KTM 200 DUKE EU - Repair Manual

KTM 200 DUKE EU

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REPAIR MANUAL 2012

125 Duke EU

125 Duke DE

200 Duke EU

200 Duke 2013 COL

Art. no. 3206127en

Table of Contents

Default Chapter4
- Table of Contents4
1 Means of Representation8
- Symbols Used8
- Formats Used8
2 Safety Advice9
- Repair Manual9
- Degrees of Risk and Symbols9
- Work Rules9
3 Important Notes10
- Guarantee, Warranty10
- Operating and Auxiliary Substances10
- Spare Parts, Accessories10
- Figures10
4 Serial Numbers11
- Chassis Number/Type Label11
- Key Number11
- Engine Number11
5 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
6 Fork, Triple Clamp17
- Cleaning the Dust Boots of the Fork Legs17
- Removing Fork Legs17
- Installing the Fork Legs18
- Disassembling the Fork Legs19
- Checking the Fork Legs21
- Assembling the Fork Legs22
- Removing the Lower Triple Clamp24
- Installing the Lower Triple Clamp26
- Checking the Steering Head Bearing Play28
- Adjusting the Steering Head Bearing Play29
7 Handlebar, Controls30
- Checking the Play in the Throttle Cable30
- Adjusting the Play in the Throttle Cable30
- Checking the Clutch Lever Play30
- Adjusting the Clutch Cable Play31
8 Shock Absorber, Swingarm32
- Adjusting the Spring Preload of the Shock Absorber32
- Removing the Shock Absorber32
- Installing the Shock Absorber32
- Removing the Spring33
- Installing the Spring33
9 Exhaust35
- Removing the Exhaust Manifold35
- Installing the Exhaust Manifold36
- Removing the Main Silencer37
- Installing the Main Silencer38
10 Air Filter39
- Removing the Air Filter39
- Installing the Air Filter39
11 Fuel Tank, Seat, Trim40
- Opening the Filler Cap40
- Closing the Filler Cap40
- Removing the Seat40
- Mounting the Seat41
- Removing the Passenger Seat41
- Mounting the Passenger Seat41
- Removing the Fuel Tank Cover41
- Installing the Fuel Tank Cover44
- Removing the Fuel Tank46
- Installing the Fuel Tank48
- Removing the Front Spoiler49
- Fitting Front Spoiler49
- Dismounting the Front Fender50
- Installing the Front Fender50
- Checking the Fuel Pressure50
- Changing the Fuel Filter52
- Replacing the Fuel Pump53
12 Wheels55
- Checking the Tire Air Pressure55
- Checking the Tire Condition55
- Checking the Brake Discs56
- Front Wheel56
- Removing the Front Wheel56
- Installing the Front Wheel56
- Removing the Brake Disc of the Front Brake57
- Installing the Brake Disc of the Front Brake57
- Rear Wheel58
- Removing the Rear Wheel58
- Installing the Rear Wheel58
- Removing the Brake Disc of the Rear Brake59
- Installing the Brake Disc of the Rear Brake59
- Checking the Chain Tension60
- Adjusting the Chain Tension60
- Checking the Chain, Rear Sprocket, and Engine Sprocket61
- Cleaning the Chain62
- Checking the Rear Hub Rubber Dampers63
13 Wiring Harness, Battery64
- Removing the Battery64
- Installing the Battery64
- Disconnecting the Negative Cable of the Battery65
- Reconnecting the Negative Cable of the Battery65
- Recharging the Battery65
- Checking the Charging Voltage66
- Changing the Fuses of Individual Power Consumers67
14 Brake System68
- Checking the Front Brake Linings68
- Changing the Front Brake Linings68
- Checking the Brake Fluid Level of the Front Brake70
- Adding Front Brake Fluid70
- Changing the Front Brake Fluid71
- Checking the Rear Brake Linings72
- Changing the Rear Brake Linings73
- Checking the Free Travel of Foot Brake Lever74
- Adjusting the Free Travel of the Foot Brake Lever75
- Checking the Rear Brake Fluid Level75
- Adding Rear Brake Fluid76
- Changing the Rear Brake Fluid76
15 Lighting System, Instruments78
- Setting Kilometers or Miles78
- Adjusting the Shift Speed RPM 178
- Adjusting the Shift Speed RPM 278
- Setting the Time79
- Resetting the Service Interval Display79
- Checking the Headlight Setting79
- Adjusting the Headlight Range80
- Changing the Parking Light Bulb81
- Changing the Headlight Bulb82
16 Engine84
- Removing the Engine84
- Installing the Engine87
- Disassembling the Engine92
- Preparations (125 Duke)92
- Draining the Engine Oil (125 Duke)92
- Removing the Chain Securing Guide93
  - Duke)93
- Removing the Valve Cover (125 Duke)93
- Removing the Spark Plug (125 Duke)93
- Removing the Clutch Cover (125 Duke)93
- Setting the Engine to Ignition Top Dead Center (125 Duke)94
- Removing the Starter Motor (125 Duke)94
- Removing the Timing Chain Tensioner95
  - Duke)95
- Removing the Camshaft (125 Duke)95
- Removing the Cylinder Head (125 Duke)96
- Removing the Piston (125 Duke)96
- Removing the Water Pump Wheel97
  - Duke)97
- Removing the Alternator Cover (125 Duke)98
- Removing the Rotor (125 Duke)98
- Removing the Starter Drive (125 Duke)99
- Removing the Balancer Shaft Drive Wheel (125 Duke)99
- Removing the Gear Position Sensor100
  - Duke)100
- Removing the Spacer (125 Duke)101
- Removing the Clutch Basket (125 Duke)101
- Removing the Primary Gear (125 Duke)102
- Removing the Oil Pump (125 Duke)102
- Removing the Shift Shaft (125 Duke)103
- Removing the Shift Drum Locating103
  - Duke)103
- Removing the Locking Lever (125 Duke)103
- Removing the Oil Filter (125 Duke)103
- Removing the Left Engine Case104
  - Duke)104
- Removing the Shift Rails (125 Duke)105
- Removing the Shift Drum (125 Duke)105
- Removing the Shift Forks (125 Duke)105
- Removing the Transmission Shafts105
  - Duke)105
  - Removing the Balancer Shaft (125 Duke)106
  - Removing the Crankshaft (125 Duke)106
- Preparations (200 Duke)106
- Draining the Engine Oil (200 Duke)106
- Removing the Chain Securing Guide107
  - Duke)107
  - Removing the Valve Cover (200 Duke)107
  - Removing the Spark Plug (200 Duke)107
- Removing the Clutch Cover (200 Duke)107
- Setting the Engine to Ignition Top Dead Center (200 Duke)108
- Removing the Starter Motor (200 Duke)108
- Removing the Timing Chain Tensioner109
  - Duke)109
- Removing the Camshaft (200 Duke)109
- Removing the Cylinder Head (200 Duke)110
- Removing the Piston (200 Duke)110
- Removing the Water Pump Wheel111
  - Duke)111
- Removing the Alternator Cover112
  - Duke)112
- Removing the Rotor (200 Duke)112
- Removing the Starter Drive (200 Duke)113
- Removing the Balancer Shaft Drive Wheel (200 Duke)113
  - Duke)114
- Removing the Spacer (200 Duke)115
- Removing the Clutch Basket (200 Duke)115
- Removing the Primary Gear (200 Duke)116
- Removing the Oil Pump (200 Duke)116
- Removing the Shift Shaft (200 Duke)117
- Removing the Shift Drum Locating117
  - Duke)117
- Removing the Locking Lever (200 Duke)117
- Removing the Oil Filter (200 Duke)117
- Removing the Left Engine Case118
  - Duke)118
- Removing the Shift Rails (200 Duke)119
- Removing the Shift Drum (200 Duke)119
- Removing the Shift Forks (200 Duke)119
- Removing the Transmission Shafts119
  - Duke)119
- Removing the Balancer Shaft (200 Duke)120
- Removing the Crankshaft (200 Duke)120
- Work on Individual Parts120
- Work on the Left Section of the Engine Case (125 Duke)120
- Work on the Right Section of the Engine Case (125 Duke)121
- Changing the Shaft Seal Ring of the Water Pump (125 Duke)121
- Removing the Main Bearing (125 Duke)122
- Checking the Radial Play of the Lower Conrod Bearing (125 Duke)123
- Changing the Conrod Bearing (125 Duke)124
- Changing the Balancer Shaft Bearing125
  - Duke)125
- Changing the Camshaft Bearing125
- Work on the Cylinder Head (125 Duke)126
- Checking the Cylinder Head (125 Duke)127
- Checking/Measuring the Cylinder127
  - Duke)127
  - Checking the Piston Ring End Gap128
  - Duke)128
  - Checking/Measuring the Piston128
  - Checking the Piston/Cylinder Mounting Clearance (125 Duke)129
  - Checking the Oil Pump (125 Duke)129
  - Checking the Oil Pressure Regulator Valve (125 Duke)129
- Checking the Clutch (125 Duke)130
- Preassembling the Clutch (125 Duke)131
- Checking the Shift Mechanism132
  - Duke)132
- Preassembling the Shift Shaft (125 Duke)133
- Disassembling the Main Shaft133
  - Duke)133
- Dismantling the Countershaft (125 Duke)134
- Checking the Transmission (125 Duke)134
- Assembling the Main Shaft (125 Duke)135
- Assembling the Countershaft (125 Duke)136
- Checking the Timing Assembly138
  - Duke)138
- Changing the Stator (125 Duke)138
- Checking the Electric Starter Drive139
  - Duke)139
- Checking the Freewheel (125 Duke)140
- Work on the Left Section of the Engine Case (200 Duke)140
- Work on the Right Section of the Engine Case (200 Duke)141
- Changing the Shaft Seal Ring of the Water Pump (200 Duke)141
- Removing the Main Bearing (200 Duke)142
- Checking the Radial Play of the Lower Conrod Bearing (200 Duke)143
- Changing the Conrod Bearing (200 Duke)144
- Changing the Balancer Shaft Bearing145
  - Duke)145
- Changing the Camshaft Bearing145
- Work on the Cylinder Head (200 Duke)146
- Checking the Cylinder Head (200 Duke)147
- Checking/Measuring the Cylinder147
  - Duke)147
- Checking the Piston Ring End Gap148
  - Duke)148
- Checking/Measuring the Piston148
- Checking the Piston/Cylinder Mounting Clearance (200 Duke)149
- Checking the Oil Pump (200 Duke)149
- Checking the Oil Pressure Regulator Valve (200 Duke)149
- Checking the Clutch (200 Duke)150
- Preassembling the Clutch (200 Duke)151
- Checking the Shift Mechanism152
  - Duke)152
- Preassembling the Shift Shaft (200 Duke)153
- Disassembling the Main Shaft153
  - Duke)153
- Dismantling the Countershaft (200 Duke)154
- Checking the Transmission (200 Duke)154
- Assembling the Main Shaft (200 Duke)155
- Assembling the Countershaft (200 Duke)156
- Checking the Timing Assembly158
  - Duke)158
  - Changing the Stator (200 Duke)158
  - Checking the Electric Starter Drive159
  - Duke)159
  - Checking the Freewheel (200 Duke)160
  - Assembling the Engine160
- Installing the Crankshaft (125 Duke)160
- Installing the Balancer Shaft (125 Duke)160
  - Duke)161
- Installing the Shift Forks (125 Duke)161
- Installing the Shift Drum (125 Duke)161
- Installing the Transmission Shafts (125 Duke)161
- Installing the Shift Rails (125 Duke)162
- Installing the Left Engine Case162
  - Duke)162
- Installing the Oil Filter (125 Duke)163
- Installing the Locking Lever (125 Duke)163
- Installing the Shift Drum Locating163
  - Duke)163
- Installing the Shift Shaft (125 Duke)164
- Installing the Oil Pump (125 Duke)164
- Installing the Primary Gear (125 Duke)165
- Installing the Clutch Basket (125 Duke)165
- Installing the Spacer (125 Duke)166
- Installing the Gear Position Sensor166
  - Duke)166
- Installing the Balancer Shaft Drive Wheel (125 Duke)167
- Installing the Starter Drive (125 Duke)168
- Installing the Rotor (125 Duke)169
- Installing the Alternator Cover (125 Duke)169
- Installing the Water Pump Cover169
  - Duke)169
- Installing the Piston (125 Duke)170
- Installing the Cylinder Head (125 Duke)171
- Installing the Camshafts (125 Duke)172
- Installing the Timing Chain Tensioner173
  - Duke)173
- Checking the Valve Clearance (125 Duke)174
- Adjusting the Valve Clearance (125 Duke)174
- Installing the Starter Motor (125 Duke)174
- Installing the Clutch Cover (125 Duke)175
- Installing the Spark Plug (125 Duke)175
- Installing the Valve Cover (125 Duke)176
- Installing the Chain Securing Guide176
  - Duke)176
- Installing the Oil Screen (125 Duke)176
- Removing the Engine from the Engine Assembly Stand (125 Duke)177
- Installing the Crankshaft (200 Duke)177
- Installing the Balancer Shaft (200 Duke)177
- Installing the Transmission Shafts178
  - Duke)178
- Installing the Shift Forks (200 Duke)178
- Installing the Shift Drum (200 Duke)178
- Installing the Shift Rails (200 Duke)179
- Installing the Left Engine Case179
  - Duke)179
- Installing the Oil Filter (200 Duke)180
- Installing the Locking Lever (200 Duke)180
- Installing the Shift Drum Locating180
  - Duke)180
  - Installing the Shift Shaft (200 Duke)181
  - Installing the Oil Pump (200 Duke)181
  - Installing the Primary Gear (200 Duke)182
  - Installing the Clutch Basket (200 Duke)182
  - Installing the Spacer (200 Duke)183
  - Installing the Gear Position Sensor (200 Duke)183
  - Installing the Balancer Shaft Drive Wheel (200 Duke)184
  - Installing the Starter Drive (200 Duke)185
  - Installing the Rotor (200 Duke)186
  - Installing the Alternator Cover (200 Duke)186
  - Installing the Water Pump Cover (200 Duke)186
  - Installing the Piston (200 Duke)187
  - Installing the Cylinder Head (200 Duke)188
  - Installing the Camshafts (200 Duke)189
  - Installing the Timing Chain Tensioner (200 Duke)190
  - Checking the Valve Clearance (200 Duke)191
  - Adjusting the Valve Clearance (200 Duke)191
  - Installing the Starter Motor (200 Duke)191
  - Installing the Clutch Cover (200 Duke)192
  - Installing the Spark Plug (200 Duke)192
  - Installing the Valve Cover (200 Duke)193
  - Installing the Chain Securing Guide (200 Duke)193
  - Installing the Oil Screen (200 Duke)193
  - Removing the Engine from the Engine Assembly Stand (200 Duke)194
17 Shift Mechanism195
- Adjusting the Shift Lever195
18 Water Pump, Cooling System196
- Draining the Coolant196
- Filling/Bleeding the Cooling System196
- Checking the Antifreeze and Coolant Level197
- Checking the Coolant Level198
19 Lubrication System200
- Oil Circuit200
- Checking the Engine Oil Level200
- Checking the Engine Oil Pressure200
- Changing the Engine Oil and Oil Filter, Cleaning the Oil Screen202
- Adding Engine Oil203
20 Ignition System204
- Alternator - Checking the Stator Winding204
21 Technical Data205
- Engine205
- 125 Duke205
- Engine Tolerance, Wear Limits206
- 125 Duke206
- 200 Duke207
- Engine Tightening Torques207
- Capacities208
- Engine Oil208
- Coolant208
- Fuel208
- Chassis209
- Electrical System209
- Tires210
- Fork210
- Shock Absorber210
- Chassis Tightening Torques210
22 Cleaning/Protective Treatment213
- Cleaning the Motorcycle213
  - Checks and Maintenance Steps for Winter Operation214
23 Storage215
- Preparing for Use after Storage215
24 Service Schedule216
25 Wiring Diagram218
- 125 Duke, 200 Duke EU)218
- 125 Duke, 200 Duke EU)220
- 125 Duke, 200 Duke EU)222
- 125 Duke, 200 Duke EU)224
- 125 Duke, 200 Duke EU)226
- 125 Duke, 200 Duke EU)228
- 125 Duke, 200 Duke EU)230
- 125 Duke, 200 Duke EU)232
- 200 Duke 2013 COL)234
- 200 Duke 2013 COL)236
- 200 Duke 2013 COL)238
- 200 Duke 2013 COL)240
- 200 Duke 2013 COL)242
- 200 Duke 2013 COL)244
- 200 Duke 2013 COL)246
- 200 Duke 2013 COL)248
26 Substances250
27 Auxiliary Substances252
28 Special Tools254
29 Standards263
- Index264

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