KTM 125 DUKE 2022 Manual

SETUP INSTRUCTIONS 2022

125 DUKE

Art. no. 3214687en

INTRODUCTION

*3214687en*

3214687en

03/2022

INTRODUCTION

Perform the work described in these setup instructions before the vehicle is delivered to the customer.

Read the setup instructions in their entirety before beginning work.

All specifications contained herein 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 produc-

tion of a particular model without prior notice. KTM accepts no liability for delivery options, deviations from fig-

ures and descriptions, misprints, and other errors. The models portrayed partly contain special equipment that

does not belong to the regular scope of supply.

These setup instructions were written to correspond to the latest state of this model series. We reserve the right

to make modifications in the interest of technical advancement without at the same time updating these setup

instructions.

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.

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)

KTM applies quality assurance processes that lead to the highest possible product quality as

defined in the ISO 9001 international quality management standard.

Issued by: TÜV Management Service

KTM Sportmotorcycle GmbH

Stallhofnerstraße 3

5230 Mattighofen, Austria

This document is valid for the following models:

125 DUKE EU (F4003V1, F4003V2)

125 DUKE JP (F4086V3, F4086V4)

125 DUKE UK (F4022V1, F4022V2)

1 MEANS OF REPRESENTATION

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.

Indicates a voltage measurement.

Indicates a current measurement.

Indicates a resistance measurement.

Indicates the end of an activity including potential rework.

1.2 Formats used

The typographical formats used in this document are explained below.

Proprietary name Indicates a proprietary name.

Name®Indicates a protected name.

Brand™ Indicates a brand available on the open market.

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

are explained in the glossary.

SETUP 2

2.1 Transport mode

H02713-01

This vehicle was blocked for transport in the software.

To operate the vehicle, the vehicle electronics must be enabled.

This process is conducted during initial setup in KTM Dealer.net.

Enabling ensures that the initial setup in KTM Dealer.net is docu-

mented.

Enabling can be performed either temporarily, e.g. for a test ride,

or permanently for vehicle handover.

Info

Make sure that the vehicle is permanently enabled before

handing it over to the customer.

2.2 Diagnostics connector

H01906-10

Diagnostics connector 1is located under the passenger seat.

2.3 Unpacking and setting up the vehicle

A00034-10

–Remove the straps and the box.

A00035-10

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

2 SETUP

A00038-10

–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 fin-

ished work on the vehicle.

–Remove the separate enclosure and unpack it. Check the sepa-

rate enclosure for completeness.

–Check the vehicle for transport damage.

A00037-10

Warning

Danger of accidents A repaired handlebar poses a

safety risk.

If the handlebar is bent or straightened, the mate-

rial becomes fatigued. The handlebar may break as a

result.

–Change the handlebar if the handlebar is damaged

or bent.

–Position the handlebar.

Info

Make sure the cables and wiring are positioned cor-

rectly.

–Position the handlebar clamp. Mount and tighten the screws

evenly.

Guideline

Screw, handle-

bar clamp

M8 20 Nm (14.8 lbf ft)

Loctite®243™

The lettering on the handlebar is in the middle of the han-

dlebar clamp.

A00036-10

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

Tighten all screws.

H03807-10

–Make sure that the clutch cable is attached to the clutch

release lever and secured.

–Check the clutch lever play. ( p. 7)

–Check the play in the throttle cable. ( p. 8)

–Mount and tighten the rear mirror on both sides.

SETUP 2

F01045-10

–Mount rear reflector 1with spring washers 2on holding

plate 3.

–Mount the retaining plate on the license plate holder.

–Mount the license plate holder.

–Carefully loosen and remove the tension belt over the link fork.

Info

An assistant prevents the motorcycle from falling over.

–Carefully loosen and remove the tension belts around the lower

triple clamp.

The vehicle is released at the front.

–Together with an assistant, take the vehicle off the pallet.

–Remove the passenger seat. ( p. 8)

E01183-01

–Take tool set out of the separate enclosure and fasten onto the

bottom of the passenger seat using the rubber straps provided

in the tool set.

–Remove the front rider's seat. ( p. 9)

–Remove spare key and KEYCODECARD from under the seat and

keep in a safe place for the handover.

Warning

Risk of injury Battery acid and battery gases cause

serious chemical burns.

–Keep 12 V batteries out of the reach of children.

–Wear suitable protective clothing and safety

glasses.

–Avoid contact with battery acid and battery gases.

–Keep sparks or open flames away from the 12 V

battery.

–Only charge 12 V batteries in well-ventilated

rooms.

–Rinse the affected area immediately with plenty of

water in the event of contact with the skin.

–Rinse eyes with water for at least 15 minutes and

consult a doctor immediately if battery acid and

battery gases get into the eyes.

–Fill the 12 V battery.

Info

Read the notes in the 12 V battery accessory pack.

–Charge the 12-V battery. ( p. 10)

–Install the 12-V battery. ( p. 12)

–Remove the remaining film, padding, the corrugated card-

board, and the other packaging material.

–Refuel. ( p. 14)

–Check the headlight setting. ( p. 15)

–Prepare the vehicle according to the specifications in

the KTM Dealer.net for handover to the customer.

2 SETUP

Info

Transport mode must be deactivated to be able to start

the motorcycle.

WORK 3

3.1 Checking the clutch lever play

Note

Clutch damage If there is no free travel by the clutch lever, the clutch will begin to slip.

–Check the free travel of the clutch lever each time before using the motorcycle.

–Adjust the free travel of the clutch lever when necessary in accordance with the specification.

F00767-10

–Check the clutch lever for smooth operation.

–Move the handlebar to the straight-ahead position.

–Pull the clutch lever until resistance is perceptible, and deter-

mine the play in the clutch lever A.

Clutch lever play A1 … 3 mm (0.04 …

0.12 in)

» If the clutch lever play does not meet the specified value:

–Adjust play in the clutch lever. ( p. 7)

–Move the handlebar to and fro over the entire steering range.

The clutch lever play must not change.

» If the clutch lever play changes:

–Check the routing of the clutch cable.

3.2 Adjusting play in the clutch lever

F00768-10

–Move the handlebar to the straight-ahead position.

–Push back sleeve 1.

–Loosen lock nut 2.

–Adjust the play in the clutch level Aby turning adjusting

screw 3.

Guideline

Clutch lever play A1 … 3 mm (0.04 …

0.12 in)

–Tighten lock nut 2.

–Position bellows 1.

3 WORK

3.3 Checking the play in the throttle cable

400192-11

–Check the throttle grip for smooth operation.

–Move the handlebar to the straight-ahead position. Turn the

throttle grip back and forth slightly and determine the play in

throttle cable A.

Throttle cable play A3 … 5 mm (0.12 … 0.2 in)

» If the throttle cable play does not meet the specified value:

–Adjust the play in the throttle cable. ( p. 8)

Danger

Danger of poisoning Exhaust gases are toxic and inhal-

ing them may result in unconsciousness and death.

–Always make sure there is sufficient ventilation

when running the engine.

–Use effective exhaust extraction when starting or

running the engine in an enclosed space.

–Start the engine and let it run at idle speed. Move the handle-

bar to and fro over the entire steering range.

The idle speed must not change.

» If the idle speed changes:

–Check the throttle cable routing.

3.4 Adjusting the play in the throttle cable

F00773-10

–Move the handlebar to the straight-ahead position.

–Push back sleeve 1.

–Loosen lock nut 2.

–Adjust the play in the throttle cable by turning barrel

adjuster 3.

Guideline

Play in throttle cable 3 … 5 mm (0.12 … 0.2 in)

–Tighten lock nut 2.

–Slide on sleeve 1.

3.5 Removing the passenger seat

H01991-10

–Insert the ignition key in seat lock 1and turn it clockwise.

–Raise the rear of the seat, push it towards the rear, and lift it

off.

–Remove the ignition key from the seat lock.

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