KTM 125 Duke EU & DE Complete Workshop Service Repair Manual 2011 2012
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REPAIR MANUAL 2013
125 Duke EU
200 Duke EU
200 Duke MAL
200 Duke 2014 COL
Art. no. 3206162en
INTRODUCTION 1
INTRODUCTION
It is important that you read this repair manual carefully and completely before the start of work.
This vehicle can only fulfill the demands placed on it in the long run if the specified service work is performed regularly by qualified
experts.
The repair manual was written to correspond to the most current state of this model series. We reserve the right to make changes in
the interest of technical advancement without, at the same time, updating this repair manual.
We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop are not specified here.
It is assumed that repair work will be performed by a fully trained mechanic.
All specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifica-
tions, 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, as well as misprints and other errors. The models portrayed partly contain spe-
cial equipment that does not belong to the regular scope of supply.
© 2013 KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
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
KTM-Sportmotorcycle AG
5230 Mattighofen, Austria
TABLE OF CONTENTS 2
TABLE OF CONTENTS
1 MEANS OF REPRESENTATION ..................................... 6
1.1 Symbols used ................................................... 6
1.2 Formats used.................................................... 6
2 SAFETY ADVICE........................................................... 7
2.1 Repair Manual .................................................. 7
2.2 Safety advice .................................................... 7
2.3 Degrees of risk and symbols ............................... 7
2.4 Work rules ........................................................ 7
3 IMPORTANT INFORMATION ......................................... 8
3.1 Guarantee, warranty .......................................... 8
3.2 Operating and auxiliary substances ..................... 8
3.3 Spare parts, accessories .................................... 8
3.4 Figures ............................................................ 8
4 SERIAL NUMBERS ...................................................... 9
4.1 Chassis number/type label ................................. 9
4.2 Key number ...................................................... 9
4.3 Engine number ................................................. 9
5 MOTORCYCLE ........................................................... 10
5.1 Raising the motorcycle with the rear wheel
stand ............................................................. 10
5.2 Taking the motorcycle off of the rear wheel
stand ............................................................. 10
5.3 Raising the motorcycle with the front wheel
stand ............................................................. 10
5.4 Taking the motorcycle off of the front wheel
stand ............................................................. 11
5.5 Raising the motorcycle with the work stand ....... 11
5.6 Removing the motorcycle from the work stand ... 12
5.7 Starting.......................................................... 13
5.8 Starting the motorcycle to make checks ............ 14
6 FORK, TRIPLE CLAMP ............................................... 15
6.1 Cleaning the dust boots of the fork legs............. 15
6.2 Removing fork legs .......................................... 15
6.3 Installing the fork legs ..................................... 17
6.4 Disassembling the fork legs.............................. 20
6.5 Checking the fork legs ..................................... 22
6.6 Assembling the fork legs .................................. 23
6.7 Removing the lower triple clamp....................... 24
6.8 Installing the lower triple clamp ....................... 27
6.9 Checking the steering head bearing play............ 29
6.10 Adjusting the steering head bearing play ........... 30
7 HANDLEBAR, CONTROLS........................................... 32
7.1 Checking the play in the throttle cable .............. 32
7.2 Adjusting the play in the throttle cable.............. 32
7.3 Checking the clutch lever play .......................... 32
7.4 Adjusting the clutch cable play ........................ 33
8 SHOCK ABSORBER, SWINGARM ................................ 34
8.1 Adjusting the spring preload of the shock
absorber ......................................................... 34
8.2 Removing the shock absorber ........................... 34
8.3 Installing the shock absorber............................ 35
8.4 Removing the spring........................................ 36
8.5 Installing the spring ........................................ 36
9 EXHAUST .................................................................. 38
9.1 Removing the exhaust manifold ........................ 38
9.2 Installing the exhaust manifold ........................ 39
9.3 Removing the main silencer ............................. 40
9.4 Installing the main silencer .............................. 42
10 AIR FILTER ............................................................... 44
10.1 Removing the air filter ..................................... 44
10.2 Installing the air filter...................................... 44
11 FUEL TANK, SEAT, TRIM ........................................... 45
11.1 Opening the filler cap ...................................... 45
11.2 Closing the filler cap ....................................... 45
11.3 Removing the seat .......................................... 45
11.4 Mounting the seat ........................................... 46
11.5 Removing the passenger seat ........................... 46
11.6 Mounting the passenger seat ............................ 46
11.7 Removing the fuel tank cover ........................... 46
11.8 Installing the fuel tank cover ............................ 49
11.9 Removing the fuel tank.................................... 51
11.10 Installing the fuel tank .................................... 53
11.11 Removing the front spoiler ............................... 54
11.12 Fitting front spoiler ......................................... 54
11.13 Dismounting the front fender ........................... 55
11.14 Installing the front fender ................................ 55
11.15 Checking the fuel pressure............................... 56
11.16 Changing the fuel filter .................................... 57
11.17 Replacing the fuel pump ................................. 58
12 WHEELS ................................................................... 60
12.1 Checking the tire air pressure ........................... 60
12.2 Checking the tire condition .............................. 60
12.3 Checking the brake discs ................................. 61
12.4 Front wheel .................................................... 61
12.4.1 Removing the front wheel ............................ 61
12.4.2 Installing the front wheel ............................. 62
12.4.3 Removing the brake disc of the front brake.... 63
12.4.4 Installing the brake disc of the front brake .... 64
12.5 Rear wheel ..................................................... 64
12.5.1 Removing the rear wheel ............................. 64
12.5.2 Installing the rear wheel .............................. 65
12.5.3 Removing the brake disc of the rear brake ..... 66
12.5.4 Installing the brake disc of the rear brake...... 67
12.5.5 Checking the chain tension .......................... 68
12.5.6 Adjusting the chain tension ......................... 68
12.5.7 Checking the chain, rear sprocket, and
engine sprocket .......................................... 69
12.5.8 Cleaning the chain ...................................... 72
12.5.9 Checking the rear hub rubber dampers.......... 73
13 WIRING HARNESS, BATTERY ..................................... 74
13.1 Removing the battery ...................................... 74
13.2 Installing the battery ....................................... 74
13.3 Disconnecting the negative cable of the
battery ........................................................... 75
13.4 Reconnecting the negative cable of the
battery ........................................................... 75
13.5 Recharging the battery .................................... 75
13.6 Checking the charging voltage .......................... 76
13.7 Changing the fuses of individual power
consumers...................................................... 77
14 BRAKE SYSTEM ........................................................ 79
14.1 Checking the front brake linings ....................... 79
14.2 Changing the front brake linings ....................... 79
14.3 Checking the brake fluid level of the front
brake ............................................................. 82
14.4 Adding front brake fluid................................... 83
14.5 Changing the front brake fluid .......................... 83
14.6 Checking the rear brake linings ........................ 86
14.7 Changing the rear brake linings ........................ 86
14.8 Checking the free travel of foot brake lever ........ 89
14.9 Adjusting the free travel of the foot brake
lever .............................................................. 89
14.10 Checking the rear brake fluid level .................... 90
TABLE OF CONTENTS 3
14.11 Adding rear brake fluid .................................... 90
14.12 Changing the rear brake fluid ........................... 91
15 LIGHTING SYSTEM, INSTRUMENTS ........................... 94
15.1 Setting kilometers or miles............................... 94
15.2 Adjusting the shift speed RPM 1 ...................... 94
15.3 Adjusting the shift speed RPM 2 ...................... 94
15.4 Setting the time .............................................. 95
15.5 Resetting the service interval display ................ 95
15.6 Checking the headlight setting ......................... 95
15.7 Adjusting the headlight range........................... 96
15.8 Changing the parking light bulb........................ 97
15.9 Changing the headlight bulb ............................ 98
16 ENGINE .................................................................. 100
16.1 Removing the engine ..................................... 100
16.2 Installing the engine...................................... 103
16.3 Engine disassembly ....................................... 108
16.3.1 Preparations (125 Duke) ........................... 108
16.3.2 Draining the engine oil (125 Duke) ............. 108
16.3.3 Removing the chain securing guide (125
Duke) ...................................................... 109
16.3.4 Removing the valve cover (125 Duke) ......... 109
16.3.5 Removing the spark plug (125 Duke) .......... 109
16.3.6 Removing the clutch cover (125 Duke) ....... 109
16.3.7 Setting the engine to ignition top dead
center (125 Duke) .................................... 110
16.3.8 Removing the starter motor (125 Duke) ...... 110
16.3.9 Removing the timing chain tensioner (125
Duke) ...................................................... 111
16.3.10 Removing the camshaft (125 Duke)............ 111
16.3.11 Removing the cylinder head (125 Duke) ..... 112
16.3.12 Removing the piston (125 Duke) ................ 112
16.3.13 Removing the water pump wheel (125
Duke) ...................................................... 113
16.3.14 Removing the alternator cover (125
Duke) ...................................................... 114
16.3.15 Removing the rotor (125 Duke) .................. 114
16.3.16 Removing the starter drive (125 Duke)........ 115
16.3.17 Removing the balancer shaft drive wheel
(125 Duke) .............................................. 115
16.3.18 Removing the gear position sensor (125
Duke) ...................................................... 116
16.3.19 Removing the spacer (125 Duke) ............... 117
16.3.20 Removing the clutch basket (125 Duke) ..... 117
16.3.21 Removing the primary gear (125 Duke) ....... 118
16.3.22 Removing the oil pump (125 Duke) ............ 118
16.3.23 Removing the shift shaft (125 Duke) .......... 119
16.3.24 Removing the shift drum locating (125
Duke) ...................................................... 119
16.3.25 Removing the locking lever (125 Duke) ....... 119
16.3.26 Removing the oil filter (125 Duke) ............. 119
16.3.27 Removing the left engine case (125
Duke) ...................................................... 120
16.3.28 Removing the shift rails (125 Duke) ........... 121
16.3.29 Removing the shift drum (125 Duke) .......... 121
16.3.30 Removing the shift forks (125 Duke) .......... 121
16.3.31 Removing the transmission shafts (125
Duke) ...................................................... 121
16.3.32 Removing the balancer shaft (125 Duke) .... 122
16.3.33 Removing the crankshaft (125 Duke) .......... 122
16.3.34 Preparations (200 Duke) ........................... 122
16.3.35 Draining the engine oil (200 Duke) ............. 122
16.3.36 Removing the chain securing guide (200
Duke) ...................................................... 123
16.3.37 Removing the valve cover (200 Duke) ......... 123
16.3.38 Removing the spark plug (200 Duke) .......... 123
16.3.39 Removing the clutch cover (200 Duke) ....... 123
16.3.40 Setting the engine to ignition top dead
center (200 Duke) .................................... 124
16.3.41 Removing the starter motor (200 Duke) ...... 124
16.3.42 Removing the timing chain tensioner (200
Duke) ...................................................... 125
16.3.43 Removing the camshaft (200 Duke)............ 125
16.3.44 Removing the cylinder head (200 Duke) ..... 126
16.3.45 Removing the piston (200 Duke) ................ 126
16.3.46 Removing the water pump wheel (200
Duke) ...................................................... 127
16.3.47 Removing the alternator cover (200
Duke) ...................................................... 128
16.3.48 Removing the rotor (200 Duke) .................. 128
16.3.49 Removing the starter drive (200 Duke)........ 129
16.3.50 Removing the balancer shaft drive wheel
(200 Duke) .............................................. 129
16.3.51 Removing the gear position sensor (200
Duke) ...................................................... 130
16.3.52 Removing the spacer (200 Duke) ............... 131
16.3.53 Removing the clutch basket (200 Duke) ..... 131
16.3.54 Removing the primary gear (200 Duke) ....... 132
16.3.55 Removing the oil pump (200 Duke) ............ 132
16.3.56 Removing the shift shaft (200 Duke) .......... 133
16.3.57 Removing the shift drum locating (200
Duke) ...................................................... 133
16.3.58 Removing the locking lever (200 Duke) ....... 133
16.3.59 Removing the oil filter (200 Duke) ............. 133
16.3.60 Removing the left engine case (200
Duke) ...................................................... 134
16.3.61 Removing the shift rails (200 Duke) ........... 135
16.3.62 Removing the shift drum (200 Duke) .......... 135
16.3.63 Removing the shift forks (200 Duke) .......... 135
16.3.64 Removing the transmission shafts (200
Duke) ...................................................... 135
16.3.65 Removing the balancer shaft (200 Duke) .... 136
16.3.66 Removing the crankshaft (200 Duke) .......... 136
16.4 Work on individual parts ................................ 136
16.4.1 Work on the left section of the engine case
(125 Duke) .............................................. 136
16.4.2 Work on the right section of the engine
case (125 Duke) ....................................... 137
16.4.3 Changing the shaft seal ring of the water
pump (125 Duke) ..................................... 137
16.4.4 Removing the main bearing (125 Duke) ...... 138
16.4.5 Checking the radial play of the lower
conrod bearing (125 Duke) ........................ 139
16.4.6 Changing the conrod bearing (125 Duke) .... 140
16.4.7 Changing the balancer shaft bearing (125
Duke) ...................................................... 141
16.4.8 Changing the camshaft bearing (125
Duke) ...................................................... 141
16.4.9 Work on the cylinder head (125 Duke) ........ 142
16.4.10 Checking the cylinder head (125 Duke) ...... 143
16.4.11 Checking/measuring the cylinder (125
Duke) ...................................................... 143
16.4.12 Checking the piston ring end gap (125
Duke) ...................................................... 144
16.4.13 Checking/measuring the piston (125
Duke) ...................................................... 144
16.4.14 Checking the piston/cylinder mounting
clearance (125 Duke)................................ 145
TABLE OF CONTENTS 4
16.4.15 Checking the oil pump (125 Duke) ............. 145
16.4.16 Checking the oil pressure regulator valve
(125 Duke) .............................................. 145
16.4.17 Checking the clutch (125 Duke)................. 146
16.4.18 Preassembling the clutch (125 Duke) ......... 147
16.4.19 Checking the shift mechanism (125
Duke) ...................................................... 148
16.4.20 Preassembling the shift shaft (125 Duke) ... 149
16.4.21 Disassembling the main shaft (125
Duke) ...................................................... 149
16.4.22 Dismantling the countershaft (125 Duke) .... 150
16.4.23 Checking the transmission (125 Duke)........ 150
16.4.24 Assembling the main shaft (125 Duke) ....... 151
16.4.25 Assembling the countershaft (125 Duke) .... 152
16.4.26 Checking the timing assembly (125
Duke) ...................................................... 154
16.4.27 Changing the stator (125 Duke) ................. 154
16.4.28 Checking the electric starter drive (125
Duke) ...................................................... 155
16.4.29 Checking the freewheel (125 Duke) ............ 156
16.4.30 Work on the left section of the engine case
(200 Duke) .............................................. 156
16.4.31 Work on the right section of the engine
case (200 Duke) ....................................... 157
16.4.32 Changing the shaft seal ring of the water
pump (200 Duke) ..................................... 157
16.4.33 Removing the main bearing (200 Duke) ...... 158
16.4.34 Checking the radial play of the lower
conrod bearing (200 Duke) ........................ 159
16.4.35 Changing the conrod bearing (200 Duke) .... 160
16.4.36 Changing the balancer shaft bearing (200
Duke) ...................................................... 161
16.4.37 Changing the camshaft bearing (200
Duke) ...................................................... 161
16.4.38 Work on the cylinder head (200 Duke) ........ 162
16.4.39 Checking the cylinder head (200 Duke) ...... 163
16.4.40 Checking/measuring the cylinder (200
Duke) ...................................................... 163
16.4.41 Checking the piston ring end gap (200
Duke) ...................................................... 164
16.4.42 Checking/measuring the piston (200
Duke) ...................................................... 164
16.4.43 Checking the piston/cylinder mounting
clearance (200 Duke)................................ 165
16.4.44 Checking the oil pump (200 Duke) ............. 165
16.4.45 Checking the oil pressure regulator valve
(200 Duke) .............................................. 165
16.4.46 Checking the clutch (200 Duke)................. 166
16.4.47 Preassembling the clutch (200 Duke) ......... 167
16.4.48 Checking the shift mechanism (200
Duke) ...................................................... 168
16.4.49 Preassembling the shift shaft (200 Duke) ... 169
16.4.50 Disassembling the main shaft (200
Duke) ...................................................... 169
16.4.51 Dismantling the countershaft (200 Duke) .... 170
16.4.52 Checking the transmission (200 Duke)........ 170
16.4.53 Assembling the main shaft (200 Duke) ....... 171
16.4.54 Assembling the countershaft (200 Duke) .... 172
16.4.55 Checking the timing assembly (200
Duke) ...................................................... 174
16.4.56 Changing the stator (200 Duke) ................. 174
16.4.57 Checking the electric starter drive (200
Duke) ...................................................... 175
16.4.58 Checking the freewheel (200 Duke) ............ 176
16.5 Engine assembly ........................................... 176
16.5.1 Installing the crankshaft (125 Duke) .......... 176
16.5.2 Installing the balancer shaft (125 Duke) ..... 176
16.5.3 Installing the transmission shafts (125
Duke) ...................................................... 177
16.5.4 Installing the shift forks (125 Duke) ........... 177
16.5.5 Installing the shift drum (125 Duke)........... 177
16.5.6 Installing the shift rails (125 Duke) ............ 178
16.5.7 Installing the left engine case (125
Duke) ...................................................... 178
16.5.8 Installing the oil filter (125 Duke) .............. 179
16.5.9 Installing the locking lever (125 Duke) ....... 179
16.5.10 Installing the shift drum locating (125
Duke) ...................................................... 179
16.5.11 Installing the shift shaft (125 Duke) ........... 180
16.5.12 Installing the oil pump (125 Duke) ............. 180
16.5.13 Installing the primary gear (125 Duke)........ 181
16.5.14 Installing the clutch basket (125 Duke) ...... 181
16.5.15 Installing the spacer (125 Duke) ................ 182
16.5.16 Installing the gear position sensor (125
Duke) ...................................................... 182
16.5.17 Installing the balancer shaft drive wheel
(125 Duke) .............................................. 183
16.5.18 Installing the starter drive (125 Duke) ........ 184
16.5.19 Installing the rotor (125 Duke) ................... 185
16.5.20 Installing the alternator cover (125 Duke) ... 185
16.5.21 Installing the water pump cover (125
Duke) ...................................................... 185
16.5.22 Installing the piston (125 Duke)................. 186
16.5.23 Installing the cylinder head (125 Duke) ...... 187
16.5.24 Installing the camshafts (125 Duke) ........... 188
16.5.25 Installing the timing chain tensioner (125
Duke) ...................................................... 189
16.5.26 Checking the valve clearance (125 Duke) .... 190
16.5.27 Adjusting the valve clearance (125 Duke) ... 190
16.5.28 Installing the starter motor (125 Duke) ....... 190
16.5.29 Installing the clutch cover (125 Duke) ........ 191
16.5.30 Installing the spark plug (125 Duke)........... 191
16.5.31 Installing the valve cover (125 Duke) .......... 192
16.5.32 Installing the chain securing guide (125
Duke) ...................................................... 192
16.5.33 Installing the oil screen (125 Duke)............ 192
16.5.34 Removing the engine from the engine
assembly stand (125 Duke) ....................... 193
16.5.35 Installing the crankshaft (200 Duke) .......... 193
16.5.36 Installing the balancer shaft (200 Duke) ..... 193
16.5.37 Installing the transmission shafts (200
Duke) ...................................................... 194
16.5.38 Installing the shift forks (200 Duke) ........... 194
16.5.39 Installing the shift drum (200 Duke)........... 194
16.5.40 Installing the shift rails (200 Duke) ............ 195
16.5.41 Installing the left engine case (200
Duke) ...................................................... 195
16.5.42 Installing the oil filter (200 Duke) .............. 196
16.5.43 Installing the locking lever (200 Duke) ....... 196
16.5.44 Installing the shift drum locating (200
Duke) ...................................................... 196
16.5.45 Installing the shift shaft (200 Duke) ........... 197
16.5.46 Installing the oil pump (200 Duke) ............. 197
16.5.47 Installing the primary gear (200 Duke)........ 198
16.5.48 Installing the clutch basket (200 Duke) ...... 198
16.5.49 Installing the spacer (200 Duke) ................ 199
TABLE OF CONTENTS 5
16.5.50 Installing the gear position sensor (200
Duke) ...................................................... 199
16.5.51 Installing the balancer shaft drive wheel
(200 Duke) .............................................. 200
16.5.52 Installing the starter drive (200 Duke) ........ 201
16.5.53 Installing the rotor (200 Duke) ................... 202
16.5.54 Installing the alternator cover (200 Duke) ... 202
16.5.55 Installing the water pump cover (200
Duke) ...................................................... 202
16.5.56 Installing the piston (200 Duke)................. 203
16.5.57 Installing the cylinder head (200 Duke) ...... 204
16.5.58 Installing the camshafts (200 Duke) ........... 205
16.5.59 Installing the timing chain tensioner (200
Duke) ...................................................... 206
16.5.60 Checking the valve clearance (200 Duke) .... 207
16.5.61 Adjusting the valve clearance (200 Duke) ... 207
16.5.62 Installing the starter motor (200 Duke) ....... 207
16.5.63 Installing the clutch cover (200 Duke) ........ 208
16.5.64 Installing the spark plug (200 Duke)........... 208
16.5.65 Installing the valve cover (200 Duke) .......... 209
16.5.66 Installing the chain securing guide (200
Duke) ...................................................... 209
16.5.67 Installing the oil screen (200 Duke)............ 209
16.5.68 Removing the engine from the engine
assembly stand (200 Duke) ....................... 210
17 SHIFT MECHANISM ................................................. 211
17.1 Adjusting the shift lever ................................. 211
18 WATER PUMP, COOLING SYSTEM ............................ 212
18.1 Draining the coolant ...................................... 212
18.2 Filling/bleeding the cooling system ................. 212
18.3 Checking the antifreeze and coolant level ........ 213
18.4 Checking the coolant level ............................. 214
19 LUBRICATION SYSTEM............................................ 216
19.1 Oil circuit ..................................................... 216
19.2 Checking the engine oil level .......................... 216
19.3 Checking the engine oil pressure .................... 216
19.4 Changing the engine oil and oil filter,
cleaning the oil screen................................... 218
19.5 Adding engine oil .......................................... 219
20 IGNITION SYSTEM................................................... 220
20.1 Alternator - checking the stator winding .......... 220
21 TECHNICAL DATA .................................................... 221
21.1 Engine ......................................................... 221
21.1.1 125 Duke ................................................ 221
21.1.2 200 Duke ................................................ 221
21.2 Engine tolerance, wear limits ......................... 222
21.2.1 125 Duke ................................................ 222
21.2.2 200 Duke ................................................ 223
21.3 Engine tightening torques .............................. 223
21.4 Capacities .................................................... 224
21.4.1 Engine oil ................................................ 224
21.4.2 Coolant .................................................... 224
21.4.3 Fuel ........................................................ 224
21.5 Chassis ........................................................ 225
21.6 Electrical system........................................... 225
21.7 Tires ............................................................ 226
21.8 Fork............................................................. 226
21.9 Shock absorber ............................................. 226
21.10 Chassis tightening torques ............................. 226
22 CLEANING/PROTECTIVE TREATMENT ....................... 229
22.1 Cleaning the motorcycle ................................ 229
22.2 Checks and maintenance steps for winter
operation...................................................... 230
23 STORAGE ................................................................ 231
23.1 Storage ........................................................ 231
23.2 Preparing for use after storage........................ 231
24 SERVICE SCHEDULE ............................................... 232
24.1 Service schedule ........................................... 232
25 WIRING DIAGRAM ................................................... 234
25.1 Page 1 of 9 (Duke EU/MAL) ........................... 234
25.2 Page 2 of 9 (Duke EU/MAL) ........................... 236
25.3 Page 3 of 9 (Duke EU/MAL) ........................... 238
25.4 Page 4 of 9 (Duke EU/MAL) ........................... 240
25.5 Page 5 of 9 (Duke EU/MAL) ........................... 242
25.6 Page 6 of 9 (Duke EU/MAL) ........................... 244
25.7 Page 7 of 9 (Duke EU/MAL) ........................... 246
25.8 Page 8 of 9 (Duke EU/MAL) ........................... 248
25.9 Page 9 of 9 (Duke EU/MAL) ........................... 250
25.10 Page 1 of 8 (Duke COL) ................................. 252
25.11 Page 2 of 8 (Duke COL) ................................. 254
25.12 Page 3 of 8 (Duke COL) ................................. 256
25.13 Page 4 of 8 (Duke COL) ................................. 258
25.14 Page 5 of 8 (Duke COL) ................................. 260
25.15 Page 6 of 8 (Duke COL) ................................. 262
25.16 page 7 of 8 (Duke COL) ................................. 264
25.17 Page 8 of 8 (Duke COL) ................................. 266
26 SUBSTANCES ......................................................... 268
27 AUXILIARY SUBSTANCES ........................................ 270
28 SPECIAL TOOLS ...................................................... 272
29 STANDARDS ........................................................... 281
INDEX ............................................................................ 282
1 MEANS OF REPRESENTATION 6
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).
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.
Denotes a voltage measurement.
Denotes a current measurement.
Denotes a resistance measurement.
1.2 Formats used
The typographical formats used in this document are explained below.
Proprietary name Identifies a proprietary name.
Name
®
Identifies a protected name.
Brand™ Identifies a trademark.
2 SAFETY ADVICE 7
2.1 Repair Manual
Read this Repair Manual carefully and thoroughly before beginning work. It contains useful information and tips that will help you
repair and maintain your vehicle.
This manual assumes that the necessary special KTM tools and KTM workplace and workshop equipment are available.
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.
2.3 Degrees of risk and symbols
Danger
Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures
are not taken.
Warning
Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.
Caution
Identifies a danger that may lead to minor injuries if the appropriate measures are not taken.
Note
Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.
Warning
Identifies a danger that will lead to environmental damage if the appropriate measures are not taken.
2.4 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 paren-
theses. 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.
3 IMPORTANT INFORMATION 8
3.1 Guarantee, warranty
The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's
Service & Warranty Booklet and in the KTM dealer.net; otherwise, all warranty claims will be void. No warranty claims can be consid-
ered for damage resulting from manipulations and/or alterations to the vehicle.
Additional information on the guarantee or 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 the operating and auxiliary substances (such as fuel and lubricants) as specified in the manual.
3.3 Spare parts, accessories
Only use spare parts and accessories approved and/or recommended by KTM. KTM accepts no liability for other products and any
resulting damage or loss.
The current KTM PowerParts for your vehicle can be found on the KTM website.
International KTM Website: http://www.ktm.com
3.4 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 dis-
assemble the component to perform the activity in question. Please follow the instructions in the text.
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Thank you for considering this comprehensive Workshop Service Repair Manual for the KTM 125 Duke EU & DE 2011-2012.
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