KTM 125-200 Duke 2013 Owner's Manual

4.5 (2)

REPAIR MANUAL 2013

125 Duke EU

200 Duke EU

200 Duke MAL

200 Duke 2014 COL

Art. no. 3206162en

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 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, as well as misprints and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of supply.

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

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

5.1Raising the motorcycle with the rear wheel

stand .............................................................

5.2Taking the motorcycle off of the rear wheel

stand .............................................................

5.3Raising the motorcycle with the front wheel

stand .............................................................

5.4Taking 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

8.1Adjusting 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

12.5.7Checking 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

13.3Disconnecting the negative cable of the

battery ...........................................................

13.4Reconnecting the negative cable of the

	battery ...........................................................	75
13.5	Recharging the battery ....................................	75
13.6	Checking the charging voltage ..........................	76

13.7Changing 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

14.3Checking 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

14.9Adjusting the free travel of the foot brake

lever ..............................................................	89
14.10 Checking the rear brake fluid level....................	90

TABLE OF CONTENTS

	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

16.3.3Removing 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

16.3.7Setting the engine to ignition top dead

center (125 Duke) ....................................	110
16.3.8 Removing the starter motor (125 Duke) ......	110

16.3.9Removing 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

16.3.13Removing the water pump wheel (125

Duke) ......................................................

113

16.3.14Removing 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

16.3.17Removing the balancer shaft drive wheel

(125 Duke) ..............................................

115

16.3.18Removing 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

16.3.24Removing 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

16.3.27Removing 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

16.3.31Removing 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

16.3.36Removing the chain securing guide (200

Duke) ......................................................

123

		3
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

16.3.40Setting the engine to ignition top dead

center (200 Duke) ....................................	124
16.3.41 Removing the starter motor (200 Duke) ......	124

16.3.42Removing 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

16.3.46Removing the water pump wheel (200

Duke) ......................................................

127

16.3.47Removing 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

16.3.50Removing the balancer shaft drive wheel

(200 Duke) ..............................................

129

16.3.51Removing 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

16.3.57Removing 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

16.3.60Removing 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

16.3.64Removing 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

16.4.1Work on the left section of the engine case

(125 Duke) ..............................................

136

16.4.2Work on the right section of the engine

case (125 Duke).......................................

137

16.4.3Changing the shaft seal ring of the water

pump (125 Duke) .....................................	137
16.4.4 Removing the main bearing (125 Duke) ......	138

16.4.5Checking the radial play of the lower

	conrod bearing (125 Duke) ........................	139
16.4.6	Changing the conrod bearing (125 Duke) ....	140

16.4.7Changing the balancer shaft bearing (125

Duke) ......................................................

141

16.4.8Changing 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

16.4.11Checking/measuring the cylinder (125

Duke) ......................................................

143

16.4.12Checking the piston ring end gap (125

Duke) ......................................................

144

16.4.13Checking/measuring the piston (125

Duke) ......................................................

144

16.4.14Checking the piston/cylinder mounting

clearance (125 Duke)................................

145

TABLE OF CONTENTS

16.4.15 Checking the oil pump (125 Duke).............

145

16.4.16Checking 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

16.4.21Disassembling 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

16.4.26Checking the timing assembly (125

Duke) ......................................................	154
16.4.27 Changing the stator (125 Duke) .................	154

16.4.28Checking the electric starter drive (125

Duke) ......................................................	155
16.4.29 Checking the freewheel (125 Duke)............	156

16.4.30Work on the left section of the engine case

(200 Duke) ..............................................

156

16.4.31Work on the right section of the engine

case (200 Duke).......................................

157

16.4.32Changing 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

16.4.36Changing the balancer shaft bearing (200

Duke) ......................................................

161

16.4.37Changing 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

16.4.40Checking/measuring the cylinder (200

Duke) ......................................................

163

16.4.41Checking the piston ring end gap (200

Duke) ......................................................

164

16.4.42Checking/measuring the piston (200

Duke) ......................................................

164

16.4.43Checking the piston/cylinder mounting

clearance (200 Duke)................................	165
16.4.44 Checking the oil pump (200 Duke).............	165

16.4.45Checking 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

16.4.50Disassembling 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

16.4.55Checking the timing assembly (200

Duke) ......................................................	174
16.4.56 Changing the stator (200 Duke) .................	174

16.4.57Checking the electric starter drive (200

Duke) ......................................................	175
16.4.58 Checking the freewheel (200 Duke)............	176

		4
16.5	Engine assembly...........................................	176
16.5.1	Installing the crankshaft (125 Duke) ..........	176
16.5.2	Installing the balancer shaft (125 Duke) .....	176

16.5.3Installing 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

16.5.7Installing 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

16.5.10Installing 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

16.5.16Installing the gear position sensor (125

Duke) ......................................................

182

16.5.17Installing 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

16.5.21Installing 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

16.5.25Installing 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

16.5.32Installing the chain securing guide (125

Duke) ......................................................	192
16.5.33 Installing the oil screen (125 Duke)............	192

16.5.34Removing 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

16.5.37Installing 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

16.5.41Installing 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

16.5.44Installing 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

16.5.50Installing the gear position sensor (200

Duke) ......................................................

199

16.5.51Installing 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

16.5.55Installing 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

16.5.59Installing 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

16.5.66Installing the chain securing guide (200

Duke) ......................................................	209
16.5.67 Installing the oil screen (200 Duke)............	209

16.5.68Removing 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

19.4Changing 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

22.2Checks 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

MEANS OF REPRESENTATION

1.1Symbols 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.

1.2Formats 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.

SAFETY ADVICE

2.1Repair 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.

2.2Safety 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.

2.3Degrees 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.

2.4Work 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.

IMPORTANT INFORMATION

3.1Guarantee, warranty

The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's Service & Warranty Booklet and in the KTM dealer.net; otherwise, all warranty claims will be void. No warranty claims can be considered for damage resulting from manipulations and/or alterations to the vehicle.

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

3.2Operating 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.

3.3Spare 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

3.4Figures

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.

SERIAL NUMBERS

4.1Chassis number/type label

The chassis number 1 is stamped on the right of the steering head.

The type label 2 is on the right of the frame behind the steering head.

B00699-10

4.2Key number

The key number 1 can be found on the KEYCODECARD.

Info

You need the key number to order a spare key. Keep the KEYCODECARD in a safe place.

B00755-10

4.3Engine number

The engine number 1 is stamped on the left side of the engine under the engine sprocket.

B00700-10

MOTORCYCLE

5.1Raising the motorcycle with the rear wheel stand

Note

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

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

–Mount the support of the wheel stand.

–Insert the adapter in the rear wheel stand.

Adapter (61029055130) ( p. 273)

Rear wheel stand (61029055400) ( p. 273)

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

B01387-01

5.2Taking the motorcycle off of the rear wheel stand

Note

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

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

–Secure the motorcycle against falling over.

–Remove the rear wheel stand and lean the vehicle on the side stand 1.

–Remove the support of the wheel stand.

B00714-10

5.3Raising the motorcycle with the front wheel stand

Note

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

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

Preparatory work

–Raise the motorcycle with the rear wheel stand. ( p. 10)

Condition

–Remove cap 1.

C00196-10

5 MOTORCYCLE

C00197-01

–Move the handlebar to the straight-ahead position. Attach the lifting gear to the steering stem.

Adapter (61029955620) ( p. 274)

Front wheel stand (61029055500) ( p. 273)

Info

Always raise the rear of the motorcycle first.

–Raise the front of the motorcycle.

5.4Taking the motorcycle off of the front wheel stand

Note

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

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

–Secure the motorcycle against falling over.

–Remove the front wheel stand.

B01388-01

– Mount cap 1.

C00196-10

5.5Raising the motorcycle with the work stand

Note

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

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

–Remove screw 1.

307317-10

MOTORCYCLE

–Mount special tool 2 on the right side of the vehicle. Work stand (62529055000) ( p. 274)

307318-10

–Remove screw 3.

307319-10

–Mount special tool 2 on the left side of the vehicle. Work stand (62529055000) ( p. 274)

307320-10

–Position the motorcycle upright, align the special tool and raise the motorcycle.

307321-10

5.6Removing the motorcycle from the work stand

Note

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

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

–Secure the motorcycle against falling over.

–Remove special tool 1.

307321-11

5 MOTORCYCLE

– Mount and tighten screws 23. Guideline

Screw, engine bearer on frame	M8	30 Nm
		(22.1 lbf ft)

307322-10

5.7Starting

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.

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 ride the vehicle without an air filter since dust and dirt can get into the engine and result in 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.

–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.
	(Duke EU/MAL)
B00782-10	(Duke EU/MAL)

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.

MOTORCYCLE

Switching off ABS (Duke EU/MAL)

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 1 button for 3 – 5 seconds.

The ABS warning lamp starts flashing; ABS is deactivated.

401685-15

5.8Starting the motorcycle to make checks

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.

Info

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

–Turn the emergency OFF switch to the position .

–Shift gear to neutral.

–Switch on the ignition by turning the ignition key to the position .

–Press the electric starter button .

Info

Do not open the throttle.

B00782-10

FORK, TRIPLE CLAMP

6.1Cleaning the dust boots of the fork legs

(Duke COL)

–Push dust boot 1 of both fork legs downwards.

Info

The dust boots should remove dust and coarse dirt particles from the fork tubes. Over time, dirt can penetrate behind the dust boots. If this dirt is not removed, the oil seals behind can start to leak.

					Warning
					Warning
					Danger of accidents Reduced braking efficiency due to oil or grease on
	304854-10
					the brake discs.

–Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.

–Clean and oil the dust boots and inside fork tube of both fork legs.

Universal oil spray ( p. 271)

–Press the dust boots back into their normal position.

–Remove excess oil.

(Duke EU/MAL)

–Push dust boot 1 of both fork legs downwards.

Info

					Warning
					Warning
					Danger of accidents Reduced braking efficiency due to oil or grease on
	307309-10
					the brake discs.

–Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.

–Clean and oil the dust boots and inside fork tube of both fork legs.

Universal oil spray ( p. 271)

–Press the dust boots back into their normal position.

–Remove excess oil.

6.2Removing fork legs

304857-10

Preparatory work

–Raise the motorcycle with the work stand. ( p. 11)

–Tie the rear of the vehicle down.

–Dismount the front fender. ( p. 55)

Main work (Duke COL)

–Remove screws 1.

–Press back the brake linings with a light lateral tilting of the brake caliper on the brake disc. Pull the brake caliper carefully back from the brake disc and hang it to one side.

Info

Do not pull the hand brake lever when the brake caliper has been removed.

FORK, TRIPLE CLAMP

–Loosen screws 2 and screw 3.

–Unscrew screw 2 about six turns and press your hand on the screw to push the wheel spindle out of the axle clamp. Remove screw 2.

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.

304858-10

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

– Remove screws 4.

– Remove the cable binder and hang the wheel speed sensor to one side.

304859-10

–Loosen screws 5. Remove the fork legs from the bottom.

304860-10

307310-10

307311-10

307312-10

(Duke EU/MAL)

–Remove screw 1.

–Remove the cable binder.

–Pull off the ABS sensor and hang it to one side.

–Remove screws 2.

–Press back the brake linings with a light lateral tilting of the brake caliper on the brake disc. Pull the brake caliper carefully back from the brake disc and hang it to one side.

Info

Do not pull the hand brake lever when the brake caliper has been removed.

–Loosen screws 3 and screw 4.

–Unscrew screw 3 about six turns and press your hand on the screw to push the wheel spindle out of the axle clamp. Remove screw 3.

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.

FORK, TRIPLE CLAMP

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

–Loosen screws 5. Remove the fork legs from the bottom.

307313-10

6.3Installing the fork legs

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.

Main work (Duke COL)

–Push the fork legs into the triple clamps.

–Align the fork legs in the required position using the fork rings.

304863-10
	–	Tighten screws 1.
	–	Tighten screws 1.
		Guideline

		Screw, top triple clamp	M8	11 Nm
				(8.1 lbf ft)
	–
	–	Tighten screws 2.
		Guideline

		Screw, bottom triple clamp	M8	15 Nm
				(11.1 lbf ft)
304860-11
304860-11

–Position the wheel speed sensor. Mount and tighten screws 3. Guideline

Remaining screws, chassis	M4	4 Nm (3 lbf ft)

304859-11

–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 4 and contact surfaces A of the spacers.

Long-life grease ( p. 270)

304861-10

FORK, TRIPLE CLAMP

–Clean screw 5 and the wheel spindle.

–Lift the front wheel into the fork, position it, and insert the wheel spindle.

–Mount and tighten screw 5. Guideline

Screw, front wheel spindle	M8	30 Nm
		(22.1 lbf ft)

304858-11

304857-11

304862-10

– Position the brake calipers and check that the brake linings are seated correctly.

– Mount screws 6 but do not tighten yet.

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

The brake calipers straighten.

– Tighten screws 6. Guideline

Screw, front brake	M8x1	27 Nm	Loctite® 243™
caliper		(19.9 lbf ft)

– Remove the fixation of the hand brake lever.

– Unload the rear of the vehicle.

– Remove the motorcycle from the work stand. ( p. 12)

– Pull the front brake and compress the fork powerfully a few times.

The fork legs straighten.

– Tighten screws 7. Guideline

Screw, fork stub	M8	15 Nm
		(11.1 lbf ft)

(Duke EU/MAL)

–Push the fork legs into the triple clamps.

–Align the fork legs in the required position using the fork rings.

307314-10
	–	Tighten screws 1.
	–	Tighten screws 1.
		Guideline

		Screw, top triple clamp	M8	11 Nm
				(8.1 lbf ft)
	–
	–	Tighten screws 2.
		Guideline

		Screw, bottom triple clamp	M8	15 Nm
				(11.1 lbf ft)
307313-11
307313-11

FORK, TRIPLE CLAMP

–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 3 and contact surfaces A of the spacers.

Long-life grease ( p. 270)

307315-10

307312-11

307311-11

307310-11

– Clean screw 4 and the wheel spindle.

– Lift the front wheel into the fork, position it, and insert the wheel spindle.

– Mount and tighten screw 4. Guideline

Screw, front wheel spindle	M8	30 Nm
		(22.1 lbf ft)

– Position the brake calipers and check that the brake linings are seated correctly.

– Mount screws 5 but do not tighten yet.

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

	The brake calipers straighten.
–	Tighten screws 5.
	Guideline

	Screw, front brake	M8x1		27 Nm	Loctite® 243™
	caliper			(19.9 lbf ft)

– Remove the fixation of the hand brake lever.
– Unload the rear of the vehicle.
–	Remove the motorcycle from the work stand. ( p. 12)
– Position the ABS sensor.
– Mount and tighten screw 6.
	Guideline

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

–Route the cable and secure with a cable binder.

–Pull the front brake and compress the fork powerfully a few times. The fork legs straighten.

–Tighten screws 7. Guideline

Screw, fork stub	M8	15 Nm
		(11.1 lbf ft)

307316-10

Finishing work

–Install front fender. ( p. 55)

FORK, TRIPLE CLAMP

6.4Disassembling the fork legs

Info

These operations are the same on both fork legs.

Condition

The fork legs have been removed.

–Clamp the fork leg in the area of the lower triple clamp. Clamping stand (T612S) ( p. 280)

201505-10

–Loosen the screw cap 1.

Info

The screw cap cannot be removed yet.

201506-10

–Empty the fork oil.

201507-10

–Release the fork leg and clamp it with the fork stub.

Info

Use soft jaws.

201508-10

–Push the outer tube downward.

–Hold screw cap 1. Loosen nut 2. Remove the screw cap.

201509-10

FORK, TRIPLE CLAMP

–Detach the outer tube from the inner tube.

Info

Place a container underneath to catch any oil that may run out.

201510-10

–Unclamp the inner tube. Drain the oil.

201511-10

–Clamp the outer tube in the area of the lower triple clamp. Clamping stand (T612S) ( p. 280)

–Remove dust boot 3.

201512-10

–Remove lock ring 4.

Info

The lock ring has a beveled end where a screwdriver can be applied.

201513-10

–Remove seal ring 5. Remove support ring 6.

201514-10

–Unclamp the outer tube.

–Heat up the outer tube in the area of sliding bushing 7. Guideline

50 °C (122 °F)

–Strike the lower edge of the outer fork tube on a wooden board. Sliding bushing 7 must fall out of its seat.

201515-10

FORK, TRIPLE CLAMP

6.5Checking the fork legs

Condition

The fork legs have been disassembled.

–Check the inner tube and the axle clamp for damage. » If damage is found:

– Change the fork leg.

201516-10

–Measure the outside diameter of the inner tube in several places.

External diameter of inner tube	42.975… 43.005 mm (1.69193…
	1.69311 in)

»If the measured value is less than the specified value:

– Change the fork leg.

200684-10

200685-10

200632-10

–Measure the run-out of the inner tube.

Run-out of inner tube	≤ 0.20 mm (≤ 0.0079 in)

»If the measured value is greater than the specified value:

–Change the fork leg.

–Check the outer tube for damage.

»If damage is found:

–Change the fork leg.

–Check the surface of the sliding bushings.

»If the dark layer A is worn off:

–Change the fork leg.

201517-10

FORK, TRIPLE CLAMP

6.6Assembling the fork legs

Info

These operations are the same on both fork legs.

Preparatory work

–Check the fork legs. ( p. 22)

Main work

–Clamp in the inner tube with the axle clamp. Guideline

Use soft jaws.

–Grease and slide on dust boot 1.

Lubricant (T511) ( p. 270)

	202092-10	Info
	202092-10	Always change the dust boot, lock ring, seal ring, and support ring.

Install the dust boot with the sealing lip and spring expander facing downward.

–Slide on lock ring 2.

–Grease and slide on seal ring 3.

Lubricant (T511) ( p. 270)

Info

Mount with the sealing lip facing down and the open side facing up.

–Slide on support ring 4.

–Sand the edges of sliding bushing 5 with 600-grit sandpaper, then clean and grease.

Fork oil (SAE 4) (48601166S1) ( p. 269)

–Slide on sliding bushing 5.

–Warm up the outer tube in the lower sliding bushing area A. Guideline

50 °C (122 °F)

–Slide the outer tube onto the inner tube.

–Hold the sliding bushing with the longer shoulder of the special tool.

Mounting tool (T528S) ( p. 280)

–Push the sliding bushing all the way into the outer tube.

202093-10

–Position the support ring.

–Hold the seal ring with the shorter shoulder of the special tool.

Mounting tool (T528S) ( p. 280)

–Push the seal ring and support ring all the way into the outer tube.

202094-10

FORK, TRIPLE CLAMP

–Mount lock ring 2.

Info

The lock ring must engage audibly.

202095-10

202096-10

202097-10

201523-10

–Install dust boot 1.

–Mount screw cap 6 onto the piston rod.

Info

Nut 7 must be turned all the way down.

– Hold the screw cap and tighten the nut. Guideline

	Nut, piston rod on screw cap		M12x1	30 Nm
				(22.1 lbf ft)

– Fill it with fork oil.

	Fork oil	450 ml	Fork oil (SAE 4) (48601166S1)
		(15.21 fl. oz.)	( p. 269)

Info

If it should be impossible to add the full quantity of oil, close the screw cap of the outer tube, unclamp the fork and bounce a number of times. Then add the remaining quantity.

–Push the outer tube upward.

–Mount screw cap 6.

–Unclamp the fork leg in the area of the lower triple clamp.

		Clamping stand (T612S) (	p. 280)

	– Tighten the screw cap.
		Guideline

		Screw cap on outer tube		M47x1.5	30 Nm
					(22.1 lbf ft)
201522-10					(22.1 lbf ft)
201522-10

6.7Removing the lower triple clamp

Preparatory work

–Raise the motorcycle with the work stand. ( p. 11)

–Tie the rear of the vehicle down.

–Dismount the front fender. ( p. 55)

–Remove the fork legs. ( p. 15)

FORK, TRIPLE CLAMP

Main work

–Remove expanding rivets 1.

307323-10

–Remove screws 2.

–Lift the headlight mask slightly and swing forward.

307324-10

–Detach connectors 3 and 4.

307325-10

–Detach connectors 5 and 6.

307326-10

–Remove the connector holder.

–Disconnect connector 7.

307327-10

–Remove the combination instrument.

307328-10

FORK, TRIPLE CLAMP

307329-10

307330-10

307331-10

307332-10

307333-10

–Remove screws 8.

–Remove the headlight mask.

–Remove screw 9.

–Remove the upper triple clamp with the handlebar and set aside.

Info

Protect the vehicle and its attachments from damage by covering them.

–Expose the cable.

–Remove nut bk.

Castle nut wrench; ½" drive (90129050100) ( p. 278)

–Remove washer bl.

–Remove steering head bearing bm.

–Remove the lower triple clamp with the steering stem.

307334-10

FORK, TRIPLE CLAMP

6.8Installing the lower triple clamp

Main work

–Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 270)

–Insert the lower triple clamp with the steering stem.

–Mount the upper steering head bearing 1.

–Mount washer 2 with the cut-out facing downward.

307334-11

	Alternative 1
	Alternative 1
	A new steering head bearing is used.
	– Mount and tighten nut 3.
		Guideline

		Nut, steering head	M30x1		Step 1
					50 Nm
					(36.9 lbf ft)
					2nd stage
					(loosen, counter-
307333-11					clockwise)
					clockwise)
					2 turns
					Step 3
					5 Nm (3.7 lbf ft)


		Castle nut wrench; ½" drive (90129050100) (		p. 278)

Alternative 2

The steering head bearing is used again.

–Mount and tighten nut 3. Guideline

Nut, steering head	M30x1	5 Nm (3.7 lbf ft)

Castle nut wrench; ½" drive (90129050000) ( p. 278)

–Secure the cable in the bracket.

307332-10

–Position the upper triple clamp with the handlebar.

307331-10

6	FORK, TRIPLE CLAMP				28
		– Mount screw 4 with the washer but do not tighten it yet.
		– Mount screw 4 with the washer but do not tighten it yet.
			Guideline

			Screw, top steering head	M16x1.5	52 Nm
					(38.4 lbf ft)

Holding lugs A reach into the drilled holes.

307330-11

–Position the headlight mask.

–Mount and tighten screw 5. Guideline

Screw, headlight mask	M6	11 Nm (8.1 lbf ft)

307329-11

–Position the combination instrument.

–Plug in connector 6.

–Mount the connector holder 7.

307327-11

–Plug in connectors 8 and 9.

307326-11

–Plug in connectors bk and bl.

307325-11

–Fold the headlight mask up.

–Mount and tighten screws bm. Guideline

Screw, headlight mask	M6	11 Nm (8.1 lbf ft)

307324-11

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