KTM 125 Duke 2016 Manual

SETUP INSTRUCTIONS 2016

125 Duke

200 Duke

Art. no. 3213457en

INTRODUCTION 1

*3213457en*

3213457en

07/2016

INTRODUCTION

The work described in these setup instructions must be performed before the vehicle is delivered to the customer.

Read the setup instructions in their entirety before beginning work.

These setup instructions were written to correspond to the latest state of this series. We reserve the right to make changes in the interest

of technical advancement without at the same time updating this 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 the work will be performed by a fully trained mechanic.

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, devi-

ations 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.

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, F4142P3, F4142P4)

200 Duke ASIA (F4188P1, F4188P2)

200 Duke 2017 BR (F4140P1, F4140P2)

200 Duke CN (F4187P1)

200 Duke 2017 CO (F4141P3, F4141P4)

200 Duke MY (F4189P1, F4189P2)

200 Duke TH (F4183P1, F4183P2)

1 MEANS OF REPRESENTATION 2

1.1 Symbols used

The meaning of specific symbols is described below.

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

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

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

Indicates information with more details or tips.

Indicates the result of a testing step.

Denotes a voltage measurement.

Denotes a current measurement.

Denotes a resistance measurement.

1.2 Formats used

The typographical formats used in this document are explained below.

Proprietary name Identifies a proprietary name.

Name®Identifies a protected name.

Brand™ Identifies a trademark.

Underlined terms Refer to technical details of the vehicle or indicate technical terms, which are explained

in the glossary.

2 SETUP 3

2.1 Unpacking and setting up the vehicle

S00786-10

–Remove the straps and box.

S00790-10

–Remove the adhesive tape in the upper area of the motorcycle.

S00789-10

–Roll down the film at the sides.

Info

To avoid damaging the motorcycle during unpacking, leave the other films

on the vehicle until you have finished work on the vehicle.

–Remove the separate enclosure and unpack it. Check the separate enclosure for

completeness.

–Check the vehicle for transport damage.

B00912-01

–Position the handlebar.

The lettering on the handlebar is situated in the middle of the handlebar

clamp.

–Position the handlebar clamps. Mount and tighten the screws evenly.

Guideline

Screw, handlebar clamp M8 21 Nm

(15.5 lbf ft)

Loctite®243™

B00913-01

–Mount and tighten the rear mirror on both sides.

–Position all controls in their exact positions on the handlebar. Tighten all screws.

700217-01

–Mount the reflector.

–Remove the protective plastic.

–Carefully loosen and remove the tensioning belt over the swingarm.

Info

An assistant prevents the motorcycle from falling over.

–Carefully loosen and remove the tensioning belts around the lower triple clamp.

The vehicle is released at the front.

2 SETUP 4

–Take the vehicle off the pallet.

Warning

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

–Keep batteries out of the reach of children.

–Wear suitable protective clothing and goggles.

–Avoid contact with battery acid and battery gases.

–Keep sparks and open flames away from the battery. Only charge in

well-ventilated rooms.

–In the event of skin contact, rinse with large amounts of water. If battery

acid gets in the eyes, rinse with water for at least 15 minutes and con-

tact a physician.

–Fill the battery.

Info

Read the notes in the battery package.

–Recharge the battery. ( p. 6)

–Install the battery. ( p. 7)

–Refuel. ( p. 9)

–Prepare the vehicle according to the specifications in the KTM Dealer.net for han-

dover to the customer.

–Set kilometers or miles. ( p. 10)

–Set the clock. ( p. 10)

3 WORK 5

3.1 Removing the passenger seat

B00712-01

–Insert the ignition key in seat lock and turn it clockwise.

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

–Remove the ignition key from the seat lock.

3.2 Mounting the passenger seat

B00724-10

–Attach hooks on the passenger seat to brackets on the subframe, and lower

it at the rear while pushing forward.

–Press down the passenger seat until it clicks into place.

Warning

Danger of accidents The passenger seat can come loose from the anchoring

if it is not mounted correctly.

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

pulling up.

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

3.3 Removing the seat

Preparatory work

–Remove the passenger seat. ( p. 5)

B00725-10

Main work

–Remove screws .

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

3.4 Mounting the seat

B00727-10

Main work

–Attach seat recesses at screws and lower at the rear.

–Mount and tighten screws .

Guideline

Screw, seat M6 10 Nm (7.4 lbf ft)

3 WORK 6

Finishing work

–Mount the passenger seat. ( p. 5)

3.5 Removing the battery

Warning

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

–Keep batteries out of the reach of children.

–Wear suitable protective clothing and goggles.

–Avoid contact with battery acid and battery gases.

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

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

15 minutes and contact a physician.

Preparatory work

–Remove the passenger seat. ( p. 5)

–Remove the seat. ( p. 5)

B00750-10

Main work

–Pull back the negative terminal cover .

–Disconnect negative cable from the battery.

B00751-10

–Pull back the positive terminal cover .

–Disconnect positive cable from the battery.

–Detach rubber band .

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

Info

Never operate the motorcycle with a discharged battery or without a battery.

In both cases, electrical components and safety devices can be damaged.

The vehicle is therefore no longer roadworthy.

3.6 Recharging the battery

Warning

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

–Keep batteries out of the reach of children.

–Wear suitable protective clothing and goggles.

–Avoid contact with battery acid and battery gases.

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

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

15 minutes and contact a physician.

Warning

Environmental hazard Batteries contain environmentally-hazardous materials.

–Do not dispose of batteries as household waste.

–Dispose of batteries at a collection point for used batteries.

Warning

Environmental hazard Hazardous substances cause environmental damage.

–Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regu-

lations.

3 WORK 7

Info

Even when there is no load on the battery, it discharges steadily.

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

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

If the charging current, charging voltage, and charging time are exceeded, the battery will be destroyed.

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

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

battery.

The battery is maintenance-free, i.e., the acid level does not have to be checked.

Preparatory work

–Remove the passenger seat. ( p. 5)

–Remove the seat. ( p. 5)

–Disconnect the negative cable of the battery.

311910-10

Main work

–Connect the battery charger to the battery. Set the battery charger.

Alternative 1

Battery charger XCharge-professional EU (00029095050)

Alternative 2

Battery charger XCharge-professional US (00029095051)

Alternative 3

Battery charger XCharge-professional GB (00029095052)

Alternative 4

Battery charger XCharge-professional CH (00029095053)

Info

Follow the instructions of the charger and the manual.

–Disconnect the battery charger after charging the battery.

Guideline

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

Charge the battery regularly when the

motorcycle is not in use

3 months

Finishing work

–Mount the seat. ( p. 5)

–Mount the passenger seat. ( p. 5)

–Set the clock. ( p. 10)

3.7 Installing the battery

B00751-11

Main work

–Position the battery in the battery holder.

Guideline

The terminals of the battery must face upwards.

(125 Duke)

Battery (FTZ-7)

(200 Duke)

Battery (FTZ-9)

–Reconnect rubber band .

–Position the positive cable and mount and tighten the screw.

–Position positive terminal cover .

3 WORK 8

B00750-11

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

–Position the negative terminal cover .

Finishing work

–Mount the seat. ( p. 5)

–Mount the passenger seat. ( p. 5)

–Set the clock. ( p. 10)

3.8 Opening the filler cap

Danger

Fire hazard Fuel is highly flammable.

The fuel in the fuel tank expands when warm and can escape if overfilled.

–Do not refuel the vehicle in the vicinity of open flames or lit cigarettes.

–Switch off the engine for refueling.

–Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.

–If any fuel is spilled, wipe it off immediately.

–Observe the specifications for refueling.

Warning

Danger of poisoning Fuel is poisonous and a health hazard.

–Avoid skin, eye and clothing contact with fuel.

–Immediately consult a doctor if you swallow fuel.

–Do not inhale fuel vapors.

–In case of skin contact, rinse the affected area with plenty of water.

–Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.

–Change your clothing in case of fuel spills on them.

–Keep fuels correctly in a suitable canister, and out of the reach of children.

Warning

Environmental hazard Improper handling of fuel is a danger to the environment.

–Do not allow fuel to enter the groundwater, the soil, or the sewage system.

B00710-10

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

Note

Danger of damage Ignition key breakage.

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

ignition keys must be replaced.

–Turn the ignition key 90° clockwise.

–Open the filler cap.

–Remove the ignition key.

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