KTM 125Duke 2012, 200Duke 2012 Owner's manual

OWNER'S MANUAL 2012

125 Duke EU

125 Duke DE

200 Duke EU

Art. no. 3211800en

DEAR KTM CUSTOMER 1

DEARKTM 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 accordingly.

We wish you a lot of enjoyment in riding this vehicle.

Enter the serial numbers of your vehicle below.

Chassis number/type label ( p. 16) Dealer's stamp

Engine number ( p. 16)

Key number ( p. 17)

The owner's manual contained the latest information for this model 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 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 delivery.

DEAR KTM CUSTOMER 2

© 2012 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 3

TABLEOF CONTENTS

MEANS OF REPRESENTATION ............................................... 6

IMPORTANT INFORMATION ................................................... 7

VIEW OF VEHICLE................................................................ 12

View of vehicle, front left (example).................................... 12

View of vehicle, rear right (example) ................................... 14

SERIAL NUMBERS............................................................... 16

Chassis number/type label ................................................. 16

Engine number................................................................. 16

Key number ..................................................................... 17

CONTROLS.......................................................................... 18

Clutch lever ..................................................................... 18

Hand brake lever .............................................................. 18

Throttle grip..................................................................... 19

Light switch..................................................................... 19

High beam flasher button .................................................. 20

Turn signal switch ............................................................ 20

Horn button ..................................................................... 21

Emergency OFF switch ...................................................... 21

Electric starter button ....................................................... 22

Ignition/steering lock ........................................................ 22

Combination instrument - overview..................................... 23

Combination instrument - activation and test ...................... 24

Combination instrument - function buttons ......................... 25

Combination instrument - indicator lamps........................... 26

Combination instrument - display....................................... 27

Combination instrument - filling level display in fuel tank..... 28

Combination instrument - TRIP F display............................ 29

Combination instrument - coolant temperature indicator ...... 30

Combination instrument - info display ................................ 31

Combination instrument - warning notes ............................. 32

Riding time/average speed menu........................................ 34

Average speed/average fuel consumption 1 menu ................ 35

Average fuel consumption 1/average fuel consumption 2

menu .............................................................................. 36

Average fuel consumption 2/service menu........................... 37

Service/range menu .......................................................... 38

Range/riding time menu .................................................... 39

Total distance menu ODO.................................................. 40

Distance menu 1 TRIP 1 ................................................... 40

Distance menu 2 TRIP 2 ................................................... 41

Setting kilometers or miles ................................................ 41

Setting the time ............................................................... 42

Adjusting the shift speed RPM 1........................................ 43

Adjusting the shift speed RPM 2........................................ 43

Opening the filler cap ....................................................... 44

Closing the filler cap ......................................................... 46

Seat lock ......................................................................... 46

Tool set ........................................................................... 47

Grab handles ................................................................... 47

Passenger footrests........................................................... 48

Shift lever........................................................................ 48

Foot brake lever................................................................ 49

Side stand ....................................................................... 50

PREPARING FOR USE .......................................................... 51

Advice on first use............................................................ 51

Running in the engine....................................................... 52

Loading the vehicle .......................................................... 52

TABLE OF CONTENTS 4

RIDING INSTRUCTIONS ....................................................... 54

Checks and maintenance when preparing for use................. 54

Starting ........................................................................... 55

Starting off ...................................................................... 56

Shifting, riding................................................................. 57

Applying the brakes .......................................................... 59

Stopping, parking ............................................................. 60

Refueling......................................................................... 62

SERVICE SCHEDULE............................................................ 64

Service schedule .............................................................. 64

TUNING THE CHASSIS......................................................... 66

Adjusting the spring preload of the shock absorber x ......... 66

Adjusting the shift lever .................................................... 66

SERVICE WORK ON THE CHASSIS ........................................ 68

Raising the motorcycle with the front wheel stand ............... 68

Taking the motorcycle off of the front wheel stand ............... 69

Raising the motorcycle with the rear wheel stand................. 70

Taking the motorcycle off of the rear wheel stand ................ 70

Removing the passenger seat............................................. 71

Mounting the passenger seat ............................................. 72

Removing the seat............................................................ 72

Mounting the seat ............................................................ 73

Checking for chain dirt accumulation ................................. 74

Cleaning the chain............................................................ 74

Checking the chain tension ............................................... 75

Adjusting the chain tension ............................................... 76

Checking the chain, rear sprocket, and engine sprocket........ 78

Removing the front spoiler................................................. 82

Fitting front spoiler........................................................... 83

BRAKES.............................................................................. 84

Checking the brake discs................................................... 84

Checking the brake fluid level of the front brake .................. 84

Adding front brake fluid x ............................................... 85

Checking the front brake linings......................................... 87

Checking the rear brake fluid level ..................................... 87

Adding rear brake fluid x ................................................ 88

Checking the free travel of foot brake lever.......................... 90

Adjusting the free travel of the foot brake lever x............... 91

Checking the rear brake linings .......................................... 92

WHEELS, TIRES .................................................................. 93

Removing the front wheel x............................................. 93

Installing the front wheel x.............................................. 93

Removing the rear wheel x .............................................. 95

Installing the rear wheel x............................................... 96

Checking the rear hub rubber dampers x .......................... 97

Checking the tire condition................................................ 99

Checking the tire air pressure .......................................... 100

ELECTRICAL SYSTEM ........................................................ 102

Removing the battery x................................................. 102

Installing the battery x.................................................. 103

Recharging the battery x............................................... 104

Changing the fuses of individual power consumers............. 107

Changing the headlight bulb ............................................ 108

Changing the parking light bulb ....................................... 111

Checking the headlight setting......................................... 115

Adjusting the headlight range .......................................... 116

TABLE OF CONTENTS 5

COOLING SYSTEM ............................................................. 119

Cooling system............................................................... 119

Checking the antifreeze and coolant level ......................... 120

Checking the coolant level............................................... 122

Draining the coolant x .................................................. 124

Filling/bleeding the cooling system x.............................. 125

TUNING THE ENGINE ........................................................ 127

Checking the play in the throttle cable.............................. 127

Adjusting the play in the throttle cable x ........................ 128

Checking the clutch lever play ......................................... 128

Adjusting the clutch cable play x................................... 129

SERVICE WORK ON THE ENGINE ....................................... 130

Checking the engine oil level ........................................... 130

Changing the engine oil and oil filter, cleaning the oil

screen x...................................................................... 130

Adding engine oil ........................................................... 133

CLEANING, CARE .............................................................. 135

Cleaning the motorcycle.................................................. 135

Checks and maintenance steps for winter operation ........... 137

STORAGE .......................................................................... 138

Storage.......................................................................... 138

Preparing for use after storage ......................................... 139

TROUBLESHOOTING.......................................................... 140

TECHNICAL DATA - ENGINE ............................................... 143

125 Duke ...................................................................... 143

200 Duke ...................................................................... 144

Capacity - engine oil ....................................................... 146

Capacity - coolant........................................................... 146

TECHNICAL DATA - ENGINE TIGHTENING TORQUES........... 147

TECHNICAL DATA - CHASSIS ............................................. 149

Lighting equipment ........................................................ 150

Tires ............................................................................. 151

Capacity - fuel................................................................ 151

TECHNICAL DATA - FORK................................................... 152

TECHNICAL DATA - SHOCK ABSORBER .............................. 153

TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ......... 154

SUBSTANCES.................................................................... 158

AUXILIARY SUBSTANCES................................................... 161

STANDARDS...................................................................... 163

INDEX ............................................................................... 164

MEANS OF REPRESENTATION 6

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 serviced opti­mally by specially trained experts using the specialist tools required.

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

Formats used

The typographical formats used in this document are explained below.

Specific name Identifies a proprietary name.

®

Name

Brand™ Identifies a brand available on the open market.

Identifies a protected name.

IMPORTANT INFORMATION 7

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.

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. Poor adjustment and tuning of the engine and chassis can lead to damage and
breakage of components.
Using the motorcycle in extreme conditions such as very muddy or wet roads can lead to above-average wear of components such as the
transmission train or the brakes. For this reason, it may be necessary to service or replace worn parts before the limit specified in the
service schedule is reached.
Pay careful attention to the prescribed running-in period and service intervals. If you observe these exactly, you will ensure a much longer
service life for your motorcycle.

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 record 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.

Fuel, oils, etc.

You should use the fuels, oils, and greases according to specifications as listed in the Owner's Manual.

IMPORTANT INFORMATION 8

Spare parts, accessories

For your own safety, only use spare parts and accessory products that have been 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.
Some spare parts and accessory products are specified in parentheses in the descriptions. Your KTM dealer will be glad to advise you.

You will find the current KTM PowerParts for your vehicle on the KTM website.
International KTM Website: http://www.ktm.com

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. Example: magneto extractor (90129009000)
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.
Where thread lockers are used on screw connections (e.g., Loctite®), follow the instructions for use from the manufacturer.
After disassembly, clean the parts that are to be reused and check them for damage and wear. Change damaged or worn parts.
Following repairs or servicing, the vehicle must be checked for roadworthiness.

Transport

Note

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

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

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.

– Switch off the engine and remove the ignition key.

IMPORTANT INFORMATION 9

– Use straps or other suitable devices to secure the motorcycle against falling over and rolling away.

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.

Notes/warnings

Pay close attention to the notes/warnings.

Info

Various information and warning labels are affixed to the vehicle. Do not remove information/warning labels. If they are missing,
you or others may not recognize potential hazards and may therefore be injured.

IMPORTANT INFORMATION 10

Grades of risks

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.

Owner's manual

– It is important that you read this owner's manual carefully and completely before making your first trip. It contains useful information

and many tips on how to operate and handle your motorcycle. Only then will you learn how to best customize the motorcycle for your
own use and to protect yourself from injury. The owner's manual also contains important information on servicing the motorcycle.

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

11

VIEW OF VEHICLE 12

3.1View of vehicle, front left (example)

B00778-10

VIEW OF VEHICLE 13

1 Combination instrument
2 Rear mirror
3 Clutch lever ( p. 18)
4 Seat
5 Passenger seat
6 Seat lock ( p. 46)
7 Grab handles ( p. 47)
8 Engine number ( p. 16)
9 Side stand ( p. 50)
10 Shift lever ( p. 48)

VIEW OF VEHICLE 14

3.2View of vehicle, rear right (example)

B00779-10

VIEW OF VEHICLE 15

1 Tool set ( p. 47)
2 Light switch ( p. 19)
2 High beam flasher button ( p. 20)
2 Turn signal switch ( p. 20)
2 Horn button ( p. 21)
3 Filler cap
4 Ignition/steering lock ( p. 22)
5 Emergency OFF switch ( p. 21)
6 Hand brake lever ( p. 18)
7 Electric starter button ( p. 22)
8 Chassis number/type label ( p. 16)
9 Passenger footrests ( p. 48)
10 Foot brake lever ( p. 49)

SERIAL NUMBERS 16

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

4.2Engine number

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

B00700-10

SERIAL NUMBERS 17

4.3Key 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

CONTROLS 18

5.1Clutch lever

The clutch lever 1 is fitted on the left side of the handlebar.

B00701-10

5.2Hand brake lever

The hand brake lever 1 is fitted on the right side of the handlebar.
The front brake is engaged using the hand brake lever.

B00702-10

CONTROLS 19

5.3Throttle grip

The throttle grip 1 is fitted on the right side of the handlebar.

B00703-10

5.4Light switch

The light switch 1 is fitted on the left side of the handlebar.

Possible states

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

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

B00704-10

CONTROLS 20

5.5High beam flasher button

The high beam flasher button 1 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.

B00705-10

5.6Turn signal switch

The turn signal switch 1 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.

B00706-10

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

CONTROLS 21

5.7Horn button

The horn button 1 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.

B00706-11

5.8Emergency OFF switch

The emergency OFF switch 1 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.

B00707-10

CONTROLS 22

5.9Electric starter button

The electric starter button 1 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.

B00708-10

5.10Ignition/steering lock

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

B00709-01

steering locked. The ignition key can be removed.

CONTROLS 23

5.11Combination instrument - overview

1 Combination instrument - display ( p. 27)
2 Combination instrument - function buttons ( p. 25)
3 Combination instrument - info display ( p. 31)
4 Combination instrument - indicator lamps ( p. 26)

401289-10

CONTROLS 24

5.12Combination instrument - 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.

401290-01

CONTROLS 25

5.13Combination instrument - function buttons

You can change the display mode with the MODE button 1.
Possible display modes are total distance traveled (TRIP 1), distance 1 (ODO) and
distance 2 (TRIP 2).
Pressing and holding the SET button 2 resets the distance 1 (TRIP 1) and
distance 2 (TRIP 2) functions to 0.0 and briefly pressing the SET button 2 changes the info
display to the next display mode.

401289-12

CONTROLS 26

5.14Combination instrument - indicator lamps

Possible states

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

The engine diagnosis warning lamp (MIL) lights up red – The OBD (onboard
diagnosis) has identified an emissions- or safety-critical fault.

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

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

High beam indicator lamp lights up blue – 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 lights up yellow – An operating safety (warning) mes­sage was detected. This is also shown in the info display.

401290-01

CONTROLS 27

5.15Combination instrument - display

The speed 1 is shown in kilometers per hour km/h or in miles per hour mph.
The tachometer 2 shows the engine speed in revolutions per minute.
The gear display 3 shows the engaged gear.
The coolant temperature appears in segment 4.
The time appears in segment 5.
The filling level in the fuel tank is displaced in segment 6.
The info display 7 shows additional information.

Info

After reconnecting the battery or changing the fuse, the time must be reset.

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

401289-11

CONTROLS 28

5.16Combination instrument - filling level display in fuel tank

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

401292-01