KTM 125 Duke 2016 Owner Manual

OWNER'S MANUAL

2016

125 Duke

200 Duke

Art. no. 3213412en

DEAR KTM CUSTOMER

DEAR KTM CUSTOMER

Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will give you enormous pleasure if you service and maintain it properly.

We hope you enjoy your new vehicle!

Enter the serial numbers of your vehicle below.

Chassis number ( p. 20)

Dealer's stamp

1

Engine number ( p. 21)

Key number ( p. 21)

The Owner's Manual contained the latest information for this model series at the time of going to print. Minor differences due to developments in design cannot be ruled out completely.

All specifications are non-binding. KTM Sportmotorcycle GmbH specifically reserves the right to modify or delete technical specifications, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt these to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery options, deviations from illustrations and descriptions, misprints, and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of supply.

© 2016 KTM Sportmotorcycle GmbH, Mattighofen Austria

All rights reserved

*3213412en*

3213412en

02/2016

DEAR KTM CUSTOMER

Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright owner.

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

2

KTM Sportmotorcycle GmbH

5230 Mattighofen, Austria

This document is valid for the following models:

125 Duke EU (F4003P1, F4003P2, F4003P3, F4003P4)

200 Duke EU (F4103P1, F4103P2)

200 Duke AR (F4142P1, F4142P2, F4142P3, F4142P4)

200 Duke ASIA (F4188P1, F4188P2)

200 Duke CN (F4187P1)

200 Duke MY (F4189P1, F4189P2)

200 Duke TH (F4183P1, F4183P2)

TABLE OF CONTENTS

TABLE OF CONTENTS

1 MEANS OF REPRESENTATION ........................................ 7

1.1

1.2

Symbols used ...................................................... 7

Formats used....................................................... 8

2 SAFETY ADVICE.............................................................. 9

2.5

2.6

2.7

2.8

2.1

2.2

2.3

2.4

Use definition...................................................... 9

Safety advice....................................................... 9

Degrees of risk and symbols ................................ 10

Tampering warning............................................. 10

Safe operation ................................................... 11

Protective clothing ............................................. 12

Work rules......................................................... 12

Environment...................................................... 12

2.9

Owner's Manual ................................................. 13

3 IMPORTANT NOTES...................................................... 14

3.1

Manufacturer and implied warranty...................... 14

3.2

3.3

3.4

3.5

Operating and auxiliary substances ...................... 14

Spare parts, accessories ..................................... 14

Service ............................................................. 15

Figures ............................................................. 15

3.6

Customer service................................................ 15

4 VIEW OF VEHICLE ........................................................ 16

4.1

4.2

View of vehicle, front left (example) ..................... 16

View of vehicle, rear right (example) .................... 18

5 SERIAL NUMBERS ....................................................... 20

5.1

Chassis number ................................................. 20

5.2

Type label ......................................................... 20

5.3

5.4

Engine number .................................................. 21

Key number....................................................... 21

3

6 CONTROLS................................................................... 22

6.1

Clutch lever....................................................... 22

6.2

6.3

Hand brake lever................................................ 22

Throttle grip ...................................................... 23

6.4

6.5

6.6

Horn button....................................................... 23

Light switch ...................................................... 24

High beam flasher button ................................... 24

6.7

6.8

Turn signal switch.............................................. 25

Emergency OFF switch ....................................... 25

6.9

Electric starter button......................................... 26

6.10

Ignition/steering lock.......................................... 26

6.11

Locking the steering........................................... 27

6.12

Unlocking the steering........................................ 27

6.13

Combination instrument ..................................... 28

6.13.1

Overview ....................................................... 28

6.13.2

Activation and test ......................................... 29

6.13.3

Warning notes ............................................... 30

6.13.4

Function buttons ........................................... 33

6.13.5

Indicator lamps ............................................. 34

6.13.6

Display ......................................................... 35

6.13.7

Filling level display in fuel tank....................... 36

6.13.8

TRIP F display............................................... 37

6.13.9

Coolant temperature indicator ......................... 38

6.13.10 Info display ................................................... 39

6.13.11 Riding time/average speed menu ..................... 40

6.13.12 Average speed/average fuel consumption 1 menu............................................................ 40

6.13.13 Average fuel consumption 1/average fuel consumption 2 menu ..................................... 41


6.13.14 Average fuel consumption 2/service menu ........ 42

6.13.15 Service/range menu........................................ 43

6.13.16 Range/riding time menu ................................. 44

6.13.17 Total distance menu ODO ............................... 45

6.13.18 Distance menu 1 TRIP 1 ................................ 46

6.13.19 Distance menu 2 TRIP 2 ................................ 46

6.13.20 Setting kilometers or miles ............................. 47

6.13.21 Setting the time............................................. 47

6.13.22 Adjusting the shift speed RPM 1 ..................... 48

6.13.23 Adjusting the shift speed RPM 2 ..................... 49

6.14

Opening the filler cap......................................... 50

6.15

Closing the filler cap .......................................... 51

6.16

Seat lock........................................................... 51

6.17

Tool set............................................................. 52

6.18

Grab handles ..................................................... 52

6.19

Passenger footrests ............................................ 53

6.20

Shift lever ......................................................... 53

6.21

Foot brake lever ................................................. 54

6.22

Side stand......................................................... 55

7 PREPARING FOR USE................................................... 56

7.1

7.2

Advice on first use ............................................. 56

Running in the engine ........................................ 57

7.3

Loading the vehicle ............................................ 58

8 RIDING INSTRUCTIONS................................................ 60

8.1

8.2

Checks and maintenance when preparing for use ................................................................... 60

Starting............................................................. 61

8.3

8.4

Starting off........................................................ 63

Shifting, riding .................................................. 63

4

8.5

8.6

8.7

8.8

Applying the brakes............................................ 66

Stopping, parking............................................... 68

Transport .......................................................... 69

Refueling .......................................................... 70

9 SERVICE SCHEDULE .................................................... 72

9.1

Additional information........................................ 72

9.2

Required work ................................................... 72

9.3

Recommended work ........................................... 74

10 TUNING THE CHASSIS ................................................. 75

10.1

Adjusting the spring preload of the shock absorber ........................................................ 75

10.2

Adjusting the shift lever...................................... 76

11 SERVICE WORK ON THE CHASSIS................................. 77

11.1

Raising the motorcycle with the rear wheel stand ................................................................ 77

11.2

Taking the motorcycle off of the rear wheel stand ................................................................ 77

11.3

Raising the motorcycle with the front wheel stand ................................................................ 78

11.4

Taking the motorcycle off of the front wheel stand ................................................................ 79

11.5

Removing the passenger seat .............................. 80

11.6

Mounting the passenger seat............................... 81

11.7

Removing the seat ............................................. 81

11.8

Mounting the seat .............................................. 82

11.9

Checking for chain dirt accumulation................... 83

11.10 Cleaning the chain ............................................. 83

11.11 Checking the chain tension ................................. 84

11.12 Adjusting the chain tension................................. 86


11.13 Checking the chain, rear sprocket, and engine sprocket............................................................ 89

11.14 Removing the front spoiler .................................. 93

11.15 Fitting front spoiler ............................................ 94

12 BRAKE SYSTEM ........................................................... 95

12.1

Antilock Braking System (ABS) (125 Duke) .......... 95

12.2

Checking the brake discs .................................... 96

12.3

Checking the brake fluid level of the front brake ... 97

12.4

Adding front brake fluid .................................. 98

12.5

Checking the front brake linings ........................ 100

12.6

Checking the free travel of foot brake lever ......... 100

12.7

Adjusting the free travel of the foot brake lever ............................................................ 101

12.8

Checking the rear brake fluid level..................... 102

12.9

Adding rear brake fluid ................................. 104

12.10 Checking the rear brake linings ......................... 107

13 WHEELS, TIRES ......................................................... 108

13.1

Removing the front wheel .............................. 108

13.2

Installing the front wheel .............................. 109

13.3

Removing the rear wheel ............................... 112

13.4

Installing the rear wheel ................................ 114

13.5

Checking the rear hub rubber dampers ........... 118

13.6

Checking the tire condition ............................... 119

13.7

Checking the tire air pressure............................ 121

14 ELECTRICAL SYSTEM ................................................. 122

14.1

Removing the battery .................................... 122

14.2

Installing the battery ..................................... 123

14.3

Recharging the battery .................................. 124

14.4

Changing the ABS fuses (125 Duke).................. 127

5

14.5

Changing the fuses of individual power consumers....................................................... 128

14.6

Changing the headlight bulb ............................. 132

14.7

Changing the parking light bulb......................... 135

14.8

Checking the headlight setting .......................... 138

14.9

Adjusting the headlight range............................ 139

15 COOLING SYSTEM ...................................................... 142

15.1

Cooling system ................................................ 142

15.2

Checking the antifreeze and coolant level ........... 143

15.3

Checking the coolant level ................................ 145

15.4

Draining the coolant ..................................... 147

15.5

Filling/bleeding the cooling system ................. 148

16 TUNING THE ENGINE................................................. 150

16.1

Checking the play in the throttle cable ............... 150

16.2

Adjusting the play in the throttle cable ........... 151

16.3

Checking the clutch lever play........................... 151

16.4

Adjusting the clutch cable play ...................... 152

17 SERVICE WORK ON THE ENGINE ................................ 153

17.1

Checking the engine oil level............................. 153

17.2

Changing the engine oil and oil filter, cleaning the oil screen ............................................... 153

17.3

Adding engine oil............................................. 156

18 CLEANING, CARE ....................................................... 158

18.1

Cleaning the motorcycle ................................... 158

18.2

Checks and maintenance steps for winter operation......................................................... 160

19 STORAGE................................................................... 162

19.1

Storage ........................................................... 162

19.2

Preparing for use after storage........................... 163

20 TROUBLESHOOTING .................................................. 164


21 TECHNICAL DATA....................................................... 167

21.1

Engine ............................................................ 167

21.1.1

125 Duke ................................................... 167

21.1.2

200 Duke ................................................... 168

21.2

Engine tightening torques ................................. 170

21.3

Capacities ....................................................... 173

21.3.1

Engine oil ................................................... 173

21.3.2

Coolant ....................................................... 173

21.3.3

Fuel ........................................................... 173

21.4

Chassis ........................................................... 174

21.5

Electrical system.............................................. 175

21.6

Tires ............................................................... 176

21.7

Fork................................................................ 176

21.8

Shock absorber ................................................ 176

21.9

Chassis tightening torques ................................ 177

22 SUBSTANCES ............................................................ 182

23 AUXILIARY SUBSTANCES ........................................... 185

24 STANDARDS .............................................................. 187

25 INDEX OF SPECIAL TERMS ......................................... 188

26 LIST OF ABBREVIATIONS............................................ 189

27 LIST OF SYMBOLS...................................................... 190

27.1

Red symbols.................................................... 190

27.2

Yellow and orange symbols................................ 190

27.3

Green and blue symbols.................................... 190

INDEX ............................................................................... 191

6

1 MEANS OF REPRESENTATION

1.1

Symbols used

The meaning of specific symbols is described below.

Indicates an expected reaction (e.g. of a work step or a function).

Indicates an unexpected reaction (e.g. of a work step or a function).

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.

Indicates a page reference (more information is provided on the specified page).

Indicates information with more details or tips.

Indicates the result of a testing step.

7

1 MEANS OF REPRESENTATION

1.2

Formats used

The typographical formats used in this document are explained below.

Specific name Identifies a proprietary name.

Name ®

Brand™

Underlined terms

Identifies a protected name.

Identifies a brand available on the open market.

Refer to technical details of the vehicle or indicate technical terms that are explained in the glossary.

8

2 SAFETY ADVICE

2.1

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.

2.2

Safety advice

A number of safety instructions need to be followed to operate the vehicle safely. Therefore, read this manual carefully. The safety instructions are highlighted in the text and are referred to at the relevant passages.

Info

The vehicle has various information and warning labels at prominent locations. Do not remove information/warning labels. If they are missing, you or others may not recognize dangers and may therefore be injured.

9

2 SAFETY ADVICE

10

2.3

Degrees of risk and symbols

Danger

Indicates a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken.

Warning

Indicates a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.

Caution

Indicates a danger that may lead to minor injuries if the appropriate measures are not taken.

Note

Indicates a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.

Warning

Indicates a danger that will lead to environmental damage if the appropriate measures are not taken.

2.4

Tampering warning

Tampering with the noise control system is prohibited. Federal law prohibits the following acts or the causing thereof:

1 The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or

2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

Among those acts presumed to constitute tampering are the acts listed below:

2 SAFETY ADVICE

1 Removal or puncturing of the main silencer, baffles, header pipes or any other components which conduct exhaust gases.

2 Removal or puncturing of parts of the intake system.

3 Lack of proper maintenance.

4 Replacing moving part of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by the manufacturer.

11

2.5

Safe operation

Danger

Danger of accidents Danger arising from the rider's judgement being impaired.

– Do not operate the vehicle while under the influence of alcohol, drugs and certain medications or physically or mentally impaired.

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.

Warning

Danger of burns Some vehicle components become very hot when the vehicle is operated.

– Do not touch hot components such as exhaust system, radiator, engine, shock absorber, and the brake system. Allow these components to cool down before starting work on them.

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.

2 SAFETY ADVICE

2.6

Protective clothing

Warning

Risk of injury Missing or poor protective clothing presents an increased safety risk.

– 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.

12

In the interest of your own safety, KTM recommends that you only operate the vehicle while wearing protective clothing.

2.7

Work rules

Special tools are necessary for certain tasks. The tools are not contained in the vehicle but can be ordered under the number in parentheses. E.g.: bearing puller (15112017000)

During assembly, non-reusable parts (e.g. self-locking screws and nuts, seals and seal rings, O-rings, pins, lock washers) must be replaced by new parts.

In some instances, a thread locker (e.g.

Loctite ® ) is required. The manufacturer instructions for use must be followed.

After disassembly, clean the parts that are to be reused and check them for damage and wear. Change damaged or worn parts.

After you complete the repair or service work, check the operating safety of the vehicle.

2.8

Environment

If you use your motorcycle responsibly, you can ensure that problems and conflicts do not occur. To protect the future of the motorcycle sport, make sure that you use your motorcycle legally, display environmental consciousness, and respect the rights of others.

When disposing of used oil, other operating and auxiliary fluids, and used components, comply with the laws and regulations of the respective country.

Because motorcycles are not subject to the EU regulations governing the disposal of used vehicles, there are no legal regulations that pertain to the disposal of an end-of-life motorcycle. Your authorized KTM dealer will be glad to advise you.

2 SAFETY ADVICE

2.9

Owner's Manual

It is important that you read this Owner's Manual carefully and completely before making your first trip. The Owner's Manual contains useful information and many tips on how to operate, handle, and maintain your motorcycle. Only then will you find out how to customize the vehicle ideally for your own use and how you can protect yourself from injury.

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.

The Owner's Manual is an important component of the vehicle and should be handed over to the new owner if the vehicle is sold.

13

3 IMPORTANT NOTES

14

3.1

Manufacturer and implied warranty

The work specified in the service schedule may only be performed in an authorized KTM workshop and must be recorded in both the

Service & Warranty Booklet and in KTM Dealer.net

, otherwise any warranty coverage will become void. Damage or secondary damage caused by tampering with and/or conversions on the vehicle are not covered by the warranty.

Additional information on the manufacturer or implied warranty and the procedures involved can be found in the Service & Warranty Booklet.

3.2

Operating and auxiliary substances

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.

Use operating and auxiliary substances (such as fuel and lubricants) as specified in the Owner's Manual.

3.3

Spare parts, accessories

For your own safety, only use spare parts and accessory products that are approved and/or recommended by KTM and have them installed by an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage or loss.

Certain spare parts and accessory products are specified in parentheses in the descriptions. Your authorized KTM dealer will be glad to advise you.

The current KTM PowerParts for your vehicle can be found on the KTM website.

International KTM Website: http://www.ktm.com

3 IMPORTANT NOTES

3.4

Service

A prerequisite for perfect operation and prevention of premature wear is that the service, care, and tuning work on the engine and chassis is properly carried out as described in the Owner's Manual. Incorrect adjustment and tuning of the engine and chassis can lead to damage and breakage of components.

Use of the vehicle under difficult conditions, such in rain, high heat or with a heavy load, can lead to considerably more rapid wear of components such as the drive train, brake system, or suspension components. For this reason, it may be necessary to inspect or replace parts before the next scheduled service.

It is imperative that you adhere to the stipulated run-in times and service intervals. If you observe these exactly, you will ensure a much longer service life for your motorcycle.

15

3.5

Figures

The figures contained in the manual may depict special equipment.

In the interest of clarity, some components may be shown disassembled or may not be shown at all. It is not always necessary to disassemble the component to perform the activity in question. Please follow the instructions in the text.

3.6

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.

International KTM Website: http://www.ktm.com

4 VIEW OF VEHICLE

4.1

View of vehicle, front left (example)

16

S00654-10


6

7

4

5

1

2

3

8

9

10

Combination instrument

Rear mirror

Clutch lever ( p. 22)

Seat

Passenger seat

Seat lock ( p. 51)

Grab handles ( p. 52)

Engine number ( p. 21)

Side stand ( p. 55)

Shift lever ( p. 53)

17


4.2

View of vehicle, rear right (example)

18

S00655-10


7

8

5

6

8

9

10

3

4

2

2

1

2

2

Tool set ( p. 52)

Light switch ( p. 24)

High beam flasher button ( p. 24)

Turn signal switch ( p. 25)

Horn button ( p. 23)

Filler cap

Electric starter button ( p. 26)

Emergency OFF switch ( p. 25)

Hand brake lever ( p. 22)

Ignition/steering lock ( p. 26)

Chassis number ( p. 20)

Type label ( p. 20)

Passenger footrests ( p. 53)

Foot brake lever ( p. 54)

19

5 SERIAL NUMBERS

5.1

Chassis number

The chassis number  is stamped on the right side of the steering head.

20

5.2

Type label

402408-10

The type label  is on the right of the frame behind the steering head.

402174-10

5 SERIAL NUMBERS

5.3

Engine number

21

The engine number  is stamped on the left side of the engine under the engine sprocket.

5.4

Key number

402486-10

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.

402245-10

6 CONTROLS

6.1

Clutch lever

The clutch lever  is fitted on the left side of the handlebar.

6.2

Hand brake lever

S00656-10

The hand brake lever  is fitted on the right side of the handlebar.

The front brake is engaged using the hand brake lever.

S00663-10

22

6 CONTROLS

6.3

Throttle grip

The throttle grip  is fitted on the right side of the handlebar.

6.4

Horn button

S00664-10

The horn button  is fitted on the left side of the handlebar.

Possible states

• Horn button in neutral position

• Horn button pressed – The horn is operated in this position.

S00660-10

23

6 CONTROLS

6.5

Light switch

The light switch  is fitted on the left side of the handlebar.

Possible states

Low beam on – The light switch is turned downward. In this position, the low beam and the tail light are switched on.

High beam on – The light switch is turned upwards. In this position, the high beam and the tail light are switched on.

6.6

S00657-10

High beam flasher button

The high beam flasher button  is fitted on the left side of the handlebar.

Possible states

• High beam flasher button in neutral position

• High beam flasher button pressed – In this position, the headlight flasher (high beam) is actuated.

24

S00659-10

6 CONTROLS

6.7

Turn signal switch

6.8

S00658-10

Emergency OFF 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 – Turn signal switch pressed to the right. The turn signal switch returns automatically to the central position after use.

To switch off the turn signal, press the turn signal switch towards the switch case.

The emergency OFF switch  is fitted on the right side of the handlebar.

Possible states

Emergency OFF switch off – In this position, the ignition circuit is interrupted, a running engine stops, and a non-running engine cannot be started.

Emergency OFF switch on – This position is required for operation; the ignition circuit is closed.

25

S00661-10

6 CONTROLS

6.9

Electric starter button

The electric starter button  is fitted on the right side of the handlebar.

Possible states

• Electric starter button in basic position

• Electric starter button pressed – In this position, the electric starter is actuated.

26

S00662-10

6.10

Ignition/steering lock

S00665-10

The ignition/steering lock is in front of the upper triple clamp.

Possible states

Ignition OFF – In this position, the ignition circuit is interrupted, a running engine stops, and a non-running engine will not start. The ignition key can be removed.

Ignition ON – In this position, the ignition circuit is closed and the engine can be started.

Steering locked – In this position, the ignition circuit is interrupted and the steering locked. The ignition key can be removed.

6 CONTROLS

6.11

Locking the steering

Note

Danger of damage The parked vehicle may roll away or fall over.

– Always place the vehicle on a firm and even surface.

– Park the vehicle.

– Turn the handlebar all the way to the left.

– Insert the key into the ignition/handlebar lock, press in, and turn to the left. Remove the key.

Steering is no longer possible.

27

400732-01

6.12

Unlocking the steering

– Insert the key into the ignition/handlebar lock, press in, and turn to the right. Remove the key.

You can now steer the bike again.

400731-01

6 CONTROLS

6.13

Combination instrument

6.13.1

Overview

3

4

1

2

Display ( p. 35)

Function buttons ( p. 33)

Info display ( p. 39)

Indicator lamps ( p. 34)

401685-10

28

6 CONTROLS

6.13.2

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.

The READY TO RACE >> logo appears on the info display.

The display then changes to the last selected mode.

29

401686-01

6 CONTROLS

6.13.3

Warning notes

Low Oil Pressure appears on the info display if the oil pressure is too low.

30

401309-01

Low Fuel Level appears on the info display if the fuel level reaches the reserve mark.

401310-01

6 CONTROLS

31

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.

Battery voltage 10.80 V

401313-01

6 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.

32

401461-01

6 CONTROLS

6.13.4

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.

(200 Duke)

Button  has no function.

(125 Duke)

The ABS can be switched off using button  .

33

401685-12

6 CONTROLS

6.13.5

Indicator lamps

401686-01

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 (onboard diagnosis) has detected an emission- or safety-critical error.

The shift warning lights up/flashes red – The set shift speed has been reached.

The idling speed indicator lamp lights up green – The transmission is shifted to idle.

The high beam indicator lamp lights up blue – The high beam is switched on.

The immobilizer indicator lamp lights up or flashes red – Status or error message for immobilizer/alarm system (optional).

The general warning lamp lights up yellow – An operating safety (warning) message was detected. This is also shown in the info display.

(125 Duke)

ABS warning lamp lights up/flashes yellow – Status or error messages relating to ABS (antilock brake system).

34

6 CONTROLS

6.13.6

Display

35

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  shows additional information.

Info

The time must be reset after the battery was disconnected or the fuse was removed.

The intensity of the LED display depends on the ambient brightness.

401685-11

6 CONTROLS

6.13.7

Filling level display in fuel tank

36

The filling level display consists of 9 bars. The more bars are lit, the more fuel is in the fuel tank.

401292-01

6 CONTROLS

6.13.8

TRIP F display

37

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.

401293-01

6 CONTROLS

6.13.9

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 – Up to three bars light up.

• Engine warm – Four to ten bars light up.

• Engine hot – Eleven to thirteen bars light up.

38

401292-01

6 CONTROLS

6.13.10 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.

39

401291-10

6 CONTROLS

6.13.11 Riding time/average speed menu

401334-01

Condition

Alternative 1

• The ignition is on.

• The motorcycle is stationary.

Alternative 2


• 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.

Info

If the ignition was switched off for over 60 minutes, the display is reset to 0.

Press the SET button briefly.

Next display mode on the info display

6.13.12 Average speed/average fuel consumption 1 menu

401465-01

Condition

Alternative 1



Alternative 2




In this menu, the average speed and the average fuel consumption 1 are displayed in

L/100 km (or L/100 miles).

40

6 CONTROLS

41

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.



6.13.13 Average fuel consumption 1/average fuel consumption 2 menu

401466-01

Condition

Alternative 1



Alternative 2




In this menu, the average fuel consumption 1 in L/100 km (or L/100 miles) and the average fuel consumption 2 in km/L (or miles/L) are displayed.

Info

The average fuel consumptions 1 and 2 are 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 fuel consumption 1 and 2 is reset to 0.



6 CONTROLS

6.13.14 Average fuel consumption 2/service menu

401467-01

Condition

Alternative 1



Alternative 2




The average fuel consumption 2 in km/L (or miles/L) and the distance to the next service are displayed in this menu.

Info

The average fuel consumption 2 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 fuel consumption 2 is reset to 0.

42



6 CONTROLS

6.13.15 Service/range menu

401468-01

Condition

Alternative 1



Alternative 2




This menu shows the distance to the next service and the range.

Info

The range depends on the average fuel consumption and the fuel quantity in the fuel tank.

The range 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 range and riding time is reset to 0.



43

6 CONTROLS

6.13.16 Range/riding time menu

401469-01

Condition

Alternative 1



Alternative 2




The range and the riding time are displayed in this menu.

Info

The range depends on the average fuel consumption and the fuel quantity in the fuel tank.

The range 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 range and riding time is reset to 0.



44

6 CONTROLS

6.13.17 Total distance menu ODO

401303-01

Condition

Alternative 1



Alternative 2



– Press the MODE button briefly and repeatedly until ODO appears on the display.

ODO shows the total distance covered.

Info

This value is retained, even if the battery is disconnected from the vehicle and/or the fuse blows.

Press the MODE button.

Next display mode on the display

45

6 CONTROLS

6.13.18 Distance menu 1 TRIP 1

401304-01

Condition

Alternative 1



Alternative 2



– Press the MODE button briefly and repeatedly until TRIP 1 appears on the display.

TRIP 1 shows the distance since the last reset, such as between two refueling stops.

TRIP 1 is always running and counts up to 999.9

.

Display of TRIP 1 is reset Press the SET button for 5 - 10 seconds.



46

6.13.19 Distance menu 2 TRIP 2

401305-01

Condition

Alternative 1



Alternative 2




TRIP 2 shows the distance since the last reset, such as between two refueling stops.

TRIP 2 is always running and counts up to 999.9

.

6 CONTROLS

Press the SET button for 5 - 10 seconds.


Display of TRIP 2 is reset


6.13.20 Setting kilometers or miles

Info

Make the country-specific setting.

Condition

The ignition is on.

The motorcycle is stationary.


– Press the MODE button for 5 - 10 seconds.

The display changes from km/h to mph or from mph to km/h .

47

6.13.21 Setting the time

401303-01

Condition

The ignition is on.


6 CONTROLS


– Press the MODE and SET buttons for 5 - 10 seconds.

The time display begins to flash.

– Set the hours display using the MODE button.

– Set the minutes display using the SET button.

– Press the MODE and SET buttons for 5 - 10 seconds.

The time is set.

401303-01

6.13.22 Adjusting the shift speed RPM 1

401307-01

Condition

The ignition is on.



– Press the MODE button for 5 - 10 seconds.

The display RPM 1 appears.

Info

The engine speed can be set at intervals of 50.

RPM 1 is the engine speed above which the shift warning light starts flashing.

– Set the speed with the MODE and SET buttons.

Info

The MODE button increases the value.

The SET button decreases the value.

– Do not activate the two buttons for approx. 15 seconds.

48

6 CONTROLS

The display RPM 1 goes out and the set speed is stored.

6.13.23 Adjusting the shift speed RPM 2

401308-01

Condition

The ignition is on.



– 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 constantly.

The speed RPM 2 must always be higher than the speed RPM 1 .

– Set the speed with the MODE and SET buttons.

Info

The MODE button increases the value.

The SET button decreases the value.

– Do not activate the two buttons for approx. 15 seconds.

The display RPM 2 goes out and the set speed is stored.

49

6 CONTROLS

50

6.14

Opening the filler cap

Danger

Fire hazard Fuel is highly flammable.

– Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.

– The fuel in the fuel tank expands when warm and may emerge if overfilled. Follow the instructions on refueling.

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. If fuel is swallowed, contact a physician immediately. Change clothing that has been contaminated with fuel. Store fuel properly in a suitable canister and keep away from children.

Warning



– Lift the cover  of the filler cap and insert the ignition key in the lock.

Note

Danger of damage Ignition key breakage.

– To take pressure off of the ignition key, push down on the filler cap. Damaged ignition keys must be replaced.

– Turn the ignition key 90° clockwise.

– Open the filler cap.

B00710-10

6 CONTROLS

– Remove the ignition key.

6.15

Closing the filler cap

B00711-01

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 clothing that has been contaminated with fuel. Immediately clean contaminated areas on the skin with soap and water.

– Close the filler cap.

– Push down the filler cap until the lock engages.

51

6.16

Seat lock

The seat lock  is located to the left of the seat.

It can be locked with the ignition key.

B00712-01

6 CONTROLS

6.17

Tool set

The tool set  is located under the passenger seat.

6.18

Grab handles

B00758-10

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

52

6 CONTROLS

6.19

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.

6.20

Shift lever

S00666-10

Shift lever  is mounted on the left side of the engine.

53

401950-10

6 CONTROLS

The gear positions can be seen in the photograph.

The neutral or idle position is between the first and second gears.

6.21

Foot brake lever

401950-11

Foot brake lever  is located in front of the right footrest.

The foot brake lever is used to activate the rear brake.

402177-10

54

6 CONTROLS

6.22

Side stand

402029-10

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 – The vehicle can be leaned on the side stand. The safety start system is active.

• Side stand folded in – This position is mandatory for all trips. The safety start system is inactive.

55

7 PREPARING FOR USE

7.1

Advice on first use

Danger

Danger of accidents Danger arising from the rider's judgement being impaired.

– Do not operate the vehicle while under the influence of alcohol, drugs and certain medications or physically or mentally impaired.

Warning

Risk of injury Missing or poor protective clothing presents an increased safety risk.

– 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.

Warning

Danger of crashing Poor vehicle handling due to different tire tread patterns on front and rear wheels.

– 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 Non-approved or non-recommended tires and wheels impact the handling characteristic.

– Only use tires/wheels approved by KTM with the corresponding speed index.

Warning

Danger of accidents Reduced road grip with new tires.

– New tires have a smooth rolling surface and therefore cannot provide full road grip. The entire rolling surface must be roughened in the first 200 kilometers (124.3 miles) by moderate riding at alternating angles. The full grip levels are not achieved until the tires have been run in.

56

Info

When using your vehicle, remember that others may feel disturbed by excessive noise.


57

– 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 and Warranty Booklet at vehicle handover.

– Before your first trip, read the entire operating instructions carefully.

– Get to know the controls.

– Get used to handling the motorcycle on a suitable piece of land before making a longer trip. Try also to ride as slowly as possible to get a better feel for the vehicle.

– Hold the handlebar firmly with both hands and keep your feet on the footrests when riding.

–

Run the engine in. ( p. 57)

7.2

Running in the engine

– During the running-in phase, do not exceed the specified engine speed.

Guideline

Maximum engine speed

During the first: 1,000 km (620 mi) 7,500 rpm

Tip

During the running-in phase, set the shift warning light to the specified engine speed.

– Adjust the shift speed RPM 1

. ( p. 48)

– Adjust the shift speed RPM 2

. ( p. 49)

– Avoid fully opening the throttle!


7.3

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.

– Mount and secure suitcase and tank rucksack according to the manufacturer's instructions.

Warning

Danger of accidents Risk of breakage of suitcase system.

– If you have fitted suitcases on your motorcycle, read the manufacturer's specifications concerning the maximum payload.

Warning

Danger of accidents Poor visibility for other road users due to slipped baggage.

– If the tail light is covered, you are less visible to traffic behind you, especially when it is dark. Check that your baggage is fixed properly at regular intervals.

Warning

Danger of accidents Changed handling characteristics and longer stopping distance with excessive payload.

– Adapt your speed according to your payload.

Warning

Danger of accidents Unstable handling characteristics due to slipped baggage.

– Check the way your baggage is fixed regularly.

58


– 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 distribution 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.)

Maximum permissible front axle load

Maximum permissible rear axle load

125 kg (276 lb.)

210 kg (463 lb.)

59

8 RIDING INSTRUCTIONS

8.1

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. 153)

–

Check the brake fluid level of the front brake. ( p. 97)

–

Check the rear brake fluid level. ( p. 102)

–

Check the front brake linings. ( p. 100)

–

Check the rear brake linings. ( p. 107)

– Check the brake system function.

–

Check the coolant level. ( p. 145)

–

Check for chain dirt accumulation. ( p. 83)

–

Check the chain tension. ( p. 84)

–

Check the tire condition. ( p. 119)

–

Check the tire air pressure. ( p. 121)

– Check the settings of all controls and ensure that they can be operated smoothly.

– Check the functioning of the electrical equipment.

– Check that baggage is correctly secured.

– Sit on the motorcycle and check the rear mirror setting.

– Check the fuel level.

60


8.2

Starting

Danger



Caution

Danger of accidents If the vehicle is operated with a discharged battery or without a battery, electronic components and safety equipment may be damaged.

– Never operate the vehicle with a discharged battery or without a battery.

Note

Engine failure Unfiltered intake air has a negative effect on the service life of the engine.

– Never operate the vehicle without an air filter as dust and dirt will enter the engine and lead to increased wear.

Note

Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine.

– Always warm up the engine at low engine speeds.

61


B00782-10

62

–

Unlock the steering. ( p. 27)

– 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. The function check of the combination instrument is run at the same time.

– Shift gear to neutral.

The green idling speed indicator lamp N lights up.

(125 Duke)

The ABS warning lamp lights up and goes back out after starting off.

– Press the electric starter button .

Info

Do not press the electric starter button until the combination instrument function check is finished.

When starting, DO NOT open the throttle. If you open the throttle during the starting procedure, fuel is not injected by the engine management system and the engine cannot start.

Press the starter for a maximum of 5 seconds. Wait for a least 5 seconds before trying again.

This motorcycle is equipped with a safety starting system. You can only start the engine if the transmission is in neutral or if the clutch is pulled when a gear is engaged. If the side stand is folded out and you shift into gear and release the clutch, the engine stops.


Switching off ABS (125 Duke)

KTM recommends riding with ABS at all times. However, situations may arise in which

ABS is not advantageous.

Condition

Vehicle stationary, engine running.

– Press the  button for 3 – 5 seconds.

The ABS warning lamp starts flashing; ABS is deactivated.

63

401685-15

8.3

Starting off

– Pull the clutch lever, engage 1st gear, release the clutch lever slowly, and simultaneously open the throttle carefully.

Tip

If the engine dies while starting off, only pull the clutch lever and press the electric starter button. You do not need to shift into neutral.

8.4

Shifting, riding

Warning

Danger of accidents Abrupt load alterations can cause the vehicle to get out of control.

– Avoid abrupt load alterations and sudden braking actions, and adapt your speed to the road conditions.

Warning

Danger of accidents If you change down at high engine speed, the rear wheel can lock up.

– Do not change into a low gear at high engine speed. The engine races and the rear wheel can lock up.


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.

– The passenger must be seated properly on the passenger seat and hold on to the front rider or the grab handles. The feet must be positioned on the passenger footrests. Note the regulations governing the minimum age of passengers.

Warning

Danger of accidents Danger of accidents caused by dangerous driving.

– Comply with traffic regulations and ride defensively and foresightedly to detect sources of danger early on.

Warning

Danger of accidents Reduced road grip with cold tires.

– On every journey, take the first miles carefully at moderate speed until the tires reach operating temperature and optimal road grip is ensured.

Warning

Danger of accidents Reduced road grip with new tires.

– New tires have a smooth rolling surface and therefore cannot provide full road grip. The entire rolling surface must be roughened in the first 200 kilometers (124.3 miles) by moderate riding at alternating angles. The full grip levels are not achieved until the tires have been run in.

64


Warning

Danger of accidents Unstable handling characteristics due to slipped baggage.

– Check the way your baggage is fixed regularly.

Warning

Danger of accidents Lack of roadworthiness.

– After a fall, check the vehicle as usual before preparing for use.

65

Note

Engine failure Overheating damages the engine.

– If the coolant temperature warning is displayed, stop immediately and take care not to endanger yourself or other traffic participants in the process.

– Allow the engine and cooling system to cool down.

– Check and, if necessary, correct the coolant level on the cooling system while it is in a cooled state.

Info

If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized KTM workshop.

401950-11

– When conditions allow (incline, road situation, etc.), you can shift into a higher gear.

– Release the throttle while simultaneously pulling the clutch lever, shift into the next gear, release the clutch and open the throttle.

Info

You can see the positions of the 6 forward gears in the figure. The neutral or idle position is between the first and second gears. First gear is used for starting off or for steep inclines.

The operating temperature is reached when 4 bars of the temperature indicator light up.


66

– Accelerate only up to a speed suitable for the road surface and weather conditions. Particularly in bends, do not shift, and accelerate very carefully.

– To shift down, brake if necessary and close the throttle at the same time.

– Pull the clutch lever and shift into a lower gear, release the clutch lever slowly and open the throttle or shift again.

– Switch off the engine if you expect to be standing for a long time.

– If the engine diagnosis warning lamp lights up during a trip, stop immediately, switch off the engine, and contact an authorized KTM workshop.

8.5

Applying the brakes

Warning

Danger of accidents Reduced braking efficiency due to a wet or dirty brake system.

– Clean or dry a dirty or wet brake system by riding and braking gently.

Warning

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.

– If the foot brake lever is not released, the brake linings drag continuously. The rear brake may fail due to overheating. Take your foot off the foot brake lever when you are not braking.

Warning

Danger of accidents Longer stopping distance due to higher overall weight.

– Take the longer stopping distance into account when carrying a passenger and baggage.


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.

67

(200 Duke)

Warning

Danger of accidents If you brake too hard, the wheels can lock.

– Adapt your braking to the traffic situation and the road conditions.

– When braking, release the throttle and apply the front and rear brakes at the same time.

– On sandy, wet, or slippery surfaces, use the rear brake.

– Braking should always be completed before you go into a bend. Change down to a lower gear appropriate to your road speed.

– On long downhill stretches, use the braking effect of the engine. Change down one or two gears, but do not over rev the engine. In this way, you have to brake far less and the brakes do not overheat.

(125 Duke)

Warning

Danger of accidents Greater stopping distance due to ABS.

– Braking should be appropriate to the driving situation and the road conditions.

Warning

Danger of accidents Very forceful braking can cause the wheels to block.

– ABS must be switched on to be effective.

– When braking, release the throttle and apply the front and rear brakes at the same time.


Info

When ABS is active, you can achieve maximum braking power even on low grip surfaces such as sandy, wet, or slippery terrain without locking of the wheels.

68

Warning

Danger of accidents Locking of the wheels due to braking action of the engine.

– Pull the clutch during emergency braking, full brake application and when braking on a slippery surface.

Warning

Danger of accidents Road grip is reduced when braking with the motorcycle at an angle or on a laterally inclined surface.

– Braking should be completed before you enter into a bend.

– Braking should always be completed before you go into a bend. Change down to a lower gear appropriate to your road speed.

– On long downhill stretches, use the braking effect of the engine. Change down one or two gears, but do not over rev the engine. In this way, you have to brake far less and the brakes do not overheat.

8.6

Stopping, parking

Warning

Risk of misappropriation Usage by unauthorized persons.

– Never leave the vehicle unattended 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.

– Do not touch hot components such as exhaust system, radiator, engine, shock absorber, and the brake system. Allow these components to cool down before starting work on them.

Note

Material damage The vehicle may be damaged by incorrect procedure when parking.


Significant damage may be caused if the vehicle rolls away or falls over.

The components for parking the vehicle are designed only for the weight of the vehicle.

– Park the vehicle on a firm and level surface.

– Ensure that nobody sits on the vehicle when the vehicle is parked on a stand.

Note

Fire hazard Some vehicle components become very hot when the vehicle is operated.

– Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from being run. Always let the vehicle cool first.

69

– Apply the brakes on the motorcycle.


– 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.

– Park the motorcycle on a firm surface.

– Swing the side stand forward with your foot as far as it will go and lean the vehicle on it.

–

Lock the steering. ( p. 27)

8.7

Transport

Note




Note

Fire hazard Some vehicle components become very hot when the vehicle is operated.

– Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from being run. Always let the vehicle cool first.

70

– Switch off the engine and remove the ignition key.

– Use tension belts or other suitable devices to secure the motorcycle against accidents or falling over.

401448-01

8.8

Refueling

Danger

Fire hazard Fuel is highly flammable.

– Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.

– The fuel in the fuel tank expands when warm and may emerge if overfilled. Follow the instructions on refueling.

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. If fuel is swallowed, contact a physician immediately. Change clothing that is contaminated with fuel.


Note

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.)

– Only refuel with clean fuel that meets the specified standards.

71

Warning



B00719-10

– Switch off the engine.

–

Open the filler cap. ( p. 50)

– Fill the fuel tank with fuel up to the lower edge  of the fuel filler.

Total fuel tank capacity, approx.

11 l (2.9 US gal) Super unleaded (ROZ 95/RON 95/PON

91) ( p. 184) (125 Duke EU,

200 Duke EU/AR/ASIA/CN/MY)

Gasohol 95 E20 (RON 95) ( p. 184)

(200 Duke TH)

–

Close the filler cap. ( p. 51)

9 SERVICE SCHEDULE

9.1

Additional information

Any further work that results from the required work or from the recommended work must be ordered separately and invoiced separately.

72

9.2

Required work

Read out the fault memory using the KTM diagnostics tool.

Check that the electrical system is functioning properly.

Change the engine oil and oil filter, clean the oil screen.

( p. 153)

Check the brake discs. ( p. 96)



Check the tire condition. ( p. 119)


Check the brake lines for damage and leakage.

Check the brake fluid level of the front brake. ( p. 97)

Check the rear brake fluid level. ( p. 102)

Check the shock absorber and fork for leaks.

Clean the dust boots of the fork legs.

Check the chain, rear sprocket, and engine sprocket. ( p. 89)


Every two years

Every year

Every 15,000 km (9,300 mi)

Every 7,500 km (4,650 mi)

After 1,000 km (620 mi)

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Check the coolant level. (

Check that the radiator fan is functioning properly.

Change the air filter. Clean the air filter box.

Check the valve clearance.

p. 145)

Check that the throttle cables are undamaged, routed without sharp bends, and set correctly.

Check the cables for damage and routing without sharp bends.

Every two years

Every year

Every 15,000 km (9,300 mi)

Every 7,500 km (4,650 mi)

After 1,000 km (620 mi)

○

○

○

○

○

●

●

●

●

● ●

● ●

● ●

●

●

●

●

●

●

●

●

Check the valve clearance, change the spark plugs.

Change the front brake fluid.

●

Change the rear brake fluid.

Check the steering head bearing play.

●

●

●

●

Check the headlight setting. ( p. 138)

Final check: Check the vehicle for roadworthiness and take a test ride.

Read out the error memory after the test ride using the KTM diagnostics tool.

Reset the service interval display.

Make the service entry in the KTM Dealer.net

and in the Service and Warranty Booklet.

○

○

○

○

○

○

● ●

● ●

● ●

● ●

● ●

● ●

●

●

●

●

●

●

○ One-time interval

● Periodic interval

73


9.3

Recommended work

Check the antifreeze.

Change the coolant.

Grease all moving parts (e.g., side stand, hand lever, chain, ...) and check for smooth operation.

Every four years

Every year

Every 7,500 km (4,650 mi)

After 1,000 km (620 mi)

○ ● ●

○

○

●

●

●

●

●

●

● Check all hoses (e.g. fuel, coolant, bleeder, drainage, etc.) and sleeves for cracking, leaks, and incorrect routing.

Check the swingarm bearing.

Check the wheel bearing for play.

Check the screws and nuts for tightness.

●

●

○ ● ● ●

○ One-time interval

● Periodic interval

74

10 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.

The best spring preload setting is achieved when it is set for the weight of the rider and that of any baggage and a passenger, thus ensuring an ideal compromise between maneuverability and stability.

B01419-10

– Turn adjusting ring  to adjust the spring preload.

Guideline

Spring preload

Standard

Full payload

3 clicks

6 clicks

Hook wrench (T106S)

Info

The spring preload can be set to 10 different positions.

75

10 TUNING THE CHASSIS

10.2

Adjusting the shift lever

Info

The adjustment range of the shift lever is limited.

S00667-10

– Loosen nuts  .

– Adjust the shift lever by turning shift rod  .

Guideline

Shift rod adjustment range  110… 122 mm (4.33… 4.8 in)

Info

Make the same adjustments on both sides.

At least five screw threads must be screwed into the seating.

– Check adjusting angle  .

Guideline

Adjusting angle shift lever

 shift rod, deflector,

– Tighten nuts  .

90°

Info

After the nuts have been tightened, the bearings of the shift rod must be centrally and identically aligned to each other in order to ensure freedom of movement in the bearing shells.

– Check the shift lever to ensure it is functioning properly and can move freely.

76

11 SERVICE WORK ON THE CHASSIS

11.1

Raising the motorcycle with the rear wheel stand

Note



77

– Mount the supports of the wheel stand.

– Insert the adapter in the rear wheel stand.

Bushing kit for lifting gear (90229955044)

Universal V adapter (61029955244)

Lifting gear, rear (61029055400)

– Stand the motorcycle upright, align the lifting gear with the swingarm and the adapters, and lift the motorcycle.

S00682-01

11.2

Taking the motorcycle off of the rear wheel stand

Note




– Secure the motorcycle against falling over.

– Remove the rear wheel stand and lean the vehicle on the side stand  .

78

402029-10

11.3

Raising the motorcycle with the front wheel stand

Note



Preparatory work

–

Raise the motorcycle with the rear wheel stand. ( p. 77)

Condition

– Remove protection cap  .

M00005-10


– Move the handlebar to the straight-ahead position. Position the wheel stand.

Adapter (61029955620)

Lifting gear, front (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

Note



Main work

– Secure the motorcycle against falling over.

– Remove the front wheel stand.

79

B01388-01


– Mount protection cap  .

M00005-10

Finishing work

–

Take the motorcycle off of the rear wheel stand. ( p. 77)

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.

– Remove the ignition key from the seat lock.

B00712-01

80


11.6

Mounting the passenger seat

B00724-10

81

– 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.

– After mounting the passenger seat, check that it is locked correctly by pulling up.

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

11.7

Removing the seat


–

Remove the passenger seat. ( p. 80)

Main work

– Remove screws  .

– Raise the rear of the seat, pull it towards the rear, and remove it upwards.

B00725-10


11.8

Mounting the seat

Main work

– Attach seat recesses 

– Mount and tighten screws at screws

 .

 and lower at the rear.

Guideline

Screw, seat M6 10 Nm (7.4 lbf ft)

82

B00727-10

Finishing work

–

Mount the passenger seat. ( p. 81)


11.9

Checking for chain dirt accumulation

– Check the chain for coarse dirt accumulation.

» If the chain is very dirty:

–

Clean the chain. ( p. 83)

400678-01

11.10

Cleaning the chain

Warning

Danger of accidents Oil or grease on the tires reduces their grip.

– Remove oil and grease with a suitable cleaning material.

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.

Warning

Environmental hazard Hazardous substances cause environmental damage.

– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

83


Info

The service life of the chain depends largely on its maintenance.

84


–


Main work

– Clean the chain regularly.

– Rinse off loose dirt with a soft jet of water.

– Remove old grease remains with chain cleaner.

Chain cleaner ( p. 185)

– After drying, apply chain spray.

Chain lube for road use ( p. 185)

400725-01

Finishing work

–


11.11

Checking 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. In addition to premature wear, this can cause the chain or the countershaft of the transmission to break in extreme cases. If the chain is too loose, however, it may fall off the engine sprocket or rear sprocket and block the rear wheel or damage the engine. Ensure that the chain tension is correct and adjust it if necessary.



–


Main work


– In the area of the chain sliding guard, press the chain upward toward the swingarm and determine chain tension  .

85

Info

Upper chain section  must be taut.

Chain wear is not always even, so you should repeat this measurement at different chain positions.

Chain tension 5… 7 mm (0.2… 0.28 in)

» If the chain tension does not meet the specification:

–

Adjust the chain tension. ( p. 86)

B00731-10

Finishing work

–



86

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. In addition to premature wear, this can cause the chain or the countershaft of the transmission to break in extreme cases. If the chain is too loose, however, it may fall off the engine sprocket or rear sprocket and block the rear wheel or damage the engine. Ensure that the chain tension is correct and adjust it if necessary.


–


–



Main work

(200 Duke)

– Loosen nut  .

– Loosen nuts  .

– Adjust the chain tension by turning adjusting screws  left and right.

Guideline


Turn the adjusting screws  left and right chain adjusters on the left and right so that the markings on the

 are in the same position relative to the reference marks  . The rear wheel is then correctly aligned.

87

S00668-10

Info

The upper part of the chain must be taut.

Chain wear is not always even, so you should check the setting at different chain positions.

– Tighten nuts  .

– Make sure that chain adjusters  are fitted correctly on adjusting screws  .

– Tighten nut  .

Guideline

Nut, rear wheel spindle M14x1.5

90 Nm

(66.4 lbf ft)


(125 Duke)

– Loosen nut

– Loosen nuts

 .

 .

– Adjust the chain tension by turning adjusting screws  left and right.

Guideline


Turn the adjusting screws  on the left and right so that the markings on the left and right chain adjusters  are in the same position relative to the reference marks  . The rear wheel is then correctly aligned.

88

S00669-10

Info

The upper part of the chain must be taut.

Chain wear is not always even, so you should check the setting at different chain positions.

– Tighten nuts  .

– Make sure that chain adjusters

– Tighten nut  .

 are fitted correctly on adjusting screws  .

Guideline


90 Nm

(66.4 lbf ft)

Finishing work

–



11.13

Checking the chain, rear sprocket, and engine sprocket


–


Main work

– 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.

89

100132-10



– Pull the lower chain section with specified weight  .

Guideline

Weight, chain wear measurement 15 kg (33 lb.)

– Measure distance  of 20 chain rollers in the lower chain section.

Info

Chain wear is not always even, so you should repeat this measurement at different chain positions.

90

1 2 3 18 19 20

401288-10

Maximum distance chain section

 at the longest 301.6 mm (11.874 in)

» If distance  is greater than the specified measurement:

– Change the power set.

Info

When the chain is replaced, the rear sprocket and engine sprocket should also be changed.

New chains wear out faster on old, worn sprockets.


– Remove screws  ,  and  . Push the chain guard aside.

91

S00670-10

– Check the chain sliding guard for wear.

» If the chain sliding guard has lost material due to wear to the extent that, in area  , drilled hole  is visible from above:

– Change the chain sliding guard.

– Check that the chain sliding guard is firmly seated.

» If the chain sliding guard is loose:

– Tighten the screws on the chain sliding guard.

C00199-10


– Position the chain guard and tighten screw  .

Guideline

Screw, chain guard EJOT PT ®

– Tighten screw  .

Guideline

Screw, chain guard EJOT PT ®

– Tighten screw  .

Guideline

Remaining screws, chassis M5

4 Nm (3 lbf ft)

4 Nm (3 lbf ft)

5 Nm (3.7 lbf ft)

92

S00670-10

Finishing work

–



11.14

Removing the front spoiler

– Remove screws  .

B00770-10

– Remove screws  .

– Take off the front spoiler.

B00771-10

93


11.15

Fitting front spoiler

– Position the front spoiler. Mount screws  but do not tighten yet.

94

B00770-10

– Mount and tighten screws  .

Guideline

Screw, front spoiler

– Tighten screw  .

Guideline


B00771-10

M6

M6

9 Nm (6.6 lbf ft)

9 Nm (6.6 lbf ft)

12 BRAKE SYSTEM

95

12.1

Antilock Braking System (ABS) (125 Duke)

The ABS unit  , which consists of a hydraulic unit, ABS control unit, and return pump, is installed under the seat. A wheel speed sensor  is located at the front and rear wheels.

Warning

Danger of accidents Changes to the vehicle impair the function of the ABS.

– Only allow the rear wheel to spin with the front brake applied away from public road traffic if the ABS is switched off.

– Do not make any changes to the suspension travel.

– Only use spare parts on the brake system which have been approved and recommended by KTM.


– Maintain the specified tire air pressure.

– Service work and repairs must be performed professionally. (Your authorized

KTM workshop will be glad to help.)

The ABS is a safety system that prevents locking of the wheels when driving straight ahead without the influence of lateral forces.

Warning

Danger of accidents Vehicle rollover

– It is not always possible to prevent vehicle rollover in extreme riding situations

(e. g. luggage loaded with a high center of gravity, varying road surfaces, steep descents, full braking without disengaging the gear). Adapt your riding style to the road conditions and your driving ability.

401687-10

The ABS operates with two independent brake circuits (front and rear brakes). During normal operation, the brake system operates like a conventional brake system without ABS.

When the ABS control unit detects a locking tendency in a wheel, ABS begins regulating

12 BRAKE SYSTEM

96 the brake pressure. The regulating process causes a slight pulsing of the hand and foot brake levers.

ABS warning lamp  must light up after the ignition is switched on and go out after starting off. If it does not go out after starting off or if it lights up while riding, this indicates a fault in the ABS. In this case, the ABS is no longer enabled and the wheels may lock during braking. The brake system itself stays functional; only ABS control is not available.

The ABS warning lamp may also light up if the rotating speeds of the front and rear wheels differ greatly under extreme riding conditions, for example when making wheelies or if the rear wheel spins. This causes the ABS to switch off.

To reenable the ABS, the vehicle must be stopped and the ignition switched off. The ABS is reenabled when the vehicle is switched on again. The ABS warning lamp goes out when you start off.

Button  can be used to switch ABS off manually (see Starting).

12.2

Checking the brake discs

Warning

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.)

400480-10

– Check the thickness of the front and rear brake discs at multiple points on each brake disc to ensure it is at least thickness  .

Info

Wear will reduce the thickness of the brake disc at contact surface brake linings.

 of the

Brake discs - wear limit

Front

Rear

3.6 mm (0.142 in)

3.6 mm (0.142 in)

12 BRAKE SYSTEM

» If the brake disc thickness is less than the specified value.

– Change the front brake disc.

– Change the rear brake disc.

– Check the front and rear brake discs for damage, cracking, and deformation.

» If the brake disc exhibits damage, cracking, or deformation:

– Change the front brake disc.

– Change the rear brake disc.

12.3

Checking the brake fluid level of the front brake

Warning

Danger of accidents Failure of the brake system.

– 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.)

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.)

97

12 BRAKE SYSTEM

– Move the brake fluid reservoir mounted on the handlebar to a horizontal position.

– Check the brake fluid level in viewer  .

» If the brake fluid level is below the MIN marking:

– Add front brake fluid.

( p. 98)

98

C00200-10

12.4

Adding front brake fluid

Warning



Warning

Skin irritation Brake fluid can cause skin irritation on contact.

– Avoid contact with skin and eyes, and keep out of the reach of children.

– Wear suitable protective clothing and goggles.

– If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately.

Warning



12 BRAKE SYSTEM

Warning



Info

Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!

Use only clean brake fluid from a sealed container.

C00201-10


–


Main work

– Move the brake fluid reservoir mounted on the handlebar to a horizontal position.

– Remove screws

– Remove cover

 .

 with membrane  .

– Add brake fluid to level  .

Guideline

Level  5 mm (0.2 in)

Brake fluid DOT 4 / DOT 5.1 ( p. 182)

– Position the cover with the membrane. Mount and tighten the screws.

Info

Clean up overflowed or spilt brake fluid immediately with water.

99

12 BRAKE SYSTEM

12.5

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.

– If the brake linings are not changed in time, the steel brake lining carriers grind on the brake disc. The braking effect is greatly reduced and the brake discs are destroyed. Check the brake linings regularly.

100

– Check the brake linings for minimum thickness  .

Minimum thickness  ≥ 1 mm ( ≥ 0.04 in)

» If the minimum thickness is less than specified:

– Change the front brake linings.

– Check the brake linings for damage and cracking.

» If there is wear or tearing:

– Change the front brake linings.

B00739-10

12.6

Checking the free travel of foot brake lever

Warning

Danger of accidents Brake system failure.

– If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to overheating. Adjust the free travel on foot brake lever according to specifications.

12 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)

» If the free travel does not meet specifications:

– Adjust the free travel of the foot brake lever.

( p. 101)

– Reconnect spring  .

101

S00671-10

12.7

Adjusting the free travel of the foot brake lever

Warning

Danger of accidents Brake system failure.

– If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to overheating. Adjust the free travel on foot brake lever according to specifications.

12 BRAKE SYSTEM

– Disconnect spring

– Release nut 

 .

and use screw  to adjust the specified free travel  .

Guideline

Free travel at foot brake lever 3… 5 mm (0.12… 0.2 in)

Info

The range of adjustment is limited.

– Hold screw 

– Attach spring and tighten nut

 .

 .

102

S00672-10

12.8

Checking the rear brake fluid level

Warning



12 BRAKE SYSTEM

Warning



103

(200 Duke)

– Stand the vehicle upright.

– Check the brake fluid level in the brake fluid reservoir.

» If the fluid level reaches the MIN marking

– Add rear brake fluid.

( p. 104)

 :

C00202-10

(125 Duke)


– Check the brake fluid level in the brake fluid reservoir.

» If the fluid level reaches the MIN marking

– Add rear brake fluid.

( p. 104)

 :

307292-10

12 BRAKE SYSTEM

12.9

Adding rear brake fluid

Warning



Warning

Skin irritation Brake fluid can cause skin irritation on contact.

– Avoid contact with skin and eyes, and keep out of the reach of children.


– If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately.

Warning



Warning



104

Info

Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!

Use only clean brake fluid from a sealed container.


–


12 BRAKE SYSTEM

Main work

(200 Duke)

Condition

The screw cap is locked.

– Remove screw  and take off the screw cap lock.

105

H01142-10

C00203-11


– Remove screw cap  with membrane  .



– Mount screw cap with membrane.

Info

Clean up overflowed or spilled brake fluid immediately with water.

Condition


– Position the screw cap lock and mount and tighten screw  .

Guideline

Screw, compensating tank cap lock, rear brake

M5 7 Nm (5.2 lbf ft)

H01142-10

12 BRAKE SYSTEM

(125 Duke)

Condition


– Remove screw  and take off the screw cap lock.

106

H01142-10

307293-11


– Remove screw cap  with membrane  .



– Mount screw cap with membrane.

Info

Clean up overflowed or spilled brake fluid immediately with water.

Condition


– Position the screw cap lock and mount and tighten screw  .

Guideline

Screw, compensating tank cap lock, rear brake

M5 7 Nm (5.2 lbf ft)

H01142-10

12 BRAKE SYSTEM

12.10

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.

– If the brake linings are not changed in time, the steel brake lining carriers grind on the brake disc. The braking effect is greatly reduced and the brake discs are destroyed. Check the brake linings regularly.

– Check the brake linings for minimum thickness  .

Minimum thickness  ≥ 1 mm ( ≥ 0.04 in)

» If the minimum thickness is less than specified:

– Change the rear brake linings.

– Check the brake linings for damage and cracking.

» If there is wear or tearing:

– Change the rear brake linings.

M00006-10

107

13 WHEELS, TIRES

13.1

Removing the front wheel

108

B00743-10


–


–

Raise the motorcycle with the front wheel stand. ( p. 78)

Main work

(200 Duke)

– Loosen screw  by several rotations.

– Release screws

– Press on screw

 .

 to push the wheel spindle out of the axle clamp.

– Remove screw  .

Warning

Danger of accidents Reduced braking effect caused by damaged brake discs.

– Always lay the wheel down in such a way that the brake discs are not damaged.

– Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of the fork.

Info

Do not pull the hand brake lever when the front wheel is removed.


109

(125 Duke)

– Remove screws

– Remove screw

 and push the fender to the side.

 and pull wheel speed sensor  out of the hole.

– Loosen screw

– Release screws

 by several rotations.

 .

– Press on screw

– Remove screw



 .

to push the wheel spindle out of the axle clamp.

Warning



– Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of the fork.

Info

Do not pull the hand brake lever when the front wheel is removed.

B01391-12

13.2

Installing the front wheel

Warning




B00744-10

Main work

(200 Duke)

– Check the wheel bearing for damage and wear.

» If the wheel bearing is damaged or worn:

– Change the wheel bearing.

– Clean and grease the shaft seal rings  and mating surfaces  of the spacers.

Long-life grease ( p. 185)

– Insert the spacers.

– 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 M8 26 Nm

(19.2 lbf ft)

– Operate the hand brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point.

–

Take the motorcycle off of the front wheel stand. ( p. 79)

– Operate the front brake and compress the fork a few times firmly.

The fork legs straighten.

– Tighten screws  .

Guideline

Screw, fork stub M8 15 Nm

(11.1 lbf ft)

110


B01392-10

(125 Duke)






– Insert the spacers.

111

– Clean the thread of the wheel spindle and screw  .

– Position the front wheel and insert the wheel spindle.


– Mount and tighten screw  .

Guideline

Screw, front wheel spindle M8 26 Nm

(19.2 lbf ft)

– Position wheel speed sensor

– Mount and tighten screw  .

 in the drill hole.

Guideline

Screw, wheel speed sensor holder M6 8 Nm (5.9 lbf ft)

– Mount and tighten screws  .

– Operate the hand brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point.

–


– Operate the front brake and compress the fork a few times firmly.

B01391-11


13.3

Removing the rear wheel

The fork legs straighten.

– Tighten screws  .

Guideline

Screw, fork stub M8

Finishing work

–



–


15 Nm

(11.1 lbf ft)

112


113

Main work

(200 Duke)

– Remove nut  and washer.

– Remove chain adjuster  .

– Hold rear wheel and wheel spindle  pull out with washer and chain adjuster  .

– Push the rear wheel forward as far as possible and take the chain off the rear sprocket.

Warning



– Pull the rear wheel back and take it out of the swingarm.

Info

Do not operate the foot brake lever when the rear wheel is removed.

S00673-10


114

(125 Duke)

– Remove screw

– Remove nut 

 and pull wheel speed sensor and washer.

 out of the hole.

– Remove chain adjuster  .

– Hold rear wheel and wheel spindle  pull out with washer and chain adjuster  .

– Push the rear wheel forward as far as possible and take the chain off the rear sprocket.

Warning



– Pull the rear wheel back and take it out of the swingarm.

Info

Do not operate the foot brake lever when the rear wheel is removed.

S00674-10

13.4

Installing the rear wheel

Warning




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.

S00676-10

Main work

(200 Duke)

– Check the rear hub rubber dampers.

( p. 118)






– Clean threads of wheel spindle and axle nut.

– Clean the fixing locations on the brake caliper support and swingarm.

– Install the rubber damper and rear sprocket carrier on the rear wheel.

– Position the rear wheel.


– Position the rear wheel on the contact surfaces in the swingarm.

– Push the rear wheel as far forward as possible and place the chain on the rear sprocket.

115


– Pull the rear wheel back and mount wheel spindle adjuster  .

 with the washer and chain

Guideline

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 nut  .

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  .


90 Nm

(66.4 lbf ft)

116

(125 Duke)

– Check the rear hub rubber dampers.

( p. 118)

S00673-11






– Clean threads of wheel spindle and axle nut.

– Clean the fixing locations on the brake caliper support and swingarm.

S00675-10


S00674-11

– Install the rubber damper and rear sprocket carrier on the rear wheel.

– Position the rear wheel.


– Push the rear wheel as far forward as possible and place the chain on the rear sprocket.

– Pull the rear wheel back and mount wheel spindle adjuster  .

 with the washer and chain

Guideline

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 nut  .

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  .

117


90 Nm

(66.4 lbf ft)

– Position wheel speed sensor

– Mount and tighten screw  .

 in the drill hole.

Guideline

Screw, wheel speed sensor holder M6

Finishing work

–


–


8 Nm (5.9 lbf ft)


–


13.5

Checking the rear hub rubber dampers

Info

The engine power is transmitted from the rear sprocket to the rear wheel via 6 rubber dampers. They eventually wear out during operation. If the rubber dampers are not changed in time, the rear sprocket carrier and the rear hub will be damaged.

118


–


– Remove the rear wheel.

( p. 112)

Main work

– Check bearing  .

» If the bearing is damaged or worn:

– Change the bearing.

– Check the rubber dampers  of the rear hub for damage and wear.

» If the rubber dampers of the rear hub are damaged or worn:

– Change all rubber dampers in the rear hub.

S00677-10


S00678-10

119

– Lay the read wheel on a workbench with the rear sprocket facing upwards and insert the wheel spindle in the hub.

– To check the play  , hold the rear wheel tight and try to rotate the rear sprocket.

Info

Measure the play on the outside of the rear sprocket.

Play in rubber dampers, rear wheel ≤ 5 mm ( ≤ 0.2 in)

» If play  is larger than the specified value:

– Change all rubber dampers in the rear hub.

Finishing work

– Install the rear wheel.

( p. 114)

–


–


–


13.6

Checking the tire condition

Warning

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.

– 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 Non-approved or non-recommended tires and wheels impact the handling characteristic.


Info

The type, condition and air pressure of the tires all have a major impact on the riding behavior of the motorcycle.

Worn tires have a negative effect on riding behavior, especially on wet surfaces.

400602-10

– Check the front and rear tires for cuts, run-in objects and other damage.

» If the tires exhibit cuts, run-in objects or other damage:

– Change the tires.

– Check the depth of the tread.

Info

Note local national regulations concerning the minimum tread depth.

Minimum tread depth ≥ 2 mm ( ≥ 0.08 in)

» If the tread depth is less than the minimum permissible depth:


– Check the age of the tires.

Info

The tire's date of the manufacture is usually part of the tire markings and is indicated by the last four digits of the 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.

120


» If a tire is more than 5 years old:


13.7

Checking the tire air pressure

Info

Low tire air pressure leads to abnormal wear and overheating of the tire.

Correct tire air pressure ensures optimal riding comfort and maximum tire service life.

400695-01

– Remove the dust cap.

– Check tire air pressure when the tires are cold.

Tire air pressure, solo

Front

Rear

2.0 bar (29 psi)

2.0 bar (29 psi)

Tire air pressure with passenger/full payload

Front 2.0 bar (29 psi)

Rear 2.2 bar (32 psi)

» If the tire air pressure does not meet specifications:

– Correct the tire air pressure.

– Mount the dust cap.

121

14 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.


– Avoid contact with battery acid and battery gases.

– Keep sparks and open flames away from the battery. Only charge in well-ventilated rooms.

– In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least 15 minutes and contact a physician.

122


–


–

Remove the seat. ( p. 81)

Main work

– Pull back the negative terminal cover

– Disconnect negative cable 

 .

from the battery.

B00750-10


– Pull back the positive terminal cover

– Disconnect positive cable 

 .

from the battery.

– Detach rubber band  .

– Pull the battery up and out of the battery holder.

123

Info

Never operate the motorcycle with a discharged battery or without a battery. In both cases, electrical components and safety devices can be damaged. The vehicle is therefore no longer roadworthy.

B00751-10

14.2

Installing the battery

B00751-11

Main work

– Position the battery in the battery holder.

Guideline

The terminals of the battery must face upwards.

(125 Duke)

Battery (FTZ-7) ( p. 175)

(200 Duke)

Battery (FTZ-9) ( p. 175)

– Reconnect rubber band 

– Position the positive cable

.

 and mount and tighten the screw.

– Position positive terminal cover  .


– Position the negative cable  and mount and tighten the screw.

– Position the negative terminal cover  .

124

B00750-11

Finishing work

–

Mount the seat. ( p. 82)

–


–

Set the clock. ( p. 47)

14.3

Recharging the battery

Warning

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

– Keep batteries out of the reach of children.


– Avoid contact with battery acid and battery gases.

– Keep sparks and open flames away from the battery. Only charge in well-ventilated rooms.

– In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least 15 minutes and contact a physician.


125

Warning

Environmental hazard The battery contains elements that are harmful to the environment.

– Do not dispose of batteries with the household waste. Dispose of a defective battery in an environmentally friendly 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 discharges steadily.

The charging level and the method of charging are very important for the service life of the battery.

Rapid recharging with a high charging current shortens the battery's service life.

If the charging current, charging voltage, or charging time is exceeded, electrolyte escapes through the safety valves. This reduces the battery capacity.

If the battery is depleted from starting the vehicle repeatedly, the battery must be charged immediately.

If the battery is left in a discharged state for an extended period, it will become over-discharged and sulfate, destroying the battery.

The battery is maintenance-free. The acid level does not have to be checked.


– Switch off all power consumers and switch off the engine.

–


–

Remove the seat. ( p. 81)

– Disconnect the negative cable of the battery to avoid damage to the onboard electronics.


126

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 battery, 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 housing  .

– Switch off the battery charger after charging and disconnect from the battery.

Guideline

The charge current, charge voltage and charge time must not be exceeded.

Charge the battery regularly when the motorcycle is not in use

3 months

– Position the negative cable and mount and tighten the screw.

– Position the negative terminal cover.

M00729-10

Finishing work

–

Mount the seat. ( p. 82)

–


–



14.4

Changing the ABS fuses (125 Duke)

Warning

Fire hazard The electrical system can be overloaded if the wrong fuses are used.

– Use only fuses with the prescribed amperage. Never bypass 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. The third fuse, which protects the ABS control unit, is located in the fuse box.


– Switch off all power consumers and the engine.

–


To change the fuse of the ABS hydraulic unit:

– Take off the protection cap and remove fuse  .

Info

A defective fuse is indicated by a burned-out fuse wire  .

M00018-10

Warning



– Use spare fuses with the correct rating only.

Fuse (75011088015) ( p. 175)

127


M00018-11

Tip

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




Fuse (90111088025) ( p. 175)

Tip

Replace spare fuse  in the fuse box so that it is available if needed.

– Mount the protection cap.

Finishing work

–


14.5

Changing the fuses of individual power consumers

Info

The fuse box with the main fuse and the fuses of the individual power consumers is located under the passenger seat.

128




–


Main work

(200 Duke)

– Open fuse box cover  .

129

B00753-10

B00754-10

– Remove the defective fuse.

Guideline

Fuse 1 - 30 A - main fuse

Fuse 2 - 15 A - combination instrument

Fuse 3 - 10 A - control unit, power relay

Fuse 4 - 15 A - ignition coil, alarm system (OPTIONAL)

Fuse 5 - 15 A - radiator fan

Fuse 6 - 15 A - horn, brake light, turn signal, high beam, low beam, parking light, tail light, license plate lamp

Info



Warning




Fuse (75011088010) ( p. 175)

Fuse (75011088015) ( p. 175)

Fuse (75011088030) ( p. 175)

Tip

Replace the spare fuse in the fuse box so that it is available if needed.

– Check that the power consumer is functioning properly.

– Close the fuse box cover.

(125 Duke)

– Open fuse box cover  .

130

S00679-10


S00680-10

131

– 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

Fuse 5 - 15 A - radiator fan

Fuse 6 - 15 A - horn, brake light, turn signal, high beam, low beam, parking light, tail light, license plate lamp

Fuse 7 - 10 A - ABS control unit

Fuse 8 - 10 A - combination instrument, control unit

Fuse 9 - 10 A - auxiliary equipment

Info


Warning




Fuse (75011088010) ( p. 175)

Fuse (75011088015) ( p. 175)

Fuse (75011088030) ( p. 175)


132

Tip

Replace the spare fuse in the fuse box so that it is available if needed.

– Check that the power consumer is functioning properly.

– Close the fuse box cover.

Finishing work

–


14.6

Changing the headlight 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.



Main work

– Remove expanding rivets  .

601915-10



– Lift the headlight mask slightly and swing forward.

601914-10

– Remove protection cap

– Unplug connector  .

 .

B00760-10

B00761-10

– Detach retaining clamp

– Remove headlight bulb



 .

.

– Position the new headlight bulb in the headlight housing.

Guideline

Insert the headlight bulb so that the catches latch into the recesses.

Headlight (H4/socket P43t) ( p. 175)

– Attach retaining clamp  .

133


– Plug in connector 

– Mount protection cap

.

 .

B00760-10

– Fold the headlight mask up.


Guideline

Screw, headlight mask M6

601914-10

– Mount expanding rivets  on both sides.

– Check that the lighting is functioning properly.

11 Nm

(8.1 lbf ft)

Loctite ® 243™

134

601915-10


135

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.



Main work


601915-10



307324-10


– Remove screws

– Remove cover



 .

.

B00762-10

– Pull the socket with bulb

– Remove the bulb.

 out of the housing.

– Position a new light bulb in the socket.

Parking light (W5W/socket W2.1x9.5d) ( p. 175)

– Position the socket with bulb  in the housing.

136

B00763-10


– Position cover  .

– Mount and tighten screws  .

B00762-10



Guideline

Screw, headlight mask M6

307324-10


– Check that the lighting is functioning properly.

11 Nm

(8.1 lbf ft)

Loctite ® 243™

137

601915-10


138

14.8

Checking the headlight setting

– Position the vehicle upright on a horizontal surface in front of a light wall and make a mark at the height of the center of the low beam headlight.

– Make another mark at a distance  under the first mark.

Guideline

Distance  5 cm (2 in)

400726-10

– Position the vehicle perpendicular to the wall at a distance on the low beam.

 from the wall and switch

Guideline

Distance  5 m (16 ft)

– The rider, with luggage and passenger if applicable, now mounts the motorcycle.

– Check the headlight setting.

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

» If the boundary between light and dark does not meet specifications:

–

Adjust the headlight range. ( p. 139)


14.9

Adjusting the headlight range

Main work


601915-10



601914-10

139


– 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).

B00764-10

140

Info

Turn clockwise to increase the headlight range; turn counterclockwise to reduce the headlight range.



Guideline

Screw, headlight mask M6 11 Nm

(8.1 lbf ft)

Loctite ® 243™

601914-10


601915-10


Finishing work

–

Check the headlight setting. ( p. 138)

141

15 COOLING SYSTEM

15.1

Cooling system

142

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 in a risk of malfunctions.



When the temperature falls, this surplus coolant is sucked back into the cooling system.

This ensures that operating the vehicle at the specified coolant temperature will not result

.

125 °C (257 °F)

B00765-10


143

The coolant is cooled by the air stream and a radiator fan moswitch.

 , which is controlled by a ther-

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

Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.

– Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down. In case of scalding, rinse immediately with lukewarm water.


144

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 immediately and contact a physician. Immediately clean contaminated areas on the skin with soap and water. If fuel is swallowed, contact a physician immediately. Change clothing that is contaminated with coolant. Keep coolant out of reach of children.

B00766-10

Condition

The engine is cold.

– Stand the motorcycle upright on a horizontal surface.

– Remove the cap of the compensating tank  .

– Check the coolant antifreeze.

− 25… − 45 °C ( − 13… − 49 °F)

» If the antifreeze in the coolant does not match the specified value:

– Correct the coolant antifreeze.

– Check the coolant level in the compensating tank.

The coolant level must be between MIN and MAX .

» If the coolant level does not match the specified value:

– Correct the coolant level.

Coolant ( p. 182)

– Mount the cap of the compensating tank.


B01552-10

– Remove radiator cap  .

– Check the coolant antifreeze.

− 25… − 45 °C ( − 13… − 49 °F)

» If the antifreeze in the coolant does not match the specified value:

– Correct the coolant antifreeze.

– Check the coolant level in the radiator.

The radiator must be completely filled.


– Correct the coolant level and find out the cause of the loss.

Coolant ( p. 182)

» If you had to add more coolant than the specified amount:

> 0.20 l (> 0.21 qt.)

– Fill/bleed the cooling system.

( p. 148)

– Mount the radiator cap.

15.3

Checking the coolant level

Warning



145


146

Warning



Condition

The engine is cold.


– Check the coolant level in the compensating tank  .

The coolant level must be between MIN and MAX .


– Correct the coolant level.

Coolant ( p. 182)

B00766-10

B01552-10

– Remove the radiator cap  and check the coolant level in the radiator.

The radiator must be completely filled.


– Correct the coolant level and find out the cause of the loss.

Coolant ( p. 182)

» If you had to add more coolant than the specified amount:

> 0.20 l (> 0.21 qt.)


( p. 148)


147

– Mount the radiator cap.

15.4

Draining the coolant

Warning



Warning



Condition

The engine is cold.


–

Remove the front spoiler. ( p. 93)

Main work

– Position the motorcycle upright.

– Place a suitable container under the engine.

– Remove screw  .

– Remove the radiator cap.

– Completely drain the coolant.

– Mount and tighten screw  with a new seal ring.

B00768-10


148

Guideline

Plug, water pump drain hole (125 Duke) M6

Plug, water pump drain hole (200 Duke) M6

8 Nm (5.9 lbf ft)

8 Nm (5.9 lbf ft)

15.5

Filling/bleeding the cooling system

Warning



Main work

– Remove radiator cap  .

B01552-11


B01553-10

149

– Release 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.

Coolant ( p. 182)

– Fill the radiator completely with coolant. Mount the radiator cap.

– Rest the vehicle on the side stand.

Danger



– 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 the MAX marking.

– Mount the cap of the compensating tank.

 and top up the coolant level up to

B00766-11

Finishing work

–

Fit the front spoiler. ( p. 94)

16 TUNING THE ENGINE

150

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 back and forth to ascertain play  in the throttle cable.

Throttle cable play 3… 5 mm (0.12… 0.2 in)

» If the throttle cable play does not meet specifications:

– Adjust the play in the throttle cable.

( p. 151)

400192-11

Danger



– Start the engine and let it run idle. Move the handlebar to and fro over the entire steering range.

The idle speed must not change.

» If the idle speed changes:

– Check the throttle cable routing.


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… 5 mm (0.12… 0.2 in)

M00731-10

– Tighten lock nut

– Slide on sleeve



 .

.

151

16.3

Checking the clutch lever play

– Check the clutch lever for smooth operation.

– Move the handlebar to the straight-ahead position. Pull the clutch lever until resistance is perceptible, and determine the play in the clutch lever  .

Clutch lever play 1… 3 mm (0.04… 0.12 in)

» If the clutch lever play does not meet specifications:

– Adjust the clutch cable play.

( p. 152)

S00681-10

Note

Clutch damage If there is no play on the clutch lever, the clutch will begin to slip.

– Before operating the motorcycle, always check the clutch lever play.

– Move the handlebar to and fro over the entire steering range.

The clutch lever play must not change.


» If the clutch lever play changes:

– Check the routing of the clutch cable.

16.4

Adjusting the clutch cable play

– Move the handlebar to the straight-ahead position.

– Push back sleeve  .

– Loosen lock nut  .

– Adjust the play in the clutch level  by turning adjusting screw  .

Guideline

Clutch lever play 1… 3 mm (0.04… 0.12 in)

– Tighten lock nut

– Position bellows



 .

.

152

S00683-10

17 SERVICE WORK ON THE ENGINE

17.1

Checking the engine oil level

Condition

The engine is at operating temperature.



Main work

– Check the engine oil level.

Info

After switching off the engine, wait one minute before checking the level.

153

S00685-10

The engine oil must be between the markings  and  .

» If the engine oil is below the marking

–

Add the engine oil. ( p. 156)

 :

» If the engine oil is above the marking

– Correct the engine oil level.

 :

17.2

Changing the engine oil and oil filter, cleaning the oil screen

Warning

Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden.

– Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water.

Warning




Info

Drain the engine oil only when the engine is warm.

S00684-10


–

Remove the front spoiler. ( p. 93)

– Stand the motorcycle on its side stand on a horizontal surface.

Main work

– Place a suitable container under the engine.

– Remove oil drain plug  with the O-ring.

– Remove oil screen  with the O-ring.

– Completely drain the engine oil.

– Clean the oil drain plug and oil screen thoroughly.

– Position oil screen  and mount and tighten oil drain plug  with the O-ring.

Guideline

Oil drain plug (125 Duke)

Oil drain plug (200 Duke)

M24x1.5

M24x1.5

15 Nm

(11.1 lbf ft)

15 Nm

(11.1 lbf ft)

154


– Remove screws

– Pull oil filter 

 . Remove oil filter cover out of the oil filter housing.

 with the O-ring.

Circlip pliers reverse (51012011000)

– Completely drain the engine oil.

– Thoroughly clean the parts and sealing surface.

B00775-10

B00776-10

– Insert oil filter  .

– Lubricate the O-ring of the oil filter cover. Mount oil filter cover

– Mount and tighten the screws.

 .

Guideline

Screw, oil filter cover (125 Duke)




M5

M6

M5

M6

8 Nm (5.9 lbf ft)

12 Nm (8.9 lbf ft)

8 Nm (5.9 lbf ft)

12 Nm (8.9 lbf ft)

Info

Too little engine oil or poor-quality engine oil results in premature wear of the engine.

155


156

– Remove filler plug  and the O-ring from the clutch cover and fill up with engine oil.

Engine oil 1.5 l (1.6 qt.) External temperature: 0… 50 °C

(32… 122 °F)

External temperature: − 10… 40 °C

(14… 104 °F)

– Install and tighten the oil filler plug with O-ring.

Engine oil

(SAE 15W/50)

( p. 182)

Engine oil

(SAE 10W/40)

( p. 183)

B00773-11

Danger



– Start the engine and check that it is oil-tight.

Finishing work

–

Fit the front spoiler. ( p. 94)

–


17.3

Adding engine oil

Info

Too little engine oil or poor-quality engine oil results in premature wear to the engine.


Main work

– Remove the oil filler plug engine oil.

 with the O-ring from the clutch cover and fill up with

Engine oil (SAE 15W/50) ( p. 182)

Engine oil (SAE 10W/40) ( p. 183)

157

B00773-10

Info

For optimal performance of the engine oil, do not mix different types of engine oil.

If appropriate, change the engine oil.

– Install and tighten the oil filler plug with O-ring.

Danger



– Start the engine and check that it is oil-tight.

Finishing work

–


18 CLEANING, CARE

158

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 pressure can cause malfunctions or destroy these parts.

Warning



Info

If you clean the motorcycle regularly, its value and appearance will be maintained over a long period.

Avoid direct sunshine on the motorcycle during cleaning.

– Seal the exhaust system to keep water out.

– First remove coarse dirt particles with a gentle spray of water.

– Spray very dirty areas with a normal motorcycle cleaner and then clean with a paintbrush.

Motorcycle cleaner ( p. 185)

401061-01


159

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.

– After rinsing the motorcycle with a gentle spray of water, allow it to dry thoroughly.

– Remove the closure of the exhaust system.

Warning

Danger of accidents Reduced braking efficiency due to a wet or dirty brake system.

– Clean or dry a dirty or wet brake system by riding and braking gently.

– After cleaning, ride the vehicle a short distance until the engine warms up.

Info

The heat produced causes water at inaccessible locations in the engine and on the brake system to evaporate.

– Push back the sleeves of the handlebar controls to allow any water that has penetrated to evaporate.

– After the motorcycle has cooled off, lubricate all moving parts and bearings.

–


– Treat bare metal parts (except for brake discs and exhaust system) with anti-corrosion materials.

Preserving materials for paints, metal and rubber ( p. 186)

– Treat all painted parts with a mild paint polish.


160

Perfect Finish and high gloss polish for paints ( p. 186)

Info

Do not polish parts that were matte when delivered as this would strongly impair the material quality.

– Treat all plastic parts and powder-coated parts with a mild cleaning and care product.

Special cleaner for glossy and matte paint finishes, metal and plastic surfaces

( p. 186)

– Oil the ignition/steering lock.

Universal oil spray ( p. 186)

18.2

Checks and maintenance steps for winter operation

Info

If the motorcycle is used in the winter, salt can be expected on the roads. Precautions need to be taken against road salt corrosion.

If the vehicle was operated in road salt, clean it with cold water after riding. Warm water would enhance the corrosive effects of salt.

–

Clean the motorcycle. ( p. 158)

– Clean the brakes.

Info

After EVERY trip on salted roads, thoroughly wash the brake calipers and brake linings with cold water and dry carefully. This should be done after the parts are cooled down and while they are installed.

After riding on salted roads, thoroughly wash the motorcycle with cold water and dry it well.

401060-01


– Treat the engine, swingarm, and all other bright and zinc-plated parts (except for the brake discs) with a wax-based corrosion inhibitor.

161

Info

Corrosion inhibitor is not permitted to come in contact with the brake discs as this would greatly reduce the braking force.

–


19 STORAGE

162

19.1

Storage

Info

If you want to garage the motorcycle for a longer period, take the following steps.

Before storing the motorcycle, check all parts for function and wear. If service, repairs or replacements are necessary, you should do this during the storage period (less workshop overload). In this way, you can avoid long workshop waiting times at the start of the new season.

401058-01

– When refueling for the last time before taking the motorcycle out of service, add fuel additive.

Fuel additive ( p. 185)

–

Refuel. ( p. 70)

–

Clean the motorcycle. ( p. 158)

– Change the engine oil and oil filter, clean the oil screen.

( p. 153)

–

Check the antifreeze and coolant level. ( p. 143)

–


– Remove the battery.

( p. 122)

– Recharge the battery.

( p. 124)

Guideline

Storage temperature of battery without direct sunlight

0… 35 °C (32… 95 °F)

– Store the vehicle in a dry location that is not subject to large fluctuations in temperature.

Info

KTM recommends jacking up the motorcycle.

–


19 STORAGE

163

–

Raise the motorcycle with the front wheel stand. ( p. 78)

– 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.

Avoid running the engine for a short time only. Since the engine cannot warm up properly, the water vapor produced during combustion condenses and causes valves and exhaust system to rust.

19.2

Preparing for use after storage

–


–


– Install the battery.

( p. 123)

–


–

Perform checks and maintenance steps when preparing for use. ( p. 60)

– Take a test ride.

401059-01

20 TROUBLESHOOTING

Faults

Engine does not crank when the electric starter button is pressed

Possible cause

Operating error

Battery discharged

Fuse 1 , 3 , 4 , or 8 is blown

Engine turns only if the clutch lever is drawn

Engine turns but does not start

No ground connection present

The vehicle is in gear

The vehicle is in gear and the side stand is folded out

Operating error

Fault in fuel injection system

Engine has too little power

Engine overheats

Air filter is very dirty

Fuel filter is very dirty


Too little coolant in cooling system

Radiator fins very dirty

Foam formation in cooling system

Thermostat defective

Fuse 5 blown

164

Action

– Go through the steps of starting the engine.

( p. 61)


( p. 124)

– Change the fuses of individual power consumers.

( p. 128)

– Check the ground connection.



– Go through the steps of starting the engine.

( p. 61)

– Read out the fault memory using the KTM diagnostics tool.

– Change the air filter.

– Check the fuel pressure.


– Check the cooling system for leakage.

–

Check the coolant level. ( p. 145)

– Clean the radiator fins.

– Drain the coolant.

( p. 147)


( p. 148)

– Check the thermostat.


( p. 128)


Faults

Engine overheats

The engine diagnosis warning lamp ( MIL ) lights up red

Engine dies during the trip

The ABS warning lamp lights up

(125 Duke)

High oil consumption

Headlight and parking light are not functioning

Turn signal, brake light, and horn are not functional

Time is not (correctly) displayed

165

Possible cause

Defect in radiator fan system


Lack of fuel

Fuse 1 , 3 , 4 , or 8 is blown

ABS fuse is blown

Large difference in wheel speeds of the front and rear wheels

Malfunction in ABS

Engine vent hose bent

Engine oil level too high

Engine oil too thin (low viscosity)

Fuse

Fuse

Fuse

Fuse

6

6

2

8 blown blown blown (200 Duke) blown (125 Duke)

Action

– Check the radiator fan system.


–

Refuel. ( p. 70)


( p. 128)

–

Change the ABS fuses. ( p. 127)

– Stop the vehicle, switch off the ignition, and start it again.

– Read out the ABS fault memory using the KTM diagnostics tool.

– Route the vent hose without bends or change it if necessary.

–


– Change the engine oil and oil filter, clean the oil screen.

( p. 153)


( p. 128)


( p. 128)


( p. 128)

–



( p. 128)

–



Faults

Battery discharged

Combination instrument shows nothing on the display

Possible cause

Ignition was not switched off when vehicle was parked

Battery is not being charged by alternator

Fuse 2 blown (200 Duke)

Fuse 8 blown (125 Duke)

Speedometer in combination instrument not functioning

Speedometer wiring harness is damaged or plug-in connector is oxidized

166

Action


( p. 124)

– Check the charging voltage.

– Check the open-circuit current.


( p. 128)

–



( p. 128)

–


– Check the wiring harness and plug-in connector.

21 TECHNICAL DATA

21.1

Engine

21.1.1

125 Duke

Design

Displacement

Stroke

Bore

Compression ratio

Control

Valve diameter, intake

Valve diameter, exhaust

Valve clearance, intake, cold

Valve clearance, exhaust, cold

Crankshaft bearing

Conrod bearing

Pistons

Piston rings

Engine lubrication

Primary transmission

Clutch

Transmission

Transmission ratio

1st gear

2nd gear

1-cylinder 4-stroke engine, water-cooled

125 cm³ (7.63 cu in)

47.2 mm (1.858 in)

58 mm (2.28 in)

12.8:1

DOHC, 4 valves controlled via cam lever, chain drive

22.5 mm (0.886 in)

19 mm (0.75 in)

0.08… 0.12 mm (0.0031… 0.0047 in)

0.13… 0.17 mm (0.0051… 0.0067 in)

Two ball bearings

Sleeve bearing

Cast light alloy

1 compression ring, 1 tapered compression piston ring, 1 oil scraper ring

Pressure circulation lubrication with one rotary pump

22:72

Clutch in oil bath/mechanically activated

6-gear, claw shifted

12:34

15:31

167


3rd gear

4th gear

5th gear

6th gear

Mixture preparation

Ignition

Alternator

Spark plug

Spark plug electrode gap

Spark plug


Cooling

Idle speed

Starting aid

21.1.2

200 Duke

Design

Displacement

Stroke

Bore

Compression ratio

Control

Valve diameter, intake

168

18:28

21:26

22:23

24:22

Electronically controlled fuel injection

Contactless controlled fully electronic ignition with digital ignition adjustment

12 V, 230 W

BOSCH VR 5 NE

0.8 mm (0.031 in)

BOSCH Super R6 VR 5 NEW

1 mm (0.04 in)

Water cooling, permanent circulation of coolant by water pump

1,450… 1,550 rpm

Electric starter

1-cylinder 4-stroke engine, water-cooled

200 cm³ (12.2 cu in)

49 mm (1.93 in)

72 mm (2.83 in)

11,5:1

DOHC, 4 valves controlled via cam lever, chain drive

28.5 mm (1.122 in)


Valve diameter, exhaust

Valve clearance, intake, cold

Valve clearance, exhaust, cold

Crankshaft bearing

Conrod bearing

Pistons

Piston rings

Engine lubrication

Primary transmission

Clutch

Transmission

Transmission ratio

1st gear

2nd gear

3rd gear

4th gear

5th gear

6th gear

Mixture preparation

Ignition

Alternator

Spark plug


169

24 mm (0.94 in)

0.08… 0.12 mm (0.0031… 0.0047 in)

0.13… 0.17 mm (0.0051… 0.0067 in)

Two ball bearings

Sleeve bearing

Cast light alloy

1 compression ring, 1 tapered compression piston ring, 1 oil scraper ring

Pressure circulation lubrication with one rotary pump

22:72

Clutch in oil bath/mechanically activated

6-gear, claw shifted

12:34

15:31

18:28

21:26

22:23

24:22

Electronically controlled fuel injection

Contactless controlled fully electronic ignition with digital ignition adjustment

12 V, 230 W

BOSCH VR 5 NE

0.8 mm (0.031 in)


Spark plug


Cooling

Idle speed

Starting aid

21.2

Engine tightening torques

Oil nozzle

Screw, engine vent plate

Screw, oil filter cover

Screw, retaining bracket

Screw, retaining bracket, stator cable

Screw, stator

Clutch cable retaining bracket screw

(125 Duke)


(200 Duke)

Cylinder head screw

Engine sprocket screw (125 Duke)

Engine sprocket screw (200 Duke)

Nut, water pump impeller

Plug, water pump drain hole

Screw, alternator cover

Screw, bearing retainer

Screw, camshaft bearing bridge

M5

M5

M5

M5

M5

M5

M6

M6

M6

M6

M6

M6

M6

M6

M6

M6

BOSCH Super R6 VR 5 NEW

1 mm (0.04 in)

Water cooling, permanent circulation of coolant by water pump

1,450… 1,550 rpm

Electric starter

170

6 Nm (4.4 lbf ft)

7 Nm (5.2 lbf ft)

8 Nm (5.9 lbf ft)

6 Nm (4.4 lbf ft)

8 Nm (5.9 lbf ft)

8 Nm (5.9 lbf ft)

6 Nm (4.4 lbf ft)

6 Nm (4.4 lbf ft)

12 Nm (8.9 lbf ft)

11 Nm (8.1 lbf ft)

11 Nm (8.1 lbf ft)

10 Nm (7.4 lbf ft)

8 Nm (5.9 lbf ft)

12 Nm (8.9 lbf ft)

12 Nm (8.9 lbf ft)

11 Nm (8.1 lbf ft)

Loctite ® 243™

Loctite ® 243™

–

Loctite ® 243™

Loctite ® 243™

Loctite ® 243™

Loctite ® 243™

Loctite ® 243™

–

–

–

–

–

Loctite ® 243™

Loctite ® 243™

–


Screw, chain securing guide

Screw, clutch cover

Screw, engine case

M6

M6

M6x40

Screw, engine case M6x60

Screw, freewheel gear retaining bracket M6

Screw, locking lever


M6

M6


Screw, oil pump

Screw, retaining bracket (125 Duke)

Screw, retaining bracket (200 Duke)

Screw, retaining bracket, shaft seal ring, clutch cover

Screw, shift drum locating

Screw, starter motor

Screw, timing chain tensioner

Screw, timing chain tensioning rail

Screw, valve cover

M6

M6

M6

M6

M6

Screw, water pump cover

Nut, conrod bearing (125 Duke)

Screw, conrod bearing (200 Duke)

Nut, exhaust flange

Nut, manifold on cylinder head

(125 Duke)

M6

M7

M7

M8

M8

M6

M6

M6

M6

M6

11 Nm (8.1 lbf ft)

12 Nm (8.9 lbf ft)

12 Nm (8.9 lbf ft)

12 Nm (8.9 lbf ft)

12 Nm (8.9 lbf ft)

12 Nm (8.9 lbf ft)

12 Nm (8.9 lbf ft)

12 Nm (8.9 lbf ft)

12 Nm (8.9 lbf ft)

12 Nm (8.9 lbf ft)

12 Nm (8.9 lbf ft)

11 Nm (8.1 lbf ft)

12 Nm (8.9 lbf ft)

12 Nm (8.9 lbf ft)

12 Nm (8.9 lbf ft)

12 Nm (8.9 lbf ft)

12 Nm (8.9 lbf ft)

12 Nm (8.9 lbf ft)

24 Nm (17.7 lbf ft)

24 Nm (17.7 lbf ft)

22 Nm (16.2 lbf ft)

15 Nm (11.1 lbf ft)

Loctite ® 243™

–

–

Loctite ® 243™

Loctite ® 243™

Loctite ® 243™

–

–

Loctite ® 243™

Loctite ® 243™

Loctite ® 243™

Loctite ® 243™

–

–

–

–

–

–

Loctite ® 243™

–

–

Loctite ® 243™

171


Nut, manifold on cylinder head

(200 Duke)

Screw, balancer shaft gear (125 Duke)

Screw, balancer shaft gear (200 Duke)

Screw, camshaft drive sprocket

(125 Duke)

Screw, camshaft drive sprocket

(200 Duke)

Screw, return spring, quick shifter

(125 Duke)

Screw, return spring, quick shifter

(200 Duke)

Stud, exhaust flange

Cylinder head screw (125 Duke)

M8

M8

M8

M8

M8

M8

M8

M8

M10

Oil pressure sensor

Rotor screw (125 Duke)

Rotor screw (200 Duke)

Screw, cylinder head (200 Duke)

Water temperature sensor

Spark plug

Nut, inner clutch hub

M10

M10

M10

M10

M10

M12

M14LH

15 Nm (11.1 lbf ft)

25 Nm (18.4 lbf ft)

25 Nm (18.4 lbf ft)

24 Nm (17.7 lbf ft)

24 Nm (17.7 lbf ft)

20 Nm (14.8 lbf ft)

20 Nm (14.8 lbf ft)

22 Nm (16.2 lbf ft)

Step 1

25 Nm (18.4 lbf ft)

Step 2

50 Nm (36.9 lbf ft)

14 Nm (10.3 lbf ft)

60 Nm (44.3 lbf ft)

60 Nm (44.3 lbf ft)

Step 1

25 Nm (18.4 lbf ft)

Step 2

50 Nm (36.9 lbf ft)

14 Nm (10.3 lbf ft)

15 Nm (11.1 lbf ft)

60 Nm (44.3 lbf ft)

–

Loctite ® 243™

Loctite ® 243™

Loctite ® 243™

Loctite ® 243™

Loctite ® 243™

Loctite ® 243™

–

Thread is oiled, head flat is greased

172

–

Loctite ® 243™

Loctite ® 243™

Thread is oiled, head flat is greased

–

–

Loctite ® 243™


Nut, primary gear/timing chain sprocket M14

Oil drain plug M24x1.5

M28 Nut, drive wheel for balancer shaft

(125 Duke)

Nut, drive wheel for balancer shaft

(200 Duke)

M28

21.3

Capacities

21.3.1

Engine oil

Engine oil 1.5 l (1.6 qt.)

21.3.2

Coolant

Coolant 1 l (1 qt.)

21.3.3

Fuel

Total fuel tank capacity, approx. 11 l (2.9 US gal)

Fuel reserve, approx.

55 Nm (40.6 lbf ft)

15 Nm (11.1 lbf ft)

60 Nm (44.3 lbf ft)

60 Nm (44.3 lbf ft)

Loctite ® 243™

–

Loctite ® 243™

Loctite ® 243™

173

External temperature: 0…

50 °C (32… 122 °F)

External temperature: − 10…

40 °C (14… 104 °F)

Engine oil (SAE 15W/50)

( p. 182)

Engine oil (SAE 10W/40)

( p. 183)

Coolant ( p. 182)

Super unleaded (ROZ 95/RON 95/PON 91) ( p. 184)

(125 Duke EU, 200 Duke EU/AR/ASIA/CN/MY)

Gasohol 95 E20 (RON 95) ( p. 184) (200 Duke TH)

1.5 l (1.6 qt.)


21.4

Chassis

Frame

Fork

Shock absorber

Brake system

Front

Rear

Suspension travel

Front

Rear

Brake discs - diameter

Front

Rear

Brake discs - wear limit

Front

Rear

Tire air pressure, solo

Front

Rear

Tire air pressure with passenger/full payload

Front

Rear

Secondary ratio (125 Duke)

Secondary ratio (200 Duke)

Lattice frame of steel tubes, powder-coated

WP Suspension

WP Suspension

Disc brake with four-pot brake caliper

Disc brake with single-piston brake caliper, floating

150 mm (5.91 in)

150 mm (5.91 in)

300 mm (11.81 in)

230 mm (9.06 in)

3.6 mm (0.142 in)

3.6 mm (0.142 in)

2.0 bar (29 psi)

2.0 bar (29 psi)

2.0 bar (29 psi)

2.2 bar (32 psi)

14:45

14:42

174


Chain

Steering head angle

Wheelbase

Seat height, unloaded

Ground clearance, unloaded

Dry weight (125 Duke)

Dry weight (200 Duke)

21.5

Electrical system

Battery (125 Duke) FTZ-7

Battery (200 Duke)

Fuse

Fuse

Fuse

Fuse

Headlight

Parking light

Instrument lights and indicator lamps

Turn signal

Brake/tail light

FTZ-9

75011088010

75011088015

90111088025

75011088030

H4/socket P43t

W5W/socket W2.1x9.5d

LED

LED

LED

5/8 x 1/4” (520) X-ring

65°

1,367±15 mm (53.82±0.59 in)

800 mm (31.5 in)

170 mm (6.69 in)

127 kg (280 lb.)

129.5 kg (285.5 lb.)

Battery voltage: 12 V

Nominal capacity: 6 Ah

Maintenance-free

Battery voltage: 12 V

Nominal capacity: 8 Ah

Maintenance-free

10 A

15 A

25 A

30 A

12 V

60/55 W

12 V

5 W

175


License plate lamp LED

21.6

Tires

Front tires

110/70 R 17 M/C 54S TL

MRF revz FC

Additional information is available in the Service section under: http://www.ktm.com

21.7

Fork

Fork part number

Fork

Fork length

Fork oil 450 ml (15.21 fl. oz.)

21.8

Shock absorber

Shock absorber part number

Shock absorber

Spring preload

Standard

Full payload

Static sag

Riding sag

Fitted length

Rear tires

150/60 R 17 M/C 66S TL

MRF revz C

90601000044

WP Suspension

736 mm (28.98 in)

Fork oil (SAE 4) (48601166S1) ( p. 183)

90604010000

WP Suspension

3 clicks

6 clicks

15 mm (0.59 in)

45… 50 mm (1.77… 1.97 in)

300 mm (11.81 in)

176


21.9

Chassis tightening torques

Exhaust clamp

Helmet holder screw

Screw, chain guard

Screw, headlight

Remaining screws, chassis

Screw, EFI control unit

Screw, license plate lamp

Screw, trim, subframe, bottom

Remaining nuts, chassis


Screw, ABS hose clamp (125 Duke)

Screw, brake line holder, rear

Screw, chain guard

Screw, fuel pump

Screw, fuel tank closure flange

Screw, fuel tank cover

Screw, fuel tank trim

Screw, license plate holder

Screw, rollover sensor

Screw, side stand switch

Screw, spoiler

Screw, subframe cover, bottom

Screw, tail end lower part

M5

M5

M5

M5

M5

M5

M5

M5

M5

M5

M5

M5

M5

M5

M4

M4

M4

M4

M5

-

EJOT PT ®

EJOT PT ®

EJOT PT ®

19 Nm (14 lbf ft)

3 Nm (2.2 lbf ft)

4 Nm (3 lbf ft)

4 Nm (3 lbf ft)

4 Nm (3 lbf ft)

5 Nm (3.7 lbf ft)

2 Nm (1.5 lbf ft)

5 Nm (3.7 lbf ft)

5 Nm (3.7 lbf ft)

5 Nm (3.7 lbf ft)

6 Nm (4.4 lbf ft)

7 Nm (5.2 lbf ft)

4 Nm (3 lbf ft)

5 Nm (3.7 lbf ft)

5 Nm (3.7 lbf ft)

4 Nm (3 lbf ft)

5 Nm (3.7 lbf ft)

11 Nm (8.1 lbf ft)

6 Nm (4.4 lbf ft)

5 Nm (3.7 lbf ft)

5 Nm (3.7 lbf ft)

5 Nm (3.7 lbf ft)

6 Nm (4.4 lbf ft)

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

Loctite ® 243™

Loctite ® 243™

–

–

–

Loctite ® 243™

Loctite ® 243™

177


Screw, tail light

Screw, windshield


Damping rubber frame screw

Nut, foot brake lever adjustment

Nut, radiator



Screw, ABS module (125 Duke)

Screw, air filter box

Screw, air filter box lid

M6

M6

M6

M6

Screw, brake fluid reservoir of rear brake M6

Screw, cable holder, side stand switch

Screw, chain sliding guard

Screw, compensating tank

Screw, foot brake cylinder

M6

M6

M6

M6

M5

M5

M6

M6

M6

M6

M6

Screw, front fender

Screw, front seat fixing


Screw, fuel tank

Screw, headlight holder

Screw, headlight mask

Screw, ignition coil

Screw, license plate holder

Screw, lower rear panel

M6

M6

M6

M6

M6

M6

M6

M6

M6

5 Nm (3.7 lbf ft)

3 Nm (2.2 lbf ft)

6 Nm (4.4 lbf ft)

7 Nm (5.2 lbf ft)

9 Nm (6.6 lbf ft)

5 Nm (3.7 lbf ft)

10 Nm (7.4 lbf ft)

10 Nm (7.4 lbf ft)

7 Nm (5.2 lbf ft)

6 Nm (4.4 lbf ft)

3 Nm (2.2 lbf ft)

9 Nm (6.6 lbf ft)

9 Nm (6.6 lbf ft)

9 Nm (6.6 lbf ft)

13 Nm (9.6 lbf ft)

9 Nm (6.6 lbf ft)

11 Nm (8.1 lbf ft)

6 Nm (4.4 lbf ft)

9 Nm (6.6 lbf ft)

13 Nm (9.6 lbf ft)

11 Nm (8.1 lbf ft)

11 Nm (8.1 lbf ft)

9 Nm (6.6 lbf ft)

12 Nm (8.9 lbf ft)

5 Nm (3.7 lbf ft)

–

–

–

–

–

–

–

–

–

–

–

–

–

–

Loctite ® 243™

–

–

–

Loctite ® 243™

–

–

Loctite ® 243™

–

Loctite ® 243™

–

178


Screw, magnetic holder on side stand

Screw, main silencer

Screw, radiator bracket

Screw, radiator holder

Screw, rear ABS sensor wheel

(125 Duke)

Screw, rear splash protector

Screw, rollover sensor holder

Screw, seat

Screw, shift lever linkage

Screw, tail end lower part, front

Screw, voltage regulator

Screw, voltage regulator holder

Screw, wheel speed sensor holder

(125 Duke)

Silent block retaining bracket screw

Nut, rear sprocket



Screw, bottom triple clamp

Screw, engine bearer on engine

Screw, engine bearer on frame

Screw, foot brake lever

Screw, fork stub

Screw, front brake disc

M6

M6

M6

M6

M6

M6

M6

M6

M6

M6

M6

M6

M6

M6

M8

M8

M8

M8

M8

M8

M8

M8

M8

5 Nm (3.7 lbf ft)

10 Nm (7.4 lbf ft)

6 Nm (4.4 lbf ft)

9 Nm (6.6 lbf ft)

8 Nm (5.9 lbf ft)

9 Nm (6.6 lbf ft)

11 Nm (8.1 lbf ft)

10 Nm (7.4 lbf ft)

11 Nm (8.1 lbf ft)

11 Nm (8.1 lbf ft)

10 Nm (7.4 lbf ft)

11 Nm (8.1 lbf ft)

8 Nm (5.9 lbf ft)

7 Nm (5.2 lbf ft)

27 Nm (19.9 lbf ft)

25 Nm (18.4 lbf ft)

25 Nm (18.4 lbf ft)

15 Nm (11.1 lbf ft)

25 Nm (18.4 lbf ft)

26 Nm (19.2 lbf ft)

16 Nm (11.8 lbf ft)

15 Nm (11.1 lbf ft)

30 Nm (22.1 lbf ft)

–

–

Loctite ® 243™

–

Loctite ® 243™

–

–

–

–

–

–

–

Loctite ® 243™

–

Loctite ® 243™

–

–

–

–

–

Loctite ® 243™

–

Loctite ® 243™

179


Screw, front wheel spindle

Screw, handlebar clamp

Screw, handrail

Screw, horn

Screw, main silencer

Screw, passenger footrest bracket

Screw, rear brake disc

Screw, shift lever

Screw, top triple clamp

Screw, front brake caliper

Banjo bolt, brake line

Fitting side stand

Fitting, engine mounting bracket

Nut mirror image left



Fitting, bottom shock absorber

Fitting, handlebar support

Nut, mirror, right

Nut, turn signal

Screw, front footrest bracket

Screw, front footrest bracket / engine bearer

Screw, side stand bracket

Screw, top shock absorber

M8

M8

M8x1

M10

M10

M10

M10

M10

M10

M8

M8

M8

M8

M8

M8

M8

M10x1.25

M10x1.25

M10LHx1.25

M10x1.25

M10x1.25

M10x1.25

M10x1.25

M10x1.25

26 Nm (19.2 lbf ft)

21 Nm (15.5 lbf ft)

32 Nm (23.6 lbf ft)

7 Nm (5.2 lbf ft)

24 Nm (17.7 lbf ft)

26 Nm (19.2 lbf ft)

30 Nm (22.1 lbf ft)

16 Nm (11.8 lbf ft)

11 Nm (8.1 lbf ft)

30 Nm (22.1 lbf ft)

24 Nm (17.7 lbf ft)

35 Nm (25.8 lbf ft)

45 Nm (33.2 lbf ft)

16 Nm (11.8 lbf ft)

45 Nm (33.2 lbf ft)

45 Nm (33.2 lbf ft)

45 Nm (33.2 lbf ft)

21 Nm (15.5 lbf ft)

16 Nm (11.8 lbf ft)

6 Nm (4.4 lbf ft)

47 Nm (34.7 lbf ft)

47 Nm (34.7 lbf ft)

25 Nm (18.4 lbf ft)

51 Nm (37.6 lbf ft)

–

–

–

–

Loctite ® 243™

Loctite ® 243™

Loctite ® 243™

Loctite ® 243™

–

Loctite ® 204™

–

–

–

–

–

–

–

Loctite ® 243™

–

–

Loctite ® 243™

–

Loctite ® 243™

Loctite ® 243™

180


Stud, rear sprocket

Nut, rear wheel spindle

Nut, swingarm pivot

Screw, top steering head

Lambda sensor

Swingarm bearing adjusting ring

M10x1.25

M14x1.5

M14x1.5

M16x1.5

M18x1.5

M22x1

Nut, steering head M30x1

50 Nm (36.9 lbf ft)

90 Nm (66.4 lbf ft)

100 Nm (73.8 lbf ft)

53 Nm (39.1 lbf ft)

19 Nm (14 lbf ft)

Tighten and ensure that there is no play

–

–

–

–

–

Loctite ® 243™

– Step 1

55 Nm (40.6 lbf ft)

2nd stage (loosen, counterclockwise)

2 turns

Step 3

5 Nm (3.7 lbf ft)

181

22 SUBSTANCES

182

Brake fluid DOT 4 / DOT 5.1

Standard/classification

– DOT

Guideline

– Use only brake fluid that complies with the specified standard (see specifications on the container) and that exhibits the corresponding properties.

Recommended supplier

Castrol

– RESPONSE BRAKE FLUID SUPER DOT 4

Motorex ®

– Brake Fluid DOT 5.1

Coolant

Guideline

– Only use high quality coolant with corrosion inhibitor for aluminum motors (even in countries with high temperatures). Using inferior antifreeze can result in corrosion and foaming.

Mixture ratio

Antifreeze protection: − 25… − 45 °C ( − 13…

− 49 °F) anti-corrosion/antifreeze distilled water


Motorex ®

– COOLANT M3.0

Engine oil (SAE 15W/50)


–

JASO T903 MA ( p. 187)

–

SAE ( p. 187) (SAE 15W/50)

22 SUBSTANCES

183

Guideline

– Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties.

Partially synthetic engine oil


Motorex ®

– Formula 4T

Engine oil (SAE 10W/40)


–

JASO T903 MA ( p. 187)

–

SAE ( p. 187) (SAE 10W/40)

Guideline

– Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties.

Partially synthetic engine oil


Motorex ®

– Formula 4T

Fork oil (SAE 4) (48601166S1)


–

SAE ( p. 187) (SAE 4)

Guideline

– Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties.

22 SUBSTANCES

Gasohol 95 E20 (RON 95)


– Gasohol 95 E20 (RON 95)

Guideline

– Only use super unleaded fuel that matches or is equivalent to the specifications.

– Super unleaded fuel with an ethanol content of 19 to 20% is permissible.

Info

Do not use fuel made of methanol (e. g. M15, M85, M100).

Do not use fuel with less than 19% ethanol (e. g. E10).

Do not use fuel with more than 20% ethanol (e. g. E30, E85, E100).

Super unleaded (ROZ 95/RON 95/PON 91)


– DIN EN 228 (ROZ 95/RON 95/PON 91)

Guideline

– Only use unleaded super fuel that matches or is equivalent to the specified fuel grade.

– Fuel with an ethanol content of up to 10 % (E10 fuel) is safe to use.

Info

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

184

23 AUXILIARY SUBSTANCES

Chain cleaner


Motorex ®

– Chain Clean

Chain lube for road use

Guideline


Motorex ®

– Chainlube Road

Fuel additive


Motorex ®

– Fuel Stabilizer

Long-life grease


Motorex ®

– Bike Grease 2000

Motorcycle cleaner


Motorex ®

– Moto Clean

185

23 AUXILIARY SUBSTANCES

Perfect Finish and high gloss polish for paints


Motorex ®

– Moto Polish & Shine

Preserving materials for paints, metal and rubber


Motorex ®

– Moto Protect

Special cleaner for glossy and matte paint finishes, metal and plastic surfaces


Motorex ®

– Quick Cleaner

Universal oil spray


Motorex ®

– Joker 440 Synthetic

186

24 STANDARDS

187

JASO T903 MA

Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Earlier, 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. In most motorcycles, the gearbox and the clutch are lubricated with the same oil as the engine. The JASO MA Standard meets these special requirements.

SAE

The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to their viscosity. The viscosity describes only one property of oil and says nothing about quality.

25 INDEX OF SPECIAL TERMS

ABS ABS Safety system that prevents locking of the wheels when driving straight ahead without the influence of lateral forces

188

26 LIST OF ABBREVIATIONS

Art. no.

ca.

cf.

e.g.

etc.

i.a.

no.

poss.

Article number circa compare for example et cetera inter alia number possibly

189

27 LIST OF SYMBOLS

27.1

Red symbols

Red symbols indicate an error condition that requires immediate intervention.

The engine diagnosis warning lamp ( MIL ) lights up red – The OBD (on-board diagnosis) has detected an emissionor safety-critical error.

The immobilizer indicator lamp lights up or flashes red – Status or error message for immobilizer/alarm system

(optional).

190

27.2

Yellow and orange symbols

Yellow and orange symbols indicate an error condition that requires prompt intervention. Active driving aids are also represented by yellow or orange symbols.

The general warning lamp lights up yellow – An operating safety (warning) message was detected. This is also shown in the info display.

ABS warning lamp lights up/flashes yellow – Status or error messages relating to ABS (antilock brake system).

27.3

Green and blue symbols

Green and blue symbols reflect information.

The turn signal indicator light flashes green simultaneously with the turn signal – The turn signal is switched on.

The idling speed indicator lamp lights up green – The transmission is shifted to idle.

The high beam indicator lamp lights up blue – The high beam is switched on.

INDEX

INDEX

A

ABS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Accessories

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Antifreeze

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

Antilock brake system

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Auxiliary substances

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

B

Baggage

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Battery

installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

recharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

Brake discs

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Brake fluid

front brake, adding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

rear brake, adding . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Brake fluid level

front brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . . 97

rear brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Brake linings

front brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . 100

rear brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Brakes

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

191

Brakes, applying

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

C

Capacity

coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173 engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156, 173 fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71, 173

Chain

chain dirt accumulation, checking . . . . . . . . . . . . . . . . . 83

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Chain tension

adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Chassis number

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Clutch cable play

adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

Clutch lever

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Clutch lever play

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

Combination instrument

activation and test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

average fuel consumption 1/average fuel consumption 2

menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

average fuel consumption 2/service menu . . . . . . . . . . . . 42

average speed/average fuel consumption 1 menu . . . . . . . 40

coolant temperature indicator . . . . . . . . . . . . . . . . . . . . . 38

display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

INDEX display TRIP F

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

distance menu 1 TRIP 1

. . . . . . . . . . . . . . . . . . . . . . . . . 46

distance menu 2 TRIP 2

. . . . . . . . . . . . . . . . . . . . . . . . . 46

filling level display in fuel tank . . . . . . . . . . . . . . . . . . . . 36

function buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

indicator lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

info display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

range/riding time menu . . . . . . . . . . . . . . . . . . . . . . . . . 44

riding time/average speed menu . . . . . . . . . . . . . . . . . . . 40

service/range menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

total distance menu ODO

. . . . . . . . . . . . . . . . . . . . . . . . 45

warning notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Coolant

draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

Coolant level

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143, 145

Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

142

filling/bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

Customer service

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

E

Electric starter button

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Emergency OFF switch

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Engine

running in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Engine number

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Engine oil

adding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

192

changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

Engine oil level

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

Engine sprocket

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Environment

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

F

Figures

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Filler cap

closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Filling up

fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Foot brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

54

free travel, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . 101

free travel, checking . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Front spoiler

installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Front wheel

installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Fuse

individual power consumers, changing . . . . . . . . . . . . . . 128

Fuses, ABS

changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

INDEX

G

Grab handles

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

H

Hand brake lever

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Headlight adjustment

adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

Headlight bulb

changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

High beam flasher button

. . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Horn button

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

I

Ignition lock

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Implied warranty

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Indicator lamps

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

K

Key number

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Kilometers or miles

adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

L

Light switch

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Loading the vehicle

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

M

Motorcycle

cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

193

raising with the front wheel stand . . . . . . . . . . . . . . . . . . 78

raising with the rear wheel stand . . . . . . . . . . . . . . . . . . . 77

taking off of the front wheel stand . . . . . . . . . . . . . . . . . . 79

taking off of the rear wheel stand . . . . . . . . . . . . . . . . . . 77

O

Oil filter

changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

Oil screen

cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

Operating substances

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Owner's Manual

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

P

Parking

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Parking light bulb

changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

Passenger footrests

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Passenger seat

mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Play in throttle cable

adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

Preparing for use

advice on first use . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

after storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

checks and maintenance when preparing for use . . . . . . . . 60

INDEX

Protective clothing

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

R

Rear hub rubber dampers

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Rear sprocket

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Rear wheel

installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Riding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

63 starting off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

S

Safe operation

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Seat

mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Seat lock

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Service

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Service schedule

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72-74

Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

53

adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Shift speed RPM 1

adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Shift speed RPM 2

adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

194

Shifting

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Shock absorber

spring preload, adjusting . . . . . . . . . . . . . . . . . . . . . . . . 75

Side stand

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Spare parts

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Starting

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Steering

locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 unlocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Steering lock

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Stopping

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Storage

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

T

Technical data

capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

chassis tightening torques . . . . . . . . . . . . . . . . . . . . . . 177

electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

engine tightening torques . . . . . . . . . . . . . . . . . . . . . . 170

fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176 shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176 tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

Throttle grip

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Time

adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

INDEX

Tire air pressure

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Tire condition

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Tool set

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Transport

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Troubleshooting

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 164-166

Turn signal switch

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Type label

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

U

Use definition

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

V

View of vehicle

front left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

rear right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

W

Warranty

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Winter operation

checks and maintenance steps . . . . . . . . . . . . . . . . . . . 160

Work rules

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

195

*3213412en*

3213412en

02/2016

KTM Sportmotorcycle GmbH

5230 Mattighofen/Austria http://www.ktm.com

Photo: Mitterbauer/KTM

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