KTM 125 DUKE 2016 Owners Guide
OWNER'S MANUAL 2016
125 Duke
200 Duke
Art. no. 3213412en
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 properly.
We hope you enjoy your new vehicle!
Enter the serial numbers of your vehicle below.
Chassis number ( p. 20) Dealer's stamp
Engine number ( p. 21)
Key number ( p. 21)
The Owner's Manual contained the latest information for this model series at the time of going to print. Minor differences due to developments in design cannot be ruled out completely.
All specifications are non-binding. KTM Sportmotorcycle GmbH specifically reserves the right to modify or delete technical specifications,
prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt these to
local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery options, deviations from illustrations and descriptions, misprints, and other errors. The models portrayed partly contain special equipment that does not
belong to the regular scope of supply.
© 2015 KTM Sportmotorcycle GmbH, Mattighofen Austria
All rights reserved
*3213412en*
3213412en
11/2015
DEAR KTM CUSTOMER 2
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 GmbH
5230 Mattighofen, Austria
This document is valid for the following models:
125 Duke EU (F4003P1, F4003P2, F4003P3, F4003P4)
200 Duke EU (F4103P1, F4103P2)
200 Duke AR (F4142P1, F4142P2)
200 Duke ASIA (F4188P1, F4188P2)
200 Duke CN (F4187P1)
200 Duke MY (F4189P1, F4189P2)
200 Duke TH (F4183P1, F4183P2)
TABLE OF CONTENTS 3
TABLEOF CONTENTS
1 MEANS OF REPRESENTATION ........................................ 7
1.1 Symbols used ...................................................... 7
1.2 Formats used....................................................... 8
2 SAFETY ADVICE.............................................................. 9
2.1 Use definition...................................................... 9
2.2 Safety advice ....................................................... 9
2.3 Degrees of risk and symbols................................ 10
2.4 Tampering warning............................................. 10
2.5 Safe operation ................................................... 11
2.6 Protective clothing ............................................. 12
2.7 Work rules ......................................................... 12
2.8 Environment...................................................... 12
2.9 Owner's Manual ................................................. 13
3 IMPORTANT NOTES...................................................... 14
3.1 Manufacturer and implied warranty...................... 14
3.2 Operating and auxiliary substances ...................... 14
3.3 Spare parts, accessories ..................................... 14
3.4 Service ............................................................. 15
3.5 Figures ............................................................. 15
3.6 Customer service................................................ 15
4 VIEW OF VEHICLE ........................................................ 16
4.1 View of vehicle, front left (example) ..................... 16
4.2 View of vehicle, rear right (example) .................... 18
5 SERIAL NUMBERS ....................................................... 20
5.1 Chassis number ................................................. 20
5.2 Type label ......................................................... 20
5.3 Engine number .................................................. 21
5.4 Key number....................................................... 21
6 CONTROLS................................................................... 22
6.1 Clutch lever ....................................................... 22
6.2 Hand brake lever................................................ 22
6.3 Throttle grip ...................................................... 23
6.4 Horn button....................................................... 23
6.5 Light switch ...................................................... 24
6.6 High beam flasher button ................................... 24
6.7 Turn signal switch.............................................. 25
6.8 Emergency OFF switch ....................................... 25
6.9 Electric starter button......................................... 26
6.10 Ignition/steering lock.......................................... 26
6.11 Locking the steering........................................... 27
6.12 Unlocking the steering........................................ 27
6.13 Combination instrument ..................................... 28
6.13.1 Overview ....................................................... 28
6.13.2 Activation and test......................................... 29
6.13.3 Warning notes ............................................... 30
6.13.4 Function buttons ........................................... 33
6.13.5 Indicator lamps ............................................. 34
6.13.6 Display ......................................................... 35
6.13.7 Filling level display in fuel tank ....................... 36
6.13.8 TRIP F display............................................... 37
6.13.9 Coolant temperature indicator ......................... 38
6.13.10 Info display ................................................... 39
6.13.11 Riding time/average speed menu ..................... 40
6.13.12 Average speed/average fuel consumption 1
menu............................................................ 40
6.13.13 Average fuel consumption 1/average fuel
consumption 2 menu ..................................... 41
TABLE OF CONTENTS 4
6.13.14 Average fuel consumption 2/service menu........ 42
6.13.15 Service/range menu........................................ 43
6.13.16 Range/riding time menu ................................. 44
6.13.17 Total distance menu ODO ............................... 45
6.13.18 Distance menu 1 TRIP 1 ................................ 46
6.13.19 Distance menu 2 TRIP 2 ................................ 46
6.13.20 Setting kilometers or miles ............................. 47
6.13.21 Setting the time............................................. 47
6.13.22 Adjusting the shift speed RPM 1 ..................... 48
6.13.23 Adjusting the shift speed RPM 2 ..................... 49
6.14 Opening the filler cap......................................... 50
6.15 Closing the filler cap .......................................... 51
6.16 Seat lock........................................................... 51
6.17 Tool set............................................................. 52
6.18 Grab handles ..................................................... 52
6.19 Passenger footrests ............................................ 53
6.20 Shift lever ......................................................... 53
6.21 Foot brake lever ................................................. 54
6.22 Side stand......................................................... 55
7 PREPARING FOR USE................................................... 56
7.1 Advice on first use ............................................. 56
7.2 Running in the engine ........................................ 57
7.3 Loading the vehicle............................................ 58
8 RIDING INSTRUCTIONS................................................ 60
8.1 Checks and maintenance when preparing for
use................................................................... 60
8.2 Starting............................................................. 61
8.3 Starting off........................................................ 63
8.4 Shifting, riding .................................................. 63
8.5 Applying the brakes............................................ 66
8.6 Stopping, parking............................................... 68
8.7 Transport .......................................................... 69
8.8 Refueling .......................................................... 70
9 SERVICE SCHEDULE .................................................... 72
9.1 Additional information ........................................ 72
9.2 Required work ................................................... 72
9.3 Recommended work ........................................... 74
10 TUNING THE CHASSIS ................................................. 75
10.1 Adjusting the spring preload of the shock
absorber ........................................................ 75
10.2 Adjusting the shift lever...................................... 76
11 SERVICE WORK ON THE CHASSIS................................. 77
11.1 Raising the motorcycle with the rear wheel
stand ................................................................ 77
11.2 Taking the motorcycle off of the rear wheel
stand ................................................................ 77
11.3 Raising the motorcycle with the front wheel
stand ................................................................ 78
11.4 Taking the motorcycle off of the front wheel
stand ................................................................ 79
11.5 Removing the passenger seat .............................. 80
11.6 Mounting the passenger seat............................... 81
11.7 Removing the seat ............................................. 81
11.8 Mounting the seat.............................................. 82
11.9 Checking for chain dirt accumulation................... 83
11.10 Cleaning the chain ............................................. 83
11.11 Checking the chain tension................................. 84
11.12 Adjusting the chain tension................................. 86
TABLE OF CONTENTS 5
11.13 Checking the chain, rear sprocket, and engine
sprocket............................................................ 89
11.14 Removing the front spoiler .................................. 93
11.15 Fitting front spoiler ............................................ 94
12 BRAKE SYSTEM ........................................................... 95
12.1 Antilock Braking System (ABS) (125 Duke) .......... 95
12.2 Checking the brake discs .................................... 96
12.3 Checking the brake fluid level of the front brake ... 97
12.4 Adding front brake fluid .................................. 98
12.5 Checking the front brake linings .......................... 99
12.6 Checking the free travel of foot brake lever ......... 100
12.7 Adjusting the free travel of the foot brake
lever ............................................................ 101
12.8 Checking the rear brake fluid level..................... 102
12.9 Adding rear brake fluid ................................. 104
12.10 Checking the rear brake linings ......................... 105
13 WHEELS, TIRES ......................................................... 107
13.1 Removing the front wheel .............................. 107
13.2 Installing the front wheel .............................. 108
13.3 Removing the rear wheel ............................... 111
13.4 Installing the rear wheel ................................ 113
13.5 Checking the rear hub rubber dampers ........... 117
13.6 Checking the tire condition ............................... 118
13.7 Checking the tire air pressure............................ 119
14 ELECTRICAL SYSTEM ................................................. 121
14.1 Removing the battery .................................... 121
14.2 Installing the battery ..................................... 122
14.3 Recharging the battery .................................. 123
14.4 Changing the ABS fuses (125 Duke).................. 126
14.5 Changing the fuses of individual power
consumers....................................................... 127
14.6 Changing the headlight bulb ............................. 131
14.7 Changing the parking light bulb......................... 134
14.8 Checking the headlight setting .......................... 137
14.9 Adjusting the headlight range............................ 138
15 COOLING SYSTEM ...................................................... 141
15.1 Cooling system ................................................ 141
15.2 Checking the antifreeze and coolant level ........... 142
15.3 Checking the coolant level ................................ 144
15.4 Draining the coolant ..................................... 146
15.5 Filling/bleeding the cooling system ................. 147
16 TUNING THE ENGINE................................................. 149
16.1 Checking the play in the throttle cable............... 149
16.2 Adjusting the play in the throttle cable ........... 150
16.3 Checking the clutch lever play........................... 150
16.4 Adjusting the clutch cable play ...................... 151
17 SERVICE WORK ON THE ENGINE ................................ 152
17.1 Checking the engine oil level............................. 152
17.2 Changing the engine oil and oil filter, cleaning
the oil screen ............................................... 152
17.3 Adding engine oil............................................. 155
18 CLEANING, CARE ....................................................... 157
18.1 Cleaning the motorcycle ................................... 157
18.2 Checks and maintenance steps for winter
operation......................................................... 159
19 STORAGE................................................................... 161
19.1 Storage ........................................................... 161
19.2 Preparing for use after storage........................... 162
20 TROUBLESHOOTING .................................................. 163
TABLE OF CONTENTS 6
21 TECHNICAL DATA....................................................... 166
21.1 Engine............................................................ 166
21.1.1 125 Duke ................................................... 166
21.1.2 200 Duke EU, 200 Duke AR,
200 Duke ASIA, 200 Duke CN,
200 Duke MY, 200 Duke TH ........................ 167
21.2 Engine tightening torques................................. 169
21.3 Capacities ....................................................... 173
21.3.1 Engine oil ................................................... 173
21.3.2 Coolant....................................................... 173
21.3.3 Fuel ........................................................... 173
21.4 Chassis ........................................................... 173
21.5 Electrical system.............................................. 175
21.6 Tires............................................................... 176
21.7 Fork................................................................ 176
21.8 Shock absorber ................................................ 176
21.9 Chassis tightening torques ................................ 177
22 SUBSTANCES ............................................................ 182
23 AUXILIARY SUBSTANCES ........................................... 185
24 STANDARDS .............................................................. 187
25 INDEX OF SPECIAL TERMS ......................................... 188
26 LIST OF ABBREVIATIONS............................................ 189
27 LIST OF SYMBOLS...................................................... 190
27.1 Red symbols.................................................... 190
27.2 Yellow and orange symbols................................ 190
27.3 Green and blue symbols.................................... 190
INDEX ............................................................................... 191
1 MEANS OF REPRESENTATION 7
1.1 Symbols used
The meaning of specific symbols is described below.
Indicates an expected reaction (e.g. of a work step or a function).
Indicates an unexpected reaction (e.g. of a work step or a function).
All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your
own safety, have these jobs performed by an authorized KTM workshop. There, your motorcycle will be optimally
cared for by specially trained experts using the specialist tools required.
Indicates a page reference (more information is provided on the specified page).
Indicates information with more details or tips.
Indicates the result of a testing step.
1 MEANS OF REPRESENTATION 8
1.2 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.
Underlined terms Refer to technical details of the vehicle or indicate technical terms that are explained in the
Identifies a protected name.
glossary.
2 SAFETY ADVICE 9
2.1 Use definition
KTM sport motorcycles are designed and constructed to meet the normal demands of regular road operation but not for use on race
courses or offroad.
Info
The motorcycle is authorized for public road traffic in the homologous version only.
2.2 Safety advice
A number of safety instructions need to be followed to operate the vehicle safely. Therefore, read this manual carefully. The safety instructions are highlighted in the text and are referred to at the relevant passages.
Info
The vehicle has various information and warning labels at prominent locations. Do not remove information/warning labels. If they
are missing, you or others may not recognize dangers and may therefore be injured.
2 SAFETY ADVICE 10
2.3 Degrees of risk and symbols
Danger
Indicates a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not
taken.
Warning
Indicates a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.
Caution
Indicates a danger that may lead to minor injuries if the appropriate measures are not taken.
Note
Indicates a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.
Warning
Indicates a danger that will lead to environmental damage if the appropriate measures are not taken.
2.4 Tampering warning
Tampering with the noise control system is prohibited. Federal law prohibits the following acts or the causing thereof:
1 The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or
element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or
2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.
Among those acts presumed to constitute tampering are the acts listed below:
2 SAFETY ADVICE 11
1 Removal or puncturing of the main silencer, baffles, header pipes or any other components which conduct exhaust gases.
2 Removal or puncturing of parts of the intake system.
3 Lack of proper maintenance.
4 Replacing moving part of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by the manufac-
turer.
2.5 Safe operation
Danger
Danger of accidents Danger arising from the rider's judgement being impaired.
– Do not operate the vehicle while under the influence of alcohol, drugs and certain medications or physically or mentally
impaired.
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death.
– When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed
space without an effective exhaust extraction system.
Warning
Danger of burns Some vehicle components become very hot when the vehicle is operated.
– Do not touch hot components such as exhaust system, radiator, engine, shock absorber, and the brake system. Allow these
components to cool down before starting work on them.
Only operate the vehicle when it is in perfect technical condition, in accordance with its intended use, and in a safe and environmentally
compatible manner.
An appropriate driver's license is needed to ride the vehicle on public roads.
Have malfunctions that impair safety promptly eliminated by an authorized KTM workshop.
Adhere to the information and warning labels on the vehicle.
2 SAFETY ADVICE 12
2.6 Protective clothing
Warning
Risk of injury Missing or poor protective clothing presents an increased safety risk.
– Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle. Always wear
protective clothing that is in good condition and meets the legal requirements.
In the interest of your own safety, KTM recommends that you only operate the vehicle while wearing protective clothing.
2.7 Work rules
Special tools are necessary for certain tasks. The tools are not contained in the vehicle but can be ordered under the number in parentheses. E.g.: bearing puller (15112017000)
During assembly, non-reusable parts (e.g. self-locking screws and nuts, seals and seal rings, O-rings, pins, lock washers) must be replaced
by new parts.
In some instances, a thread locker (e.g. Loctite®) is required. The manufacturer instructions for use must be followed.
After disassembly, clean the parts that are to be reused and check them for damage and wear. Change damaged or worn parts.
After you complete the repair or service work, check the operating safety of the vehicle.
2.8 Environment
If you use your motorcycle responsibly, you can ensure that problems and conflicts do not occur. To protect the future of the motorcycle
sport, make sure that you use your motorcycle legally, display environmental consciousness, and respect the rights of others.
When disposing of used oil, other operating and auxiliary fluids, and used components, comply with the laws and regulations of the
respective country.
Because motorcycles are not subject to the EU regulations governing the disposal of used vehicles, there are no legal regulations that pertain to the disposal of an end-of-life motorcycle. Your authorized KTM dealer will be glad to advise you.
2 SAFETY ADVICE 13
2.9 Owner's Manual
It is important that you read this Owner's Manual carefully and completely before making your first trip. The Owner's Manual contains useful information and many tips on how to operate, handle, and maintain your motorcycle. Only then will you find out how to customize the
vehicle ideally for your own use and how you can protect yourself from injury.
Keep the Owner's Manual in an accessible place to enable you to refer to it as needed.
If you would like to know more about the vehicle or have questions on the material you read, please contact an authorized KTM dealer.
The Owner's Manual is an important component of the vehicle and should be handed over to the new owner if the vehicle is sold.
3 IMPORTANT NOTES 14
3.1 Manufacturer and implied warranty
The work specified in the service schedule may only be performed in an authorized KTM workshop and must be recorded in both the
Service & Warranty Booklet and in KTM Dealer.net, otherwise any warranty coverage will become void. Damage or secondary damage caused
by tampering with and/or conversions on the vehicle are not covered by the warranty.
Additional information on the manufacturer or implied warranty and the procedures involved can be found in the Service & Warranty Booklet.
3.2 Operating and auxiliary substances
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to get into the ground water, the ground, or the sewage system.
Use operating and auxiliary substances (such as fuel and lubricants) as specified in the Owner's Manual.
3.3 Spare parts, accessories
For your own safety, only use spare parts and accessory products that are approved and/or recommended by KTM and have them installed
by an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage or loss.
Certain spare parts and accessory products are specified in parentheses in the descriptions. Your authorized KTM dealer will be glad to
advise you.
The current KTM PowerParts for your vehicle can be found on the KTM website.
International KTM Website: http://www.ktm.com
3 IMPORTANT NOTES 15
3.4 Service
A prerequisite for perfect operation and prevention of premature wear is that the service, care, and tuning work on the engine and chassis
is properly carried out as described in the Owner's Manual. Incorrect adjustment and tuning of the engine and chassis can lead to damage
and breakage of components.
Use of the vehicle under difficult conditions, such in rain, high heat or with a heavy load, can lead to considerably more rapid wear of
components such as the drive train, brake system, or suspension components. For this reason, it may be necessary to inspect or replace
parts before the next scheduled service.
It is imperative that you adhere to the stipulated run-in times and service intervals. If you observe these exactly, you will ensure a much
longer service life for your motorcycle.
3.5 Figures
The figures contained in the manual may depict special equipment.
In the interest of clarity, some components may be shown disassembled or may not be shown at all. It is not always necessary to disassemble the component to perform the activity in question. Please follow the instructions in the text.
3.6 Customer service
Your authorized KTM dealer will be happy to answer any questions you may have on your vehicle and KTM.
A list of authorized KTM dealers can be found on the KTM website.
International KTM Website: http://www.ktm.com
4 VIEW OF VEHICLE 16
4.1 View of vehicle, front left (example)
S00654-10
4 VIEW OF VEHICLE 17
1 Combination instrument
2 Rear mirror
3 Clutch lever ( p. 22)
4 Seat
5 Passenger seat
6 Seat lock ( p. 51)
7 Grab handles ( p. 52)
8 Engine number ( p. 21)
9 Side stand ( p. 55)
10 Shift lever ( p. 53)
4 VIEW OF VEHICLE 18
4.2 View of vehicle, rear right (example)
S00655-10
4 VIEW OF VEHICLE 19
1 Tool set ( p. 52)
2 Light switch ( p. 24)
2 High beam flasher button ( p. 24)
2 Turn signal switch ( p. 25)
2 Horn button ( p. 23)
3 Filler cap
4 Electric starter button ( p. 26)
5 Emergency OFF switch ( p. 25)
6 Hand brake lever ( p. 22)
7 Ignition/steering lock ( p. 26)
8 Chassis number ( p. 20)
8 Type label ( p. 20)
9 Passenger footrests ( p. 53)
10 Foot brake lever ( p. 54)
5 SERIAL NUMBERS 20
0011
0011
5.1 Chassis number
The chassis numberis stamped on the right side of the steering head.
402408-10
5.2 Type label
The type labelis on the right of the frame behind the steering head.
402174-10
5 SERIAL NUMBERS 21
5.3 Engine number
The engine numberis stamped on the left side of the engine under the engine sprocket.
402486-10
5.4 Key number
The key numbercan be found on the KEYCODECARD.
Info
You need the key number to order a spare key. Keep the KEYCODECARD in a safe
place.
402245-10
6 CONTROLS 22
6.1 Clutch lever
The clutch leveris fitted on the left side of the handlebar.
S00656-10
6.2 Hand brake lever
The hand brake leveris fitted on the right side of the handlebar.
The front brake is engaged using the hand brake lever.
S00663-10
6 CONTROLS 23
6.3 Throttle grip
The throttle gripis fitted on the right side of the handlebar.
S00664-10
6.4 Horn button
The horn buttonis fitted on the left side of the handlebar.
Possible states
• Horn button in neutral position
• Horn button pressed – The horn is operated in this position.
S00660-10
6 CONTROLS 24
6.5 Light switch
The light switchis fitted on the left side of the handlebar.
Possible states
Low beam on – The light switch is turned downward. In this position, the
low beam and the tail light are switched on.
High beam on – The light switch is turned upwards. In this position, the
high beam and the tail light are switched on.
S00657-10
6.6 High beam flasher button
The high beam flasher buttonis 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.
S00659-10
6 CONTROLS 25
6.7 Turn signal switch
The turn signal switchis 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.
S00658-10
6.8 Emergency OFF switch
S00661-10
To switch off the turn signal, press the turn signal switch towards the switch case.
The emergency OFF switchis 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.
6 CONTROLS 26
6.9 Electric starter button
The electric starter buttonis 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.
S00662-10
6.10 Ignition/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
S00665-10
steering locked. The ignition key can be removed.
6 CONTROLS 27
6.11 Locking the steering
Note
Danger of damage The parked vehicle may roll away or fall over.
– Always place the vehicle on a firm and even surface.
– Park the vehicle.
– Turn the handlebar all the way to the left.
– Insert the key into the ignition/handlebar lock, press in, and turn to the left. Remove
the key.
Steering is no longer possible.
400732-01
6.12 Unlocking the steering
– Insert the key into the ignition/handlebar lock, press in, and turn to the right. Remove
the key.
You can now steer the bike again.
400731-01
6 CONTROLS 28
6.13 Combination instrument
6.13.1 Overview
1 Display ( p. 35)
2 Function buttons ( p. 33)
3 Info display ( p. 39)
4 Indicator lamps ( p. 34)
401685-10
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