the clock. ( p. 46) 14.3 Recharging the battery Warning...
  • Page 118 – 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 119 ELECTRICAL SYSTEM Main work – Connect the battery charger to the battery. Switch on the battery charger. Battery charger (58429074000) You can also use the battery charger to test rest potential and start potential of the bat- tery, and to test the alternator. With this device, you cannot overcharge the battery. Info Never remove lid Charge the battery with a maximum of 10% of the capacity specified on battery...

  • Page 120: Changing The Abs Fuses

    ELECTRICAL SYSTEM 14.4 Changing the ABS fuses Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used. – Use only fuses with the prescribed amperage. Never by-pass or repair fuses. Info Two fuses for the ABS are located under the passenger seat. These fuses protect the return pump and the hydraulic unit of the ABS.

  • Page 121: Changing The Fuses Of Individual Power Consumers

    ELECTRICAL SYSTEM Replace spare fuse in the fuse box so that it is available if needed. – Mount the protection cap. To change the fuse of the ABS return pump: – Take off the protection cap and remove fuse Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used.
  • Page 122 ELECTRICAL SYSTEM Preparatory work – Switch off all power consumers and switch off the engine. – Remove the passenger seat. ( p. 78) Main work – Open fuse box cover. – Remove the defective fuse. 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...

  • Page 123: Changing The Headlight Bulb

    ELECTRICAL SYSTEM Fuse (75011088010) ( p. 165) Fuse (75011088015) ( p. 165) Fuse (75011088030) ( p. 165) Replace the spare fuse in the fuse box so that it is available if needed. – Check that the power consumer is functioning properly. –...
  • Page 124 ELECTRICAL SYSTEM Main work – Remove expanding rivets 601915-10 – Remove screws – Lift the headlight mask slightly and swing forward. 601914-10 – Take off protection cap – Disconnect plug-in connector B00760-10...
  • Page 125 ELECTRICAL SYSTEM – Detach retaining clamp – Remove headlight bulb – Position the new headlight bulb in the headlight housing. Headlight (H4/socket P43t) ( p. 165) Info Insert the headlight bulb so that the catches latch into the recesses. – Attach retaining clamp B00761-10 –...

  • Page 126: Changing The Parking Light Bulb

    ELECTRICAL SYSTEM – Mount expanding rivets on both sides. – Check that the lighting is functioning properly. 601915-10 14.7 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 127 ELECTRICAL SYSTEM – Remove screws – Lift the headlight mask slightly and swing forward. 307324-10 – Remove screws – Take off cover B00762-10...
  • Page 128 ELECTRICAL SYSTEM – Pull the socket with bulb out of the housing. – Remove the bulb. – Position a new light bulb in the socket. Parking light (W5W/socket W2.1x9.5d) ( p. 165) – Position the socket with bulb in the housing. B00763-10 –...
  • Page 129 ELECTRICAL SYSTEM – 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. – Check that the lighting is functioning properly. 601915-10...

  • Page 130: Checking The Headlight Setting

    ELECTRICAL SYSTEM 14.8 Checking the headlight setting – Position the vehicle upright on a horizontal surface in front of a light wall and make a 0 0 A mark at the height of the center of the low beam headlight. –...

  • Page 131: Adjusting The Headlight Range

    ELECTRICAL SYSTEM 14.9 Adjusting the headlight range Main work – Remove expanding rivets 601915-10 – Remove screws – Lift the headlight mask slightly and swing forward. 601914-10...
  • Page 132 ELECTRICAL SYSTEM – 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 133 ELECTRICAL SYSTEM Finishing work – Check the headlight setting. ( p. 128)

  • Page 134: Cooling System

    COOLING SYSTEM 15.1 Cooling system Water pump in the engine circulates the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap . Heat expansion causes excess coolant to flow into compensating tank When the temperature falls, this surplus coolant is sucked back into the cooling system.

  • Page 135: Checking The Antifreeze And Coolant Level

    COOLING SYSTEM The coolant is cooled by the air stream and a radiator fan , which is controlled by a ther- moswitch. The lower the speed, the less the cooling effect. Dirty cooling fins also reduce the cooling effect. 401768-10 15.2 Checking the antifreeze and coolant level Warning...
  • Page 136 COOLING SYSTEM Warning Danger of poisoning Coolant is poisonous and a health hazard. – Coolant must not come into contact with the skin, eyes, or clothing. If contact occurs with the eyes, rinse with water immedi- ately and contact a physician. Immediately clean contaminated areas on the skin with soap and water. If coolant is swallowed, contact a physician immediately.

  • Page 137: Checking The Coolant Level

    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. B01552-10 »...
  • Page 138 COOLING SYSTEM Warning Danger of poisoning Coolant is poisonous and a health hazard. – Coolant must not come into contact with the skin, eyes, or clothing. If contact occurs with the eyes, rinse with water immedi- ately and contact a physician. Immediately clean contaminated areas on the skin with soap and water. If coolant is swallowed, contact a physician immediately.

  • Page 139: Draining The Coolant

    COOLING SYSTEM Alternative 2 Coolant (mixed ready to use) ( p. 171) » If you had to add more coolant than the specified amount: > 0.20 l (> 0.21 qt.) – Fill/bleed the cooling system. p. 138) – Mount the radiator cap. 15.4 Draining the coolant Warning...

  • Page 140: Filling/Bleeding The Cooling System

    COOLING SYSTEM Main work – Stand the motorcycle upright. – Place a suitable container under the engine. – Remove screw – Remove the radiator cap. – Completely drain the coolant. – Mount screw with a new seal ring and tighten it. Guideline B00768-10 Plug, water pump drain hole (125 Duke)
  • Page 141 COOLING SYSTEM – Remove radiator cap B01552-11 – Open bleeder screw by three turns. – Tilt the vehicle slightly to the right. – Pour in coolant until it emerges without bubbles at the bleeder screw, and then mount and tighten the bleeder screw immediately. Alternative 1 Coolant ( p.
  • Page 142 COOLING SYSTEM – Start the engine and let it run warm. – Stop the engine and allow it to cool down. – When the engine is cool, check the coolant level in the radiator and, if necessary, add coolant. – Remove the cap of the compensating tank and add coolant until the coolant level is up to the MAX mark.

  • Page 143: Tuning The Engine

    TUNING THE ENGINE 16.1 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 backwards and forwards to ascertain the play in the throttle cable. Throttle cable play 3…...

  • Page 144: Adjusting The Play In The Throttle Cable

    TUNING THE ENGINE 16.2 Adjusting the play in the throttle cable – Move the handlebar to the straight-ahead position. – Push back sleeve – Loosen lock nut – Adjust the play in the throttle cable by turning adjusting screw Guideline Throttle cable play 3…...

  • Page 145: Adjusting The Clutch Cable Play

    TUNING THE ENGINE » If the clutch lever play changes: – Check the routing of the clutch cable. 16.4 Adjusting the clutch cable play – Move the handlebar to the straight-ahead position. – Push back sleeve – Loosen lock nut –...

  • Page 146: Service Work On The Engine

    SERVICE WORK ON THE ENGINE 17.1 Checking the engine oil level Condition The engine is at operating temperature. Preparatory work – Stand the motorcycle upright on a horizontal surface. Main work – Check the engine oil level. Info After switching off the engine, wait one minute before checking the level. The engine oil must be between the lower and upper edge of the oil level viewer.
  • Page 147 SERVICE WORK ON THE ENGINE Info Drain the engine oil only when the engine is warm. Preparatory work – Remove the front spoiler. ( p. 90) – Stand the motorcycle on its side stand on a horizontal surface. Main work –...
  • Page 148 SERVICE WORK ON THE ENGINE – Remove screws . Remove the oil filter cover with the O-ring. – Pull oil filter out of the oil filter housing. Circlip pliers reverse (51012011000) – Completely drain the engine oil. – Thoroughly clean the parts and sealing area. B00775-10 –...

  • Page 149: Adding Engine Oil

    SERVICE WORK ON THE ENGINE – Remove the oil filler plug with the O-ring from the clutch cover and fill up with engine oil. Engine oil After oil change 1.2 l (1.3 qt.) External temper- Engine oil approx. ature: 0… 50 °C (SAE 15W/50) (32…...
  • Page 150 SERVICE WORK ON THE ENGINE Main work – Remove the oil filler plug with the O-ring from the clutch cover and fill up with engine oil. Engine oil (SAE 15W/50) ( p. 172) Engine oil (SAE 10W/40) ( p. 172) Info For optimal performance of the engine oil, do not mix different types of engine oil.

  • Page 151: Cleaning, Care

    CLEANING, CARE 18.1 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 pres- sure can cause malfunctions or destroy these parts.
  • Page 152 CLEANING, CARE Info Use warm water containing normal motorcycle cleaner and a soft sponge. Never apply motorcycle cleaner to a dry vehicle; always rinse the vehicle with water first. If the vehicle was operated in road salt, clean it with cold water. Warm water would enhance the corrosive effects of salt.

  • Page 153: Checks And Maintenance Steps For Winter Operation

    CLEANING, CARE High-luster polish for paint ( p. 175) – Treat all plastic parts and powder-coated parts with a mild cleaning and care product. Paint cleaner and polish for high-gloss and matte finishes, bare metal and plastic surfaces ( p. 175) –...
  • Page 154 CLEANING, CARE Info Corrosion inhibitor is not permitted to come in contact with the brake discs as this would greatly reduce the braking force. – Clean the chain. ( p. 81)

  • Page 155: Storage

    115) Guideline Storage temperature of battery without 0… 35 °C (32… 95 °F) direct sunlight – Store the vehicle in a dry location that is not subject to large fluctuations in tempera- ture. Info KTM recommends jacking up the motorcycle.

  • Page 156: Preparing For Use After Storage

    STORAGE – Raise the motorcycle with the rear wheel stand. ( p. 75) – Raise the motorcycle with the front wheel stand. ( p. 76) – Cover the motorcycle with a tarp or similar cover that is permeable to air. Info Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion.

  • Page 157: Troubleshooting

    Operating error Go through the steps of starting the engine. p. 60) – Defect in fuel injection system Read out the fault memory using the KTM diag- nostics tool. – Engine has too little power Air filter is very dirty Change the air filter.
  • Page 158 Defect in radiator fan system Check the radiator fan system. – The engine diagnosis warning Defect in fuel injection system Read out the fault memory using the KTM diag- lamp (MIL) lights up red nostics tool. – Engine dies during the trip Lack of fuel Refuel.
  • Page 159 TROUBLESHOOTING Faults Possible cause Action – Battery discharged Battery is not being charged by alter- Check the charging voltage. nator – Check the open-circuit current. – Combination instrument shows nothing Fuse 8 blown Change the fuses of individual power consumers. on the display p.

  • Page 160: 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 161: Duke Eu/Mal

    TECHNICAL DATA 4th gear 21:26 5th gear 22:23 6th gear 24:22 Mixture preparation Electronically controlled fuel injection Ignition Contactless controlled fully electronic ignition with digital ignition adjustment Alternator 12 V, 238 W Spark plug BOSCH VR 5 NE Spark plug electrode gap 0.8 mm (0.031 in) Cooling Water cooling, permanent circulation of coolant by water pump...
  • Page 162 TECHNICAL DATA Crankshaft bearing Two ball bearings Conrod bearing Sleeve bearing Pistons Cast light alloy 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...

  • Page 163: Engine Tightening Torques

    TECHNICAL DATA 21.2 Engine tightening torques ® Oil jet 6 Nm (4.4 lbf ft) Loctite 243™ ® Screw, engine vent plate 7 Nm (5.2 lbf ft) Loctite 243™ – Screw, oil filter cover 8 Nm (5.9 lbf ft) ® Screw, retaining bracket 6 Nm (4.4 lbf ft) Loctite 243™...
  • Page 164 TECHNICAL DATA – Screw, timing chain tensioner 12 Nm (8.9 lbf ft) ® Screw, timing chain tensioning rail 12 Nm (8.9 lbf ft) Loctite 243™ – Screw, valve cover 12 Nm (8.9 lbf ft) – Screw, water pump cover 12 Nm (8.9 lbf ft) –...

  • Page 165: Capacities

    TECHNICAL DATA 21.3 Capacities 21.3.1 Engine oil Engine oil First filling 1.5 l (1.6 qt.) External temperature: 0… Engine oil (SAE 15W/50) 50 °C (32… 122 °F) p. 172) External temperature: −10… Engine oil (SAE 10W/40) 40 °C (14… 104 °F) p.

  • Page 166: Chassis

    TECHNICAL DATA 21.4 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) Rear 150 mm (5.91 in) Brake discs - diameter...

  • Page 167: Electrical System

    TECHNICAL DATA Chain 5/8 x 1/4” (520) O‑ring Steering head angle 65° Wheelbase 1,367±15 mm (53.82±0.59 in) Seat height, unloaded 800 mm (31.5 in) Ground clearance, unloaded 170 mm (6.69 in) Weight without fuel, approx. (125 Duke) 127 kg (280 lb.) Weight without fuel, approx.

  • Page 168: 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 21.7 Fork Fork part number 90101000044 Fork WP Suspension Fork length 736 mm (28.98 in)

  • Page 169: Chassis Tightening Torques

    TECHNICAL DATA 21.9 Chassis tightening torques – Screw, chain guard EJOT PT ® 4 Nm (3 lbf ft) – Screw, headlight EJOT PT ® 4 Nm (3 lbf ft) – Remaining screws, chassis 4 Nm (3 lbf ft) – Screw, EFI control unit 4 Nm (3 lbf ft) –...
  • Page 170 TECHNICAL DATA – Screw, air filter box 6 Nm (4.4 lbf ft) – Screw, bottom of rear part 11 Nm (8.1 lbf ft) – Screw, brake fluid reservoir of rear brake 9 Nm (6.6 lbf ft) ® Screw, cable holder, side stand switch 9 Nm (6.6 lbf ft) Loctite 243™...
  • Page 171 TECHNICAL DATA – Remaining nuts, chassis 30 Nm (22.1 lbf ft) – Remaining screws, chassis 25 Nm (18.4 lbf ft) – Screw, bottom triple clamp 15 Nm (11.1 lbf ft) – Screw, engine bearer on frame 30 Nm (22.1 lbf ft) ®...
  • Page 172 TECHNICAL DATA – Screw, front footrest bracket M10x1.25 46 Nm (33.9 lbf ft) ® Screw, side stand bracket M10x1.25 25 Nm (18.4 lbf ft) Loctite 243™ – Screw, top shock absorber M10x1.25 50 Nm (36.9 lbf ft) – Stud, rear sprocket M10x1.25 50 Nm (36.9 lbf ft) –...

  • Page 173: 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 correspond- ing properties. KTM recommends Castrol and Motorex ® products. Supplier Castrol –...
  • Page 174 SAE ( p. 177) (SAE 15W/50) Guideline – Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties. KTM recommends Motorex ® products. Partially synthetic engine oil Supplier Motorex ®...
  • Page 175 According to – SAE ( p. 177) (SAE 5) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding proper- ties. KTM recommends Motorex ® products. Supplier Motorex ® –...

  • Page 176: 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 177 AUXILIARY SUBSTANCES High-luster polish for paint Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Moto Polish Long-life grease Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Bike Grease 2000 Motorcycle cleaner Guideline – KTM recommends Motorex ®...
  • Page 178 AUXILIARY SUBSTANCES Universal oil spray Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Joker 440 Synthetic...

  • Page 179: 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 specification. Whereas long service intervals are demanded for automobile engines, high performance at high engine speeds are in the foreground for motorcycle engines.

  • Page 180: Index

    INDEX INDEX Brakes, applying ....... . . 65 ABS ......... 92 Capacity Accessories .
  • Page 181 INDEX display TRIP F ....... . 36 changing ........144 distance menu 1 TRIP 1 .
  • Page 182 INDEX raising with the rear wheel stand ....75 taking off of the front wheel stand ....77 Grab handles .
  • Page 183 INDEX Shock absorber spring preload, adjusting ......73 Rear hub rubber dampers Side stand ........54 checking .
  • Page 184 INDEX Transport ........68 Troubleshooting .
  • Page 185 *3211963en* 3211963en 02/2013 KTM-Sportmotorcycle AG Photo: Mitterbauer/KTM 5230 Mattighofen/Austria http://www.ktm.com...

This manual is also suitable for:

200 duke eu200 duke mal2013 125 duke2013 200 duke

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