KTM 125 Duke 2013 - User Manual

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REPAIR MANUAL 2013

125 Duke EU

200 Duke EU

200 Duke MAL

200 Duke 2014 COL

Art. no. 3206162en

Main Page

Table of Contents4
Means of Representation8
Symbols Used8
Formats Used8
Safety Advice9
Repair Manual9
Degrees of Risk and Symbols9
Work Rules9
Important Information10
Guarantee, Warranty10
Operating and Auxiliary Substances10
Spare Parts, Accessories10
Figures10
Serial Numbers11
Chassis Number/Type Label11
Key Number11
Engine Number11
Motorcycle12
Raising the Motorcycle with the Rear Wheel Stand12
Taking the Motorcycle off of the Rear Wheel Stand12
Raising the Motorcycle with the Front Wheel Stand12
Taking the Motorcycle off of the Front Wheel Stand13
Raising the Motorcycle with the Work Stand13
Removing the Motorcycle from the Work Stand14
Starting15
Starting the Motorcycle to Make Checks16
Fork, Triple Clamp17
Cleaning the Dust Boots of the Fork Legs17
Removing Fork Legs17
Installing the Fork Legs19
Disassembling the Fork Legs22
Checking the Fork Legs24
Assembling the Fork Legs25
Removing the Lower Triple Clamp26
Installing the Lower Triple Clamp29
Checking the Steering Head Bearing Play31
Adjusting the Steering Head Bearing Play32
Handlebar, Controls34
Checking the Play in the Throttle Cable34
Adjusting the Play in the Throttle Cable34
Checking the Clutch Lever Play34
Adjusting the Clutch Cable Play35
Shock Absorber, Swingarm36
Adjusting the Spring Preload of the Shock Absorber36
Removing the Shock Absorber36
Installing the Shock Absorber37
Removing the Spring38
Installing the Spring38
Exhaust40
Removing the Exhaust Manifold40
Installing the Exhaust Manifold41
Removing the Main Silencer42
Installing the Main Silencer44
Air Filter46
Removing the Air Filter46
Installing the Air Filter46
Fuel Tank, Seat, Trim47
Opening the Filler Cap47
Closing the Filler Cap47
Removing the Seat47
Mounting the Seat48
Removing the Passenger Seat48
Mounting the Passenger Seat48
Removing the Fuel Tank Cover48
Installing the Fuel Tank Cover51
Removing the Fuel Tank53
Installing the Fuel Tank55
Removing the Front Spoiler56
Fitting Front Spoiler56
Dismounting the Front Fender57
Installing the Front Fender57
Checking the Fuel Pressure58
Changing the Fuel Filter59
Replacing the Fuel Pump60
Wheels62
Checking the Tire Air Pressure62
Checking the Tire Condition62
Checking the Brake Discs63
Front Wheel63
Removing the Front Wheel63
Installing the Front Wheel64
Removing the Brake Disc of the Front Brake65
Installing the Brake Disc of the Front Brake66
Rear Wheel66
Removing the Rear Wheel66
Installing the Rear Wheel67
Removing the Brake Disc of the Rear Brake68
Installing the Brake Disc of the Rear Brake69
Checking the Chain Tension70
Adjusting the Chain Tension70
Checking the Chain, Rear Sprocket, and Engine Sprocket71
Cleaning the Chain74
Checking the Rear Hub Rubber Dampers75
Wiring Harness, Battery76
Removing the Battery76
Installing the Battery76
Disconnecting the Negative Cable of the Battery77
Reconnecting the Negative Cable of the Battery77
Recharging the Battery77
Checking the Charging Voltage78
Changing the Fuses of Individual Power Consumers79
Brake System81
Checking the Front Brake Linings81
Changing the Front Brake Linings81
Checking the Brake Fluid Level of the Front Brake84
Adding Front Brake Fluid85
Changing the Front Brake Fluid85
Checking the Rear Brake Linings88
Changing the Rear Brake Linings88
Checking the Free Travel of Foot Brake Lever91
Adjusting the Free Travel of the Foot Brake Lever91
Checking the Rear Brake Fluid Level92
Adding Rear Brake Fluid92
Changing the Rear Brake Fluid93
Lighting System, Instruments96
Setting Kilometers or Miles96
Adjusting the Shift Speed RPM 196
Adjusting the Shift Speed RPM 296
Setting the Time97
Resetting the Service Interval Display97
Checking the Headlight Setting97
Adjusting the Headlight Range98
Changing the Parking Light Bulb99
Changing the Headlight Bulb100
Engine102
Removing the Engine102
Installing the Engine105
Engine Disassembly110
Preparations (125 Duke)110
Draining the Engine Oil (125 Duke)110
Removing the Chain Securing Guide111
Duke)111
Removing the Valve Cover (125 Duke)111
Removing the Spark Plug (125 Duke)111
Removing the Clutch Cover (125 Duke)111
Setting the Engine to Ignition Top Dead Center (125 Duke)112
Removing the Starter Motor (125 Duke)112
Removing the Timing Chain Tensioner113
Duke)113
Removing the Camshaft (125 Duke)113
Removing the Cylinder Head (125 Duke)114
Removing the Piston (125 Duke)114
Removing the Water Pump Wheel115
Duke)115
Removing the Alternator Cover116
Duke)116
Removing the Rotor (125 Duke)116
Removing the Starter Drive (125 Duke)117
Removing the Balancer Shaft Drive Wheel (125 Duke)117
Removing the Gear Position Sensor118
Duke)118
Removing the Spacer (125 Duke)119
Removing the Clutch Basket (125 Duke)119
Removing the Primary Gear (125 Duke)120
Removing the Oil Pump (125 Duke)120
Removing the Shift Shaft (125 Duke)121
Removing the Shift Drum Locating121
Duke)121
Removing the Locking Lever (125 Duke)121
Removing the Oil Filter (125 Duke)121
Removing the Left Engine Case122
Duke)122
Removing the Shift Rails (125 Duke)123
Removing the Shift Drum (125 Duke)123
Removing the Shift Forks (125 Duke)123
Removing the Transmission Shafts123
Duke)123
Removing the Balancer Shaft (125 Duke)124
Removing the Crankshaft (125 Duke)124
Preparations (200 Duke)124
Draining the Engine Oil (200 Duke)124
Removing the Chain Securing Guide125
Duke)125
Removing the Valve Cover (200 Duke)125
Removing the Spark Plug (200 Duke)125
Removing the Clutch Cover (200 Duke)125
Setting the Engine to Ignition Top Dead Center (200 Duke)126
Removing the Starter Motor (200 Duke)126
Removing the Timing Chain Tensioner127
Duke)127
Removing the Camshaft (200 Duke)127
Removing the Cylinder Head (200 Duke)128
Removing the Piston (200 Duke)128
Removing the Water Pump Wheel129
Duke)129
Removing the Alternator Cover130
Duke)130
Removing the Rotor (200 Duke)130
Removing the Starter Drive (200 Duke)131
Removing the Balancer Shaft Drive Wheel (200 Duke)131
Duke)132
Removing the Spacer (200 Duke)133
Removing the Clutch Basket (200 Duke)133
Removing the Primary Gear (200 Duke)134
Removing the Oil Pump (200 Duke)134
Removing the Shift Shaft (200 Duke)135
Removing the Shift Drum Locating135
Duke)135
Removing the Locking Lever (200 Duke)135
Removing the Oil Filter (200 Duke)135
Removing the Left Engine Case136
Duke)136
Removing the Shift Rails (200 Duke)137
Removing the Shift Drum (200 Duke)137
Removing the Shift Forks (200 Duke)137
Removing the Transmission Shafts137
Duke)137
Removing the Balancer Shaft (200 Duke)138
Removing the Crankshaft (200 Duke)138
Work on Individual Parts138
Work on the Left Section of the Engine Case (125 Duke)138
Work on the Right Section of the Engine Case (125 Duke)139
Changing the Shaft Seal Ring of the Water Pump (125 Duke)139
Removing the Main Bearing (125 Duke)140
Checking the Radial Play of the Lower Conrod Bearing (125 Duke)141
Changing the Conrod Bearing (125 Duke)142
Changing the Balancer Shaft Bearing143
Duke)143
Changing the Camshaft Bearing143
Work on the Cylinder Head (125 Duke)144
Checking the Cylinder Head (125 Duke)145
Checking/Measuring the Cylinder145
Duke)145
Checking the Piston Ring End Gap146
Duke)146
Checking/Measuring the Piston146
Checking the Piston/Cylinder Mounting Clearance (125 Duke)147
Checking the Oil Pump (125 Duke)147
Checking the Oil Pressure Regulator Valve (125 Duke)147
Checking the Clutch (125 Duke)148
Preassembling the Clutch (125 Duke)149
Checking the Shift Mechanism150
Duke)150
Preassembling the Shift Shaft (125 Duke)151
Disassembling the Main Shaft151
Duke)151
Dismantling the Countershaft (125 Duke)152
Checking the Transmission (125 Duke)152
Assembling the Main Shaft (125 Duke)153
Assembling the Countershaft (125 Duke)154
Checking the Timing Assembly156
Duke)156
Changing the Stator (125 Duke)156
Checking the Electric Starter Drive157
Duke)157
Checking the Freewheel (125 Duke)158
Work on the Left Section of the Engine Case (200 Duke)158
Work on the Right Section of the Engine Case (200 Duke)159
Changing the Shaft Seal Ring of the Water Pump (200 Duke)159
Removing the Main Bearing (200 Duke)160
Checking the Radial Play of the Lower161
Conrod Bearing (200 Duke)161
Changing the Conrod Bearing (200 Duke)162
Changing the Balancer Shaft Bearing163
Duke)163
Changing the Camshaft Bearing163
Work on the Cylinder Head (200 Duke)164
Checking the Cylinder Head (200 Duke)165
Checking/Measuring the Cylinder165
Duke)165
Checking the Piston Ring End Gap166
Duke)166
Checking/Measuring the Piston166
Checking the Piston/Cylinder Mounting Clearance (200 Duke)167
Checking the Oil Pump (200 Duke)167
Checking the Oil Pressure Regulator Valve (200 Duke)167
Checking the Clutch (200 Duke)168
Preassembling the Clutch (200 Duke)169
Checking the Shift Mechanism170
Duke)170
Preassembling the Shift Shaft (200 Duke)171
Disassembling the Main Shaft171
Duke)171
Dismantling the Countershaft (200 Duke)172
Checking the Transmission (200 Duke)172
Assembling the Main Shaft (200 Duke)173
Assembling the Countershaft (200 Duke)174
Checking the Timing Assembly176
Duke)176
Changing the Stator (200 Duke)176
Checking the Electric Starter Drive177
Duke)177
Checking the Freewheel (200 Duke)178
Engine Assembly178
Installing the Crankshaft (125 Duke)178
Installing the Balancer Shaft (125 Duke)178
Duke)179
Installing the Shift Forks (125 Duke)179
Installing the Shift Drum (125 Duke)179
Installing the Shift Rails (125 Duke)180
Installing the Left Engine Case180
Duke)180
Installing the Oil Filter (125 Duke)181
Installing the Locking Lever (125 Duke)181
Installing the Shift Drum Locating181
Duke)181
Installing the Shift Shaft (125 Duke)182
Installing the Oil Pump (125 Duke)182
Installing the Primary Gear (125 Duke)183
Installing the Clutch Basket (125 Duke)183
Installing the Spacer (125 Duke)184
Installing the Gear Position Sensor184
Duke)184
Installing the Balancer Shaft Drive Wheel (125 Duke)185
Installing the Starter Drive (125 Duke)186
Installing the Rotor (125 Duke)187
Installing the Alternator Cover (125 Duke)187
Installing the Water Pump Cover187
Duke)187
Installing the Piston (125 Duke)188
Installing the Cylinder Head (125 Duke)189
Installing the Camshafts (125 Duke)190
Installing the Timing Chain Tensioner191
Duke)191
Checking the Valve Clearance (125 Duke)192
Adjusting the Valve Clearance (125 Duke)192
Installing the Starter Motor (125 Duke)192
Installing the Clutch Cover (125 Duke)193
Installing the Spark Plug (125 Duke)193
Installing the Valve Cover (125 Duke)194
Installing the Chain Securing Guide194
Duke)194
Installing the Oil Screen (125 Duke)194
Removing the Engine from the Engine Assembly Stand (125 Duke)195
Installing the Crankshaft (200 Duke)195
Installing the Balancer Shaft (200 Duke)195
Installing the Transmission Shafts196
Duke)196
Installing the Shift Forks (200 Duke)196
Installing the Shift Drum (200 Duke)196
Installing the Shift Rails (200 Duke)197
Installing the Left Engine Case197
Duke)197
Installing the Oil Filter (200 Duke)198
Installing the Locking Lever (200 Duke)198
Installing the Shift Drum Locating198
Duke)198
Installing the Shift Shaft (200 Duke)199
Installing the Oil Pump (200 Duke)199
Installing the Primary Gear (200 Duke)200
Installing the Clutch Basket (200 Duke)200
Installing the Spacer (200 Duke)201
Installing the Gear Position Sensor (200 Duke)201
Installing the Balancer Shaft Drive Wheel (200 Duke)202
Installing the Starter Drive (200 Duke)203
Installing the Rotor (200 Duke)204
Installing the Alternator Cover (200 Duke)204
Installing the Water Pump Cover (200 Duke)204
Installing the Piston (200 Duke)205
Installing the Cylinder Head (200 Duke)206
Installing the Camshafts (200 Duke)207
Installing the Timing Chain Tensioner (200 Duke)208
Checking the Valve Clearance (200 Duke)209
Adjusting the Valve Clearance (200 Duke)209
Installing the Starter Motor (200 Duke)209
Installing the Clutch Cover (200 Duke)210
Installing the Spark Plug (200 Duke)210
Installing the Valve Cover (200 Duke)211
Installing the Chain Securing Guide (200 Duke)211
Installing the Oil Screen (200 Duke)211
Removing the Engine from the Engine Assembly Stand (200 Duke)212
Shift Mechanism213
Adjusting the Shift Lever213
Water Pump, Cooling System214
Draining the Coolant214
Filling/Bleeding the Cooling System214
Checking the Antifreeze and Coolant Level215
Checking the Coolant Level216
Lubrication System218
Oil Circuit218
Checking the Engine Oil Level218
Checking the Engine Oil Pressure218
Changing the Engine Oil and Oil Filter, Cleaning the Oil Screen220
Adding Engine Oil221
Ignition System222
Alternator - Checking the Stator Winding222
Technical Data223
Engine223
125 Duke223
Engine Tolerance, Wear Limits224
125 Duke224
200 Duke225
Engine Tightening Torques225
Capacities226
Engine Oil226
Coolant226
Fuel226
Chassis227
Electrical System227
Tires228
Fork228
Shock Absorber228
Chassis Tightening Torques228
Cleaning/Protective Treatment231
Cleaning the Motorcycle231
Checks and Maintenance Steps for Winter Operation232
Storage233
Preparing for Use after Storage233
Service Schedule234
Wiring Diagram236
Duke EU/MAL)236
Duke EU/MAL)238
Duke EU/MAL)240
Duke EU/MAL)242
Duke EU/MAL)244
Duke EU/MAL)246
Duke EU/MAL)248
Duke EU/MAL)250
Duke EU/MAL)252
Duke COL)254
Duke COL)256
Duke COL)258
Duke COL)260
Duke COL)262
Duke COL)264
Duke COL)266
Duke COL)268
Substances270
Auxiliary Substances272
Special Tools274
Standards283
Index284

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KTM 125 Duke 2013 Specifications

General

Brand	KTM
Model	125 Duke 2013
Category	Motorcycle
Language	English

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