KTM 125 DUKE EU Manual

SETUP INSTRUCTIONS 2013

125 Duke EU

200 Duke EU

200 Duke MAL

200 Duke 2014 COL

Art. no. 3213052en

INTRODUCTION 1

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.

Print out the current PDI form found on the KTM DEALER.NET.

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

est 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 AG specifically reserves the right to modify or delete technical specifica-

tions, 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 spe-

cial 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

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.

2 SETUP 3

2.1 Unpacking and setting up the vehicle

B00911-01

–Remove the box and the plastic packaging.

Info

To avoid damaging the motorcycle during the setup, leave the protective

film on the vehicle until you have finished.

–Check the vehicle for transport damage.

–Unpack the separate enclosure and check its contents on the basis of the enclosure

list.

B00912-01

–Position the handlebar.

The lettering on the handlebar should be situated in the middle of the handle-

bar clamp.

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

Guideline

Screw, handlebar clamp M8 21 Nm

(15.5 lbf ft)

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.

–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)

2 SETUP 4

–Print out the current PDI form found on KTM DEALER.NET and perform the delivery

inspection.

–Set kilometers or miles. ( p. 9)

–Set the clock. ( p. 9)

3 WORK 5

3.1 Removing the passenger seat

B00712-01

–Insert the ignition key in seat lock 1and 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 1on the passenger seat to brackets 2on 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 1.

–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 Aat screws 1and lower at the rear.

–Mount and tighten screws 2.

Guideline

Screw, seat M6 11 Nm (8.1 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 1.

–Disconnect the negative cable 2of the battery.

B00751-10

–Pull back the positive terminal cover 3.

–Disconnect the positive cable 4of the battery.

–Detach rubber band 5.

–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 The battery contains elements that are harmful to the environment.

–Do not discard batteries with the household waste. Dispose of faulty batteries in an environmentally compatible manner.

Give the battery to your authorized KTM dealer or dispose of it at a collection point for used batteries.

3 WORK 7

Info

Even when there is no load on the battery, it still loses power steadily.

The charge state and the type of charge are very important for the service life of the battery.

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

If the charging current, charging voltage, and charging time are exceeded, electrolyte escapes through the safety valves. This

reduces the battery capacity.

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 sulfate, destroying the

battery.

The battery is maintenance-free, which means that the acid level does not need to be checked.

Preparatory work

–Switch off all power consumers and switch off the engine.

–Remove the passenger seat. ( p. 5)

–Remove the seat. ( p. 5)

–Disconnect the negative cable of the battery to avoid damage to the motorcycle's

electronics.

B01395-10

Main work

–Connect the battery charger to the battery. Switch on the battery charger.

Battery charger (58429074000)

You can also use the battery charger to test rest potential and start potential of the

battery, and to test the alternator. With this device, you cannot overcharge the bat-

tery.

Info

Never remove lid 1.

Charge the battery with a maximum of 10% of the capacity specified on

battery housing 2.

–Switch off the charger after charging. Disconnect the battery.

Guideline

The charge current, charge voltage and charge 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. 9)

3.7 Installing the battery

B00751-11

Main work

–Position the battery in the battery holder.

Info

The battery terminals must be at the top.

–Attach rubber band 1.

–Reconnect the positive cable 2of the battery.

–Position positive terminal cover 3.

3 WORK 8

B00750-11

–Connect the negative cable 4of the battery.

–Position the negative terminal cover 5.

Finishing work

–Mount the seat. ( p. 5)

–Mount the passenger seat. ( p. 5)

–Set the clock. ( p. 9)

3.8 Opening the filler cap

Danger

Fire hazard Fuel is highly flammable.

–Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no

fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.

–The fuel in the fuel tank expands when warm and may emerge if overfilled. Follow the instructions on refueling.

Warning

Danger of poisoning Fuel is poisonous and a health hazard.

–Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with

the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with

soap and water. If fuel is swallowed, contact a physician immediately. Change clothing that is contaminated with fuel.

Store fuel properly in a suitable canister and keep away from children.

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.

B00710-10

–Lift the cover 1of 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.

3.9 Closing the filler cap

B00711-01

Warning

Fire hazard Fuel is highly flammable, poisonous and harmful to your

health.

–After closing the filler cap, ensure that it is locked properly. Change

clothing that has been contaminated with fuel. Immediately clean con-

taminated areas on the skin with soap and water.

–Close the filler cap.

–Push down the filler cap until the lock engages.

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