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OWNER`S MANUAL 2013 125 Duke EU 200 Duke EU 200 Duke MAL

1. Move the handlebar to and fro over the entire steering range The clutch lever play must not change 16 TUNING THE ENGINE 142 Ifthe clutch lever play changes Check the routing of the clutch cable Move the handlebar to the straight ahead position Push back sleeve O Loosen lock nut Adjust the play in the clutch level Q by turning adjusting screw 9 Guideline Clutch lever play 1 3 mm 0 04 0 12 in Tighten lock nut Q Slide on sleeve 1B00730 10 17 SERVICE WORK ON THE ENGINE 143 17 1 Checking the engine oil level 59595959550 Gondition The engine is at operating temperature Preparatory work Stand the motorcycle upright on a horizontal surface Main work Check the engine oil level e Info After switching off the engine wait one minute before checking the level The engine oil must be between the lower and upper edge of the oil level viewer If the engine oil level is not at the specified level Add the engine oil p 146 Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden Wear appropriate protective clothing and safety gloves In case of burns rinse immediately with lukewarm water Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicabl
2. RESPONSE BRAKE FLUID SUPER DOT 4 Motorex Brake Fluid DOT 5 1 Guideline Use only suitable coolant also in countries with high temperatures Use of low quality antifreeze can lead to corrosion and foaming KTM recommends Motorex products Mixture ratio Antifreeze protection 25 45 C 13 50 corrosion inhibitor antifreeze 49 F 50 distilled water 40764070 Supplier Motorex COOLANT G48 22 SUBSTANCES 171 According to JASO T903 MA p 176 SAE p 176 SAE 15W 50 Guideline Use only engine oils that comply with the specified standards see specifications on the container and that possess the corresponding properties KTM recommends Motorex products Partially synthetic engine oil Supplier Motorex Formula 4T According to JASO T903 MA p 176 SAE p 176 SAE 10W 40 Guideline Use only engine oils that comply with the specified standards see specifications on the container and that possess the corresponding properties KTM recommends Motorex products Partially synthetic engine oil Supplier Motorex Formula 4T 22 SUBSTANCES 172 Fork oil SAE 5 0H53 According to SAE p 176 SAE 5 Guideline Use only oils that comply with the specified standards see specifications on the container and that possess the corresponding proper ties KTM recommends Motorex products Supplier Motore
3. Ifthe chain tension does not meet specifications Adjust the chain tension p 83 11 12 Adjusting the chain tension VVarning Danger of accidents Danger caused by incorrect chain tension lf the chain tension is too high the components of the secondary power train chain engine sprocket rear sprocket bearings in transmission and rear wheel are under additional load Apart from premature wear in extreme cases the chain can rupture or the countershaft of the transmission can break On the other hand if the chain Is loose it can fall off the engine sprocket or the rear sprocket and block the rear wheel or damage the engine Check the chain tension and correct if necessary 11 SERVICE VVORK ON THE CHASSIS 84 Preparatory work Check the chain tension p 82 Main vvork Loosen nut O Loosen nuts Q Adjust the chain tension by turning adjusting screws on the left and right Guideline Turn adjusting screws on the left and right so that the markings on the left and right chain adjuster O are in the same position in relation to reference marks O The rear wheel is then correctly aligned e Info The upper chain section must be taut Chain wear is not always even so you should check the setting at different chain positions Tighten nuts Q Make sure that chain adjusters O are fitted correctly on adjusting screws 6 Tighten nut O Guideline Nut rear wheel spindle M
4. 111 14 ELECTRICAL SYSTEM 112 14 1 Removing the A A Warning b 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 the battery away from sparks or open flames Charge only in well ventilated areas 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 78 Remove the seat p 79 Main work Pull back the negative terminal cover Disconnect the negative cable of the battery 14 ELECTRICAL SYSTEM 113 5 UM 41 Ika B00751 10 l4 B00751 m Pull back the positive terminal cover Disconnect the positive cable O of the battery Detach rubber band Pull the battery up and out of the battery holder e 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 vehi cle is therefore no longer roadworthy Main work Position the battery in the battery holder e Info The battery terminals must be at the top Attach rubber band Reconnect the positive cable of the battery Position positive terminal
5. ana 19 2 Preparing for use after storage TROUBLESHOOTING uo FPECAHNICAKDAT A river daa bout E obti cedrus Alel ENGINE yn ides A 21 1 1 125 DUKE yan anka teste iiu en Ku er n bronca Stet 21 1 2 7200 Duke EU NAD C e are aaa 21 2 Engine tightening torques eese TABLE OF GONTENTS 21 3 1 S PACI ES yy ka AWA Y 162 AES Bl a silal cl ei Las E E E a NN 162 2132 CODA ats dele KH a e c ra e nek ees 162 ZA t MEME SU Dr r 162 ZU MET pa r dt 163 21 5 Electrical SySEem ayi kay a kelan OR an RAS VAR Nul 164 JO A A a an 165 2 J TOU Kal kana ss 165 Ze SHOCK ADSONDEN paa tenda ki nn hs puis kewa MAUS 165 21 9 Chassis tightening torques esee 166 22 SUBS LAN CE S gen a HM WA R NA Mae MA Gas 170 23 AUXILIARY SUBSTANC S soii n kel da ke biy naya ei ds 173 24 STANDARDS tectis eden Det he KA S s 176 1 MEANS OF REPRESENTATION 1 1 Symbols used The meaning of specific symbols is described below Y Indicates an expected reaction e g of a work step or a function X 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 A 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
6. in the housing Position cover Mount and tighten screws T B00762 10 14 ELECTRICAL SYSTEM 126 Fold the headlight mask up Mount and tighten screws Guideline Screw headlight mask 11 Nm 8 1 Ibf ft Mount expanding rivets on both sides Check that the lighting is functioning properly 14 ELECTRICAL SYSTEM 127 14 8 Checking the headlight setting Position the vehicle upright on a horizontal surface in front of a light wall and make a mark at the height of the center of the low beam headlight Make another mark at a distance under the first mark Guideline an Position the vehicle vertically at a distance Q in front of the wall and switch on the low beam Guideline E LUCR The rider with luggage and passenger if applicable now mounts the motorcycle Check the headlight setting The light dark boundary must lie exactly on the lower mark when the motorcycle is ready to operate with the rider mounted along with any luggage and a passenger if applicable Ifthe boundary between light and dark does not meet specifications Adjust the headlight range p 128 14 ELECTRICAL SYSTEM 14 9 Adjusting the headlight range Main work Remove expanding rivets Remove screws Lift the headlight mask slightly and swing forward 128 14 ELECTRICAL SYSTEM 129 Adjust the beam distance of the headlight by turning scre
7. nenn a eyek a need cna 62 8 5 Applying the brakK S aaa eg r un d si as 65 8 6 Stoppina Dal Kil en s vende an euet citer v tie a via 67 8 7 TEANS DOUG pes ven e a e a testetur uda dst 68 8 8 FR TIC MINE gn l A Ke v n KAREN d K bA RI uo 69 10 11 12 SERVICE SCHEDULE aid 9 1 Service Schedules gdhi TUNING THE CHASSIS area ses dan la l n rum Pra hea 10 1 Adjusting the spring preload of the shock AISORDE Sana a wn k n 10 2 Adjusting the shift even iii nana nana ane nene neve veres SERVICE WORK ON THE CHAS Susini 11 1 Raising the motorcycle with the rear wheel St E LU e ne bA Ee 11 2 Taking the motorcycle off of the rear wheel us n e pre E ETE 11 3 Raising the motorcycle with the front wheel A 11 4 Taking the motorcycle off of the front wheel A E IT 11 5 Removing the passenger Seat 11 6 Mounting the passenger seat esee 11 7 Removing the seat eese 11 8 Mounting the Seat kada i rt e Vid eb NY 11 9 Checking for chain dirt accumulation 11 10 Cleaning the chain nana n aaa kU 11 11 Checking the chain tension kau u ana nana nan ane nene eee 11 12 Adjusting the chain tension seeesesee 11 13 Checking the chain rear sprocket and engine SPOCK oran MID RI CM e Wak 11 14 Removing the front spoiler sees 11 15 Fitting front Spoiler oos save o kil rn Tam un eo keka PRAN STO
8. Dirty cooling fins also reduce the cooling effect Warning y Danger of scalding During motorcycle operation the coolant gets very hot and is under pressure Do not remove the radiator cap radiator hoses or other cooling system components when the engine is hot Allow the engine and cooling system to cool down In case of scalding rinse immediately with lukewarm water 15 COOLING SYSTEM 13 Warning Danger of poisoning Coolant is poisonous and a health hazard C9 Avoid contact between coolant and skin eyes and clothing If it gets into your eyes rinse immediately with water and contact a doctor Wash affected skin areas immediately with soap and water If coolant is swallowed contact a doctor immediately Change clothes that have come into contact with coolants Keep coolant out of the reach of children Condition The engine is cold Stand the motorcycle upright on a horizontal surface Remove the cap of the compensating tank Check the coolant antifreeze d ae AG TC Lona 749 T Ifthe coolant antifreeze does not meet specifications Correct the coolant antifreeze Check the coolant level in the compensating tank The coolant level must be between MIN and MAX Ifthe coolant level does not meet specifications Correct the coolant level Alternative 1 Coolant p 170 Alternative 2 Coolant mixed ready to use p 170 Mount the cap of the compen
9. Foot brake lever O is located in front of the right footrest The foot brake lever is used to activate the rear brake 93 6 CONTROLS 54 620 Side stand 0 The side stand O is on the left side of the vehicle The side stand is used to park the motorcycle e Info The side stand must be folded up during motorcycle use Side stand is coupled with the safety start system see the riding instructions Possible states e Side stand folded out The vehicle can be leaned on the side stand The safety start system is active e Side stand folded in This position is mandatory for all trips The safety start system is inactive 7 7 1 PREPARING FOR USE 55 Advice on first use 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 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 Warning Danger of crashing Poor vehicle handling due to different tire tread patterns on front and rear wheels The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control ove
10. O Indicates a page reference more information is provided on the specified page 1 2 Formats used The typographical formats used in this document are explained below Specific name Identifies a proprietary name Name Identifies a protected name Brand Identifies a brand available on the open market 2 SAFETY ADVICE 8 24 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 e Info The motorcycle is authorized for public road traffic in the homologous version only A number of safety instructions need to be followed to operate the vehicle safely Therefore read this manual carefully The safety instruc tions are highlighted in the text and are referred to at the relevant passages e 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 9 2 3 Degrees of risk and symbols Danger A Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken A Warning Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken Caution A Identifies a danger that may lead to minor injuries if the appropriate mea
11. brake light turn signal high beam low beam parking light tail light license plate lamp Fuse 7 10 A ABS Fuse 8 10 A for auxiliary equipment permanent positive Fuse 9 10 A for auxiliary equipment accessories connected with ignition switch Fuse 10 10 A control unit e Info A defective fuse is indicated by a burned out fuse wire Q Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used Use only fuses with the prescribed amperage Never by pass or repair fuses Use spare fuses with the correct rating only Fuse 75011088010 p 164 Fuse 75011088015 p 164 14 14 6 Note ELECTRICAL SYSTEM 120 Fuse 75011088030 p 160 e Tip Replace the spare fuse in the fuse box so that it is available if needed Check that the power consumer is functioning properly Close the fuse box cover Finishing vvork Mount the passenger seat p 79 Changing the headlight bulb Damage to reflector Reduced brightness Grease on the lamp will evaporate due to the heat and be deposited on the reflector Clean the lamp and keep it free of grease before mounting Preparatory vvork Switch off all power consumers and switch off the engine Main work Remove expanding rivets O 14 ELECTRICAL SYSTEM 121 y FM Remove screws Lift the headlight mask slightly and swing forward lt Take off protection
12. TENIS urat d k kra bez A 12 1 ABS antilock brake system M L 12 2 Checking the brake discs aaa aaa aaa aaa nene EE TABLE OF GONTENTS 13 14 12 3 Checking the brake fluid level of the front brake 93 12 4 Adding front brake fluid amp ga 12 5 Checking the front brake linings 95 12 6 Checking the free travel of foot brake lever 96 12 7 Adjusting the free travel of the foot brake Ic itet ion h t UTEM 97 12 8 Checking the rear brake fluid level 98 12 9 Adding rear brake fluid 99 12 10 Checking the rear brake linings 101 WHEELS TIRE Skena 102 13 1 Removing the front wheel 102 13 2 Installing the front wheel 103 13 3 Removing the rear wheel amp 104 13 4 Installing the rear wheel 105 13 5 Checking the rear hub rubber dampers 107 13 6 Checking the tire condition 109 13 7 Checking the tire air pressure 110 ELECTRICAL SYSTEM cartis 112 14 1 Removing the battery l 112 14 2 Installing the battery 113 14 3 Recharging the battery dua aaa 114 14 4 Changing the ABS fuses eese 117 1
13. TawnG nin TT TT Screw fuel tank tim js TT TT Screw license plate holder M5 Mimea Sems N amp ELTON Sueewmiei fws ELIO Nat foot brake lever adjusiment M6 own 4 AD Nat radaor E sine znrn TT Remalning nus css i6 IA TT TT 21 TECHNICAL DATA 167 Remaining screws chassis 10 Nm 7 4 Ibf ft Sere ABS ose damp Ne IC Screw airfiterbox M6 maior SSS KT M6 BA TT TT TTTTT Screw brake fuid reservori rear bake N IR Screw cable holder side stand switch M6 9Nm amp 6Ib lez Sere chain sin guard me INSI hoeta ne EA O EIC hem zw 0 Serew front fender e Ti me ee TJE TT Sorem front seat ning CN emer Serew fueltank CO werin E Sorem headligt older M6 O Tr nae n rn JET Sorem headlight mask ME r0 TT TT Serew ritin col ME OMR TT TT Screw censo plate older M amp AO Sorem radiata bracket M6 emea Sorem radiator older M6 INR Sorem rer splash roet 67 emee TT Screw rollover sensorfolder M6 Mmea TT TT TT Sms WEN A A amea bara 00 Screw voltage regulator M6 Townganrn TJE TT 21 TECHNICAL DATA 168 Screw voltage regulator holder 15 Nm 11 1 Ibf ft Serv wee gpeed sersar me mes Je Remaining nats chassis 8 ROMA JET Remaining serewe ch
14. 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 Steering locked The ignition key can be removed 6 CONTROLS 27 6 11 1 Overview Display p 34 Function buttons p 32 info display p 38 Indicator lamps p 33 gt GO NI 401685 10 6 6 11 2 GONTROLS Activation and test 401686 01 28 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 O to 199 and back The remaining display segments outside the info display light up briefly The READY TO RACE gt gt logo appears on the info display The display then changes to the last selected mode 6 6 11 3 GONTROLS warning notes Low Oil Pressure appears on the info display if the oil pressure is too low Low Fuel Level appears on the info display if the fuel level reaches the reserve mark 29 6 CONTROLS 30 High Goolant Temperature appears on the info display if the coolant temperature rises above the specified value Coolant temperature 129 06 257 k Side Stand Down appears on the info display if the side stand is folded down L
15. bearing for damage and wear Ifthe wheel bearing is damaged or worn Change the wheel bearing Clean and grease the shaft seal rings and mating surfaces Q of the spacers Long life grease p 174 Insert the spacers 13 WHEELS TIRES 104 Clean the thread of the wheel spindle and screw Position the front wheel and insert the wheel spindle Y The brake linings are correctly positioned Mount and tighten screw Guideline Screw front wheel spindle M8 25 Nm 18 4 Ibf ft Insert wheel speed sensor into the hole Mount and tighten screw O Guideline Screw wheel speed sensor 8 Nm 5 9 Ibf ft Mount and tighten screws Take the motorcycle off of the front wheel stand p 77 Pull the front wheel brake and push down hard on the fork several times to align the fork legs Tighten screws O Guideline Screw fork stub M8 15 Nm 11 1 Ibf ft Finishing work Take the motorcycle off of the rear wheel stand p 75 13 3 Removing the rear wheel 4 Preparatory work Raise the motorcycle with the rear wheel stand p 75 Main work Remove screw O and pull wheel speed sensor out of the hole 13 WHEELS TIRES 105 Remove nut and the washer Remove chain adjuster O Holding the rear wheel withdraw wheel spindle Push the rear wheel forward as far as possible and take the chain off the rear sprocket A Warning Dan
16. brake may fail due to overheating Take your foot off the foot brake lever when you are not braking Warning Danger of accidents Longer stopping distance due to higher overall weight Take the longer stopping distance into account when carrying a passenger and baggage 8 RIDING INSTRUCTIONS 66 Warning Danger of accidents Delayed brake action on salted roads A A There may be salt deposits on the brake discs In order to restore the normal braking efficiency you will need to remove the deposits from the discs by carefully applying the brakes Warning Danger of accidents Greater stopping distance due to ABS Braking should be appropriate to the driving situation and the road conditions Warning Danger of accidents Excessively forceful braking can cause the wheels to block ABS must be switched on to be effective When braking release the throttle and apply the front and rear brakes at the same time A A Info When ABS is active you can achieve maximum braking power even on low grip surfaces such as sandy wet or slippery terrain without locking of the wheels Warning Danger of accidents Locking of the wheels due to braking action of the engine Pull the clutch during emergency braking full brake application and when braking on a slippery surface Warning Danger of accidents Road grip is reduced when braking with the motorcycle at an angle or on a laterally inclined surface B
17. brake system If the brake fluid level falls below the MIN mark this indicates a leakage in the brake system or worn out brake linings Check the brake system and do not continue riding Your authorized KTM workshop will be glad to help Warning Danger of accidents Reduced braking efficiency due to old brake fluid Change the brake fluid of the front and rear brake according to the service schedule Your authorized KTM workshop will be glad to help Move the brake fluid reservoir mounted on the handlebar to a horizontal position Check the brake fluid level in viewer Ifthe brake fluid is below the MIN marking Add front brake fluid p 94 C00200 10 12 12 4 A BRAKE SYSTEM 94 Adding front brake fluid 4 Warning Danger of accidents Failure of the brake system Ifthe brake fluid level falls below the MIN mark this indicates a leakage in the brake system or worn out brake linings Check the brake system and do not continue riding Your authorized KTM workshop will be glad to help Warning Skin irritation Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and keep out of the reach of children Wear suitable protective clothing and goggles f brake fluid comes into contact with the eyes flush the eyes thoroughly with water and consult a physician immediately Warning Danger of accidents Reduced braking efficiency due to old
18. cap O Disconnect plug in connector Detach retaining clamp O Remove headlight bulb Position the new headlight bulb in the headlight housing Headlight H4 socket P43t p 164 e Info Insert the headlight bulb so that the catches latch into the recesses 14 ELECTRICAL SYSTEM 122 Attach retaining clamp O Connect plug in connection Mount protection cap Q Fold the headlight mask up Mount and tighten screws Guideline Screw headlight mask 11 Nm 8 1 Ibf ft o y 3 aaa b s k SS NELA 14 ELECTRICAL SYSTEM 123 Mount expanding rivets on both sides Check that the lighting is functioning properly 14 7 Changing the parking light bulb Note Damage to reflector Reduced brightness Grease on the lamp will evaporate due to the heat and be deposited on the reflector Clean the lamp and keep it free of grease before mounting Preparatory work Switch off all power consumers and switch off the engine Main work Remove expanding rivets 14 ELECTRICAL SYSTEM 124 Remove screws Lift the headlight mask slightly and swing forward Remove screws O Take off cover O AS Nsco76210 14 ELECTRICAL SYSTEM 125 Pull the socket with bulb out of the housing Remove the bulb Position a new light bulb in the socket Parking light W5W socket W2 1x9 5d p 164 Position the socket with bulb
19. chassis number is stamped on the right of the steering head The type label is on the right of the frame behind the steering head 10 The engine number O is stamped on the left side of the engine under the engine sprocket B00700 10 9 SERIAL NUMBERS 2 53 Keymumber HH The key number can be found on the KEYCODECARD e Info You need the key number to order a spare key Keep the KEYGODECARD in a safe place B00755 10 6 CONTROLS 22 BI Clutch lever The clutch lever O is fitted on the left side of the handlebar The hand brake lever O is fitted on the right side of the handlebar The front brake is engaged using the hand brake lever B00702 10 6 CONTROLS 23 The throttle grip O is fitted on the right side of the handlebar B00703 10 The horn button Q is fitted on the left side of the handlebar Possible states e Horn button in neutral position e Horn button ts pressed The horn is operated in this position B00706 11 6 CONTROLS 24 65 Lightswiteh 0 The light switch O 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 The high beam flasher button is fitted on the left side of the handlebar Possible states e High beam f
20. designed for the weight of the motorcycle only Do not sit on the motorcycle when it is supported by the side stand only The side stand and or the frame could be damaged and the motorcycle could fall over Brake the motorcycle Shift gear to neutral 8 RIDINGINSTRUCTIONS 68 Switch off the ignition by turning the ignition key to the position 4 e Info If the engine is switched off with the emergency OFF switch and the ignition remains switched on at the ignition lock power continues to flow to most power consumers and the battery will discharge You should therefore always switch off the engine with the ignition key the emergency OFF switch is intended for emergencies only Park the motorcycle on a firm surface Swing the side stand forward with your foot as far as it will go and lean the vehicle on it Lock the steering by turning the handlebar fully to the left pressing down the ignition key to position amp and turning it to position LIK To make the steering lock engage more easily move the handlebar a little to the left and right Remove the ignition key 8 1 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 w
21. during braking The brake system itself stays functional only ABS control is not available The ABS warning lamp may also light up if the rotating speeds of the front and rear wheels differ greatly under extreme riding conditions for example when making wheelies or if the rear wheel spins This causes the ABS to switch off To reenable the ABS the vehicle must be stopped and the ignition switched off The ABS is reenabled when the vehicle is switched on again The ABS warning lamp goes out when you start off Button can be used to switch ABS off manually see Starting 12 2 Checking the brake discs Warning Danger of accidents Reduced braking efficiency due to worn brake disc s Change the worn brake disc s without delay Your authorized KTM workshop will be glad to help Check the thickness of the front and rear brake discs at several places on the disk to see if it conforms to measurement e Info Wear reduces the thickness of the brake disc in area of the brake disc Brake discs vvear limit Ifthe brake disc thickness is less than the specified value 400480 10 12 BRAKE SYSTEM 93 Change the brake discs 4 Check the front and rear brake discs for damage cracking and deformation Ifthe brake disc shows signs of damage cracking or deformation Change the brake discs V 12 3 Checking the brake fluid level of the front brake Warning Danger of accidents Failure of the
22. of the combination instrument is run at the same time Shift gear to neutral Y The green idling speed indicator lamp N lights up Y The ABS warning lamp lights up and goes back out after starting off Press the electric starter button 6 Info Do not press the electric starter button until the combination instrument func tion check is finished When starting DO NOT open the throttle If you open the throttle during the start ing procedure fuel is not injected by the engine management system and the engine cannot start Press the starter for a maximum of 5 seconds Wait for a least 5 seconds before trying again This motorcycle is equipped with a safety starting system You can only start the engine if the transmission is in neutral or if the clutch is pulled when a gear is engaged If the side stand is folded out and you shift into gear and release the clutch the engine stops 8 RIDINGINSTRUCTIONS 62 Svvitching off ABS KTM recommends riding with ABS at all times However situations may arise in which ABS is not advantageous Condition Vehicle stationary engine running Press the button for 3 5 seconds Y The ABS warning lamp starts flashing ABS is deactivated 401685 15 Pull the clutch lever engage 1st gear release the clutch lever slowly and simultaneously open the throttle carefully e Tip If the engine dies while starting off only pull the clutch lever and press the electric starter b
23. 123 Passenger footrests cee ee ee ee 52 Passenger seat MOUNTING acne t 5 E 19 A e ze a aq et Mo eau t e aea Wa decd 78 Play in throttle cable AUS MNS Dd e way aR ae ate oe de a A Ode We 141 CHECKING yoegan E A UD ad 140 Preparing for use advice Onm TIF SUS os ks nahe god oe a we Pt t OA 0 44 55 after Storag er A NES E a 153 checks and maintenance when preparing for use 59 Protective clothing o o 11 INDEX R Rear hub rubber dampers CUSCO e mua aa GE Be SE nis 107 Rear sprocket CHOC KI IB ac irr e aad pen a 85 Rear wheel ASTANE nce SoS A SE ee 105 sn E e gi nj a EEEEEHnHEHHE MMDMM 104 KO Sa d Ka k fet Qay ee A K al AR a 62 STARLING OI es reas AEA E 62 S Safe operation ux ues Na een RC XO XC Oo ERO ye lea i RSS 10 Seat gas TRES 80 nou sas nE DA E 9 Seat lOCGK a euim ROS ORCI e dib Sy N 50 SENE Cast s e a toe cleat ohn ch tup xd de gg 13 Service schedule as 71 72 SHIHTE VON Face dh n Sean oc week eee edd ooi a 52 OJ UST cs a e E eae ph ra Gino E 74 Shift speed RPM 1 CLUS A i io oc de I aE ae MC ca ER Wo Se vb ie 47 Shift speed RPM 2 cel lal S2 47 S A c r 62 180 Shock absorher Spring preload adjusting leen 13 Side SLANG 1 ra e e eR o eon EHRE 54 E et ores ac a Bento uou a od m acte t Ge 13 Sici ker eee SO uv n e re dd Gede se 60 p la ss ica ak ER HHHH HHHH e 26 STODDI
24. 14x1 5 60 Nm 44 3 Ibf ft 11 SERVICE WORK ON THE CHASSIS 85 11 13 Checking the chain rear sprocket and engine sprocket Check the rear sprocket and engine sprocket for wear Ifthe rear sprocket and engine sprocket are worn Change the power set e Info The engine sprocket rear sprocket and chain should always be replaced together 100132 10 11 SERVICE VVORK ON THE CHASSIS 86 Shift gear to neutral Pull the lower chain section with specified weight Q Guideline Weight chain wear measurement 15 kg 33 Ib Measure the distance of 20 chain links in the lower chain section e Info Chain wear is not always even so you should repeat this measurement at differ ent chain positions Maximum distance at the longest 301 6 mm 11 874 in chain section If the distance O is greater than the specified measurement Change the power set amp e Info OOO OA j O OJO O When the chain is replaced the rear sprocket and engine sprocket 1 2 3 18 19 20 should also be changed New chains wear out faster on old vvorn sprockets 401288 10 1 SERVICE WORK ON THE CHASSIS Remove screws and O and release screw Push the chain guard aside Check the chain sliding guard for wear If drill hole O becomes visible on the chain sliding guard in area O Change the chain sliding guard Check that the chain sliding guard is firmly seated If th
25. 4 5 Changing the fuses of individual power CONSUE SS nn 118 14 6 Changing the headlight bulb 120 14 7 Changing the parking light bulb 123 14 8 Checking the headlight setting 127 14 9 Adjusting the headlight range 128 15 16 17 18 19 20 21 CODING STIS T ENG oa e uade nda tuus A LO Cooling Ss SM gen dust met pix Ue RA VECES 15 2 Checking the antifreeze and coolant level 15 3 Checking the coolant level 15 4 Draining the coolant 15 5 Filling bleeding the cooling system TUNING TRE ENGINE aint dd ni 16 1 Checking the play in the throttle cable 16 2 Adjusting the play in the throttle cable 4 16 3 Checking the clutch lever play 16 4 Adjusting the clutch cable play SERVICE WORK ON THE ENGINE eene 17 1 Checking the engine oil level 17 2 Changing the engine oil and oil filter cleaning theol Sereen As y y aryan nan yan Dae etc ate kana 1 3 Adding engine Oli ti yaka AZAN CLEANING CARE nn eia assets 18 1 Cleaning the motorcycle i un ana aaa nana nan nene nene renes 18 2 Checks and maintenance steps for vvinter ODA ATION e b VE n a a SANA E ND tintadas DEAS SORA Ce eynan Raneya y nei oh
26. EU MAL 129 5 kg 285 5 Ib 21 5 Electrical system Battery 125 Duke Battery voltage 12 V Nominal capacity 6 Ah Maintenance free Battery 200 Duke EU MAL Battery voltage 12 V Nominal capacity 8 Ah Maintenance free Fuse 5011088015 15 A Headlight H4 socket P43t 12 V 60 55 W Parking light W5W socket W2 1x9 5d Instrument lights and indicator lamps LED Turn signal LED 21 TECHNICAL DATA 165 Brake tail light LED License plate lamp LED 21 6 Tires Rear tires 110 70 R 17 M C 54S TL 150 60 R 17 M C 66S TL MRF revz FC MRF revz C Additional information is available in the Service section under http www ktm com 21 7 Fork Fork part number 90101000044 Fork length 736 mm 28 98 in Fork oil SAE 5 p 172 21 8 Shock absorber Shock absorber part number 90604010000 Shock absorber WP Suspension Spring preload Static sag 25 mm 0 98 in Riding sag 45 50 mm 1 77 1 97 in 21 TECHNICAL DATA 166 Fitted length 30mm l81i 21 9 Chassis tightening torques Serew changed e iNsGB JET Semea Tsrere Am TT o Wemdnmpsoew dus ma ARM TT Screw EFI conto nit M Ama TT TT TTTTT Sorem trim subframe bom wa AMB TT TT Remaining screws chassis ms emer TT Serew fuel pump js 8NwG7ii TT TT Screw fuel tank closue fangs M5 3NmQZii TT TT Sorem fueltank cover M5
27. FEMOVING nba a RS ER os 102 Fuse individual power consumers changing 118 Fuses ABS GJAK GIN D d st s OR AR a Si e n e n te es 117 INDEX Grab handles nahna Be ch IJ e EP K K KI 51 Hand brake lever i se ee sd ie q de e ew Seow wee ewes 22 Headlight adjustment SS es T oe te Es ee 128 CT CON nab y tay arth Grose eG Gah Meh a ewe od Baga se 127 Headlight bulb CNANSINE s is l AE Cae ine 120 High beam flasher button 24 FIOM DURON i te a A ie qi s eat 23 Ignition lock 54 it LL LL e o NO K K KII K K e K K K KIIR 26 Indicator lamps 33 Key number po ee a KIRI aa P KK 21 Kilometers or miles A e do dare e OEC bi 45 EIPHESWIEGIE a Cen eS NN A K ea EA a ek desto tie Ar AO o 24 Loading the vehicle 0 cece ee ees 57 Motorcycle ard abana de ardeat noe do RE NI H a 148 raising with the front wheel stand 76 179 raising with the rear wheel stand iii 15 taking off of the front wheel stand 77 taking off of the rear wheel stand 15 Dil filter CAME g S MM i eoe aa A so i a Dite t d Sel a 143 Oil screen A A E 143 Operating substances o ooo o 13 Owner s Manual VII VII III KIRI es 12 PAKNE eat k o Ste ers e nen a ee ke e KK ae M ve F r eee ek e B ke 67 Parking light bulb E HH
28. I RI KIRI ooo KI 101 BIaKBS Locutus KON den dard xe s es Eee ees 65 177 Brakes applying VIRI RIK ee 65 C Capacity COON ANN s user Sd e Dede e WU A ate Geen 162 la OM lt a 162 PES p ica deu Weak aca e AAA 10 162 Chain chain dirt accumulation checking 81 CHECKIN suae ie er wan wo abe bk A e e A YA ae we S 85 erol SEHEK KRKRHR ao a Raed 81 Chain tension UU SEMIN pa bao caet Se Tal RTS oci a S ert las Meo ORT aL wu aR Se 83 ea qiu TT 82 Chassis number LL LV LV VV KIRI ee es 20 Clutch cable play c jU SH qen de Anak ete NAM e a oto Da 142 Gl tcli leVer io aa Ra Ra RE REH mre a r d Ear CERO oa 22 Clutch lever play CHECKING ca see are abal a de M hn aA Sh 141 Combination instrument activation and test ean ton a2 gee RR al w 2 duha e v s 28 average fuel consumption 1 average fuel consumption 2 E as ice E QI 40 average fuel consumption 2 service menu 41 average speed average fuel consumption 1 menu 39 coolant temperature indicator o oo o 37 ODA Sa Se are RARI T cr e cee et ee 34 INDEX CISD lay TRIP si aya A e EBORE 36 distance menu 1 TRIP 1 44 distance menu 2 TRIP 2 5 215 3 ay Sw Re K K 45 filling level display in fuel tank o 39 POMC OF DUELOS ARDE gate Du s er 32 mole ator Jas aga e od cod ee a tp esie Gaf 33 aer ng z
29. IT S ad S est itus atia rb ese eut en ens Z 16 4 1 View of vehicle front left example 16 4 2 View of vehicle rear right example 18 SERIAL NUMBERS ca 20 5i Chassis number type label eeess e 20 5 2 Engine Number yyy band da tn ds tA E Eua eddie 20 5 3 Key IOC nen A 2 4144524 pot 21 CONTROL S omo aorta 22 6 1 ARA DD E E EES Dan 22 3 6 2 Hand brake lever esee 22 6 3 T jI peya SUD Lari das ato bius N dade th use t nce eti s 29 6 4 ROM DUO 23 6 5 NES WI ad 24 6 6 High beam flasher button ocococococononononononanononos 24 6 1 Turn signal SWItCh dandis ti idos 2b 6 8 Emergency OFF SYVItC ha aa aaa aaa nene nene nenen enes 25 6 9 Electric starter Dutti 26 6 10 Ignition steering lOCK oocococococcconocconcronororononos 26 6 11 Combination instrument aa ua una nana nana nane ke neneve veres 21 6 11 1 CV ON VIC EM 21 6 11 2 Activation and testa dida 28 5 11 3 Warning NOLES ys Kall yay e keni dle elem C Is 29 odlop Puncuon DUEHOPS ajer sh rw aere epe rd sa Kan pe 32 511 5 lal 0 lece dirane T 93 A A ante an oos NN 34 6 11 7 filling level display in fuel tank 39 Gl TRIPA 36 6 11 9 Coolant temperature indicator 31 GALO ARO GI SP AV na 38 6 11 11 Riding time average speed menu 39 6 11 12 Average speed average fuel consumption 1 nil Tal e ld daba 39 6 11 13 Average fuel
30. OWNER S MANUAL 2013 125 Duke EU 200 Duke EU 200 Duke MAL Art no 3211963en DEAR KTM 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 20 Dealer s stamp Engine number p 20 Key number p 21 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 supply 2012 KTM Sportmotorcycle AG Mattighofen Austria All rights reserved Reproduction even in part as well as copying of all kinds is permitted only wit
31. Set the clock p 46 14 ELECTRICAL SYSTEM 117 JAN Warning MA Fire hazard The electrical system can be overloaded if the wrong fuses are used Use only fuses with the prescribed amperage Never by pass or repair fuses e Info l Two fuses for the ABS are located under the passenger seat These fuses protect the return pump and the hydraulic unit of the ABS The third fuse which protects the ABS control unit is located in the fuse box Preparatory work Switch off all power consumers and the engine Remove the passenger seat p 78 To change the fuse of the ABS hydraulic unit Take off the protection cap and remove fuse Insert the new fuse Fuse 58011109115 p 164 Mount the protection cap 14 ELECTRICAL SYSTEM 118 To change the fuse of the ABS return pump Take off the protection cap and remove fuse Insert the new fuse Fuse 58011109125 p 164 Mount the protection cap Finishing work Mount the passenger seat p 79 e Info The fuse box with the main fuse and the fuses of the individual power consumers is located under the passenger seat Preparatory work Switch off all power consumers and switch off the engine Remove the passenger seat p 78 14 ELECTRICAL SYSTEM 119 Main vvork Open fuse box cover Remove the defective fuse Guideline Fuse 5 15 A radiator fan Fuse 6 15 A horn
32. TO lt i lt et ed EA Rl X Waran eee 67 IDA C kd Pe eae ay ee Ee oe ee 152 T Technical data Capa OS da date ss Gh Puede on ES 162 Cie SSIS aran e V RIPE GAs MINET diya ok Ke on ae eae at 163 chassis tightening torques llle 166 electrical SYSTEM ss ALA KK a da oa eost ww Be led kun 164 TONG car Go Q nd we to oe isl aed e as a 157 engine tightening torques aaa 160 E NE 165 shock absorber a kk kK sd e E e KK 165 WES sod aiuta d Re as wh Ma are ac ened fas 165 Throttle TID a iun naa KA eae E case RC OE OR d 23 Time aU SEWN ais a Ve dr do SUR dere Doe 46 Tire air pressure malc p a n Se sar ap S e mm 110 Tire condition COCKS zare an TARRE EEEE ETENEE Gust Qe ka ee eee d 109 TOSCO lt k a eed NY oes gos woe V Ew kr eee ee 51 INDEX GATI S n M TC nde Sd R T Gd Ni 68 Troubleshooting ii aaa 154 156 Turn signal switch i iv zx ox al a 25 Type label os uio od ga 20 Use definition suka Jh yak ab a e hak ap URSUS es 8 View of vehicle HOLE SE Sana Sta vua I ed l e aie a aa in aun WALA 16 O IN bok d ed 18 Wanani A E ha d EAE HYS des 13 Winter operation checks and maintenance steps sn 150 Work rules canda a ae Se ALA A a BABA andaba OS E 11 181 WWW KTM COM 3211963en 12 2012 KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com ZZ e Photo Mitterbauer KTM
33. WHEELS TIRES 107 Pull the rear wheel back and mount wheel spindle e Info Mount the left and right chain adjusters O in the same position Mount nut and washer Push the rear wheel forward so that the chain adjusters are on the screws and tighten nut O Guideline In order for the rear wheel to be correctly aligned the markings on the left and right chain adjusters must be in the same position relative to the reference marks Q Nut rear wheel spindle M14x1 5 60 Nm 44 3 Ibf ft Insert wheel speed sensor into the hole Mount and tighten screw O Guideline Screw wheel speed sensor 8 Nm 5 9 Ibf ft Finishing work Take the motorcycle off of the rear wheel stand p 75 e Info The engine power is transmitted from the rear sprocket to the rear wheel via 6 rubber dampers They eventually wear out during operation If the rubber dampers are not changed in time the rear sprocket carrier and the rear hub will be damaged 13 WHEELS TIRES 108 Preparatory work Raise the motorcycle with the rear wheel stand p 75 Remove the rear wheel W4 p 104 Main work Check bearing O Ifthe bearing is damaged or worn Change the bearing Check the rubber dampers of the rear hub for damage and wear Ifthe rubber dampers of the rear hub are damaged or worn Change all rubber dampers in the rear hub Lay the read wheel on a workbench with the rear spro
34. al motorcycle cleaner and a soft sponge Never apply motorcycle cleaner to a dry vehicle always rinse the vehicle with water first If the vehicle was operated in road salt clean it with cold water Warm water would enhance the corrosive effects of salt After rinsing the motorcycle with a gentle spray of water allow it to dry thoroughly Remove the closure of the exhaust system Warning Danger of accidents Reduced braking efficiency due to a wet or dirty brake sys tem Clean or dry a dirty or wet brake system by riding and braking gently After cleaning ride the vehicle a short distance until the engine warms up e Info The heat produced causes vvater at inaccessible locations in the engine and on the brake system to evaporate Push back the sleeves of the handlebar controls to allow any water that has penetrated to evaporate After the motorcycle has cooled off lubricate all moving parts and bearings Clean the chain p 81 Treat bare metal parts except for brake discs and exhaust system with anti corrosion materials Cleaning and preserving materials for metal rubber and plastic p 173 Treat all painted parts with a mild paint polish 18 CLEANING CARE 150 Treat all plastic parts and powder coated parts with a mild cleaning and care product Paint cleaner and polish for high gloss and matte finishes bare metal and plastic surfaces p 174 Oil the ignition steering lock Universal oil sp
35. an the oil screen 4 9 p 143 Headlight and parking light are not Fuse 6 blown Change the fuses of individual power consumers functioning p 118 Turn signal brake light and horn are Fuse 6 blown Change the fuses of individual power consumers not functional p 118 Time is not correctly displayed Fuse 2 blown Change the fuses of individual power consumers p 118 Set the clock p 46 Battery discharged Ignition not switched off when vehicle Recharge the battery 9 p 114 was parked 20 TROUBLESHOOTING 156 Faults Possible cause Action Battery discharged Battery is not being charged by alter Check the charging voltage nator Check the open circuit current 4 Combination instrument shows nothing Fuse 2 blown Change the fuses of individual power consumers on the display p 118 Set the clock p 46 Speedometer in combination instru Speedometer wiring harness is dam Check the wiring harness and plug in connection ment not functioning aged or plug in connection Is oxidized 21 TECHNICAL DATA 157 21 1 Engine 21 1 1 125 Duke Displacement 125 cm3 7 63 cu in 1 L ring 1 tapered compression piston ring 1 oil scraper ring Transmission ratio 21 TECHNICAL DATA 158 Ath gear 21 26 bth gear 22 29 6th gear 24 22 Mixture preparation Electronically controlled fuel injection Ignition Contactless controlled fully electronic ignition with d
36. appears on the info display 401293 01 6 11 9 GONTROLS Coolant temperature indicator 401292 01 The temperature display consists of 13 bars The more bars that light up the hotter the coolant When all bars light up the following warning note appears on the info display High Coolant Temperature Possible states e Engine cold Up to three bars light up e Engine warm Four to ten bars light up e Engine hot Eleven to thirteen bars light up 37 6 6 11 10 GONTROLS info display 401291 10 Various warning notes appear on info display O If the general warning lamp Y lights up the corresponding warning note is shown on the info display 38 6 CONTROLS 39 6 11 11 Riding timefaverage speed menu Condition Alternative 1 e The ignition is on e he motorcycle is stationary Alternative 2 e The ignition is on e he motorcycle is moving Press the SET button briefly and repeatedly until the desired info display appears The riding time and average speed are displayed in this menu e Info If the ignition was switched off for over 60 minutes the display is reset to O Press the SET button Next display mode on the info display briefly 6 11 12 Average speed average fuel consumption 1 menu Condition Alternative 1 e The ignition is on e he motorcycle is stationary Alternative 2 e The ignition is on e he motorcycle is moving Press the SET button brie
37. arm from being run Always let the vehicle cool first 8 RIDINGINSTRUCTIONS 69 Switch off the engine and remove the ignition key Use tension belts or other suitable devices to secure the motorcycle against accidents or falling over 401448 01 8 8 Refueling 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 Fuel in the fuel tank expands when warm and can escape if the tank is overfilled See the notes on refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid contact of the fuel with skin eyes and clothing Do not inhale fuel vapors If fuel gets into your eyes rinse immediately with water and contact a doctor Wash affected skin areas immediately with soap and water If fuel is swallowed contact a doc tor immediately Change clothing that has come into contact with fuel Note Material damage Premature clogging of the fuel filter din some countries and regions the available fuel quality and cleanliness may not be sufficient This will result in problems with the fuel system Your authorized KTM workshop will be glad to help 8 RIDINGINSTRUCTIONS 70 Only refuel with clean fuel that meets the specified standards Warning Environmental hazard Improper handli
38. ashes red Status or error message for immobilizer alarm system OPTIONAL The general warning lamp lights up yellow An operating safety warning message was detected This is also shown in the info display ABS warning lamp lights up flashes yellow Status or error messages relat ing to ABS antilock brake system 401686 01 6 11 6 GONTROLS Display 401685 11 34 The speed O is shown in kilometers per hour km h or in miles per hour mph The tachometer shows the engine speed in revolutions per minute The gear display shows the engaged gear The coolant temperature appears in segment O The time appears in segment O The filling level in the fuel tank is displaced in segment Q The info display amp shows additional information e 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 6 6 11 7 GONTROLS filling level display in fuel tank 401292 01 35 The filling level display consists of 9 bars The more bars are lit the more fuel is in the fuel tank 6 CONTROLS 36 6 11 8 TRIP F display If the fuel level drops to the reserve mark the display mode automatically changes to TRIP F and starts to count from 0 0 regardless of the previous display mode e info At the same time as the display mode TRIP F the general warning lamp lights up and the vvarning note Lovy Fuel Level
39. assis ME INBA JET Sorem bottom triple clamp e emam JET Screw engine bearer on fam e ze Nmuo2 rn JET Screw forkstub _ IN TT JET Screw front wheel spinde img INBA TT o Screw handlebar clamp _ 8 2Nm 88bf Screw panda M8 SINmG2SH TT screw ton TT M8 ET Sere rear footrest bracket NS REMAIN tiza Bomae IN 007 Na mir A l N iBbh TT IMpumsga mo NM WM CSCS Remaining nuts chassis wo omes Remaining serewe cass mo emezo 21 TECHNICAL DATA 169 Fitting handlebar support M10x1 25 21 Nm 15 5 Ibf ft Nut rear sprocket screw Mi d25 a2 nn 23e r5 OO Oo sew front footrest bracket moas ae nim s rr JET Serem top shock absorber moas som eseve Je IT Sui rear sprocket moas Je nm s br Nat rear wheel spindle MIS SONOMA rn JET Nat swingarm pot maas INE JET Screw top sternere Miis RMB H o Swingarm bearing adjusting ring Tighten and ensure that there is no play Nut steering head Step 1 50 Nm 36 9 Ibf ft 2nd stage loosen counter clockwise 2 turns Step 3 5 Nm 3 7 Ibf ft 22 SUBSTANCES 170 Brake fluid DOT 4 DOTST HH According to DOT Guideline Use only brake fluid that complies vvith the specified standard see specifications on the container and that possesses the correspond ing properties KTM recommends Castrol and Motorex products Supplier Castrol
40. brake fluid Change the brake fluid of the front and rear brake according to the service schedule Your authorized KTM workshop will be glad to help Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info Avoid contact between brake fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container 12 BRAKE SYSTEM 95 Move the brake fluid reservoir mounted on the handlebar to a horizontal position Remove screws Remove cover QY with membrane O Add brake fluid to level Q Guideline 5 mn 02 i Brake fluid DOT 41 DOT 5 1 p 170 Position the cover with the membrane Mount and tighten the screws e Info Clean up overflowed or spilt brake fluid immediately with water 12 5 Checking the front brake linings Warning Danger of accidents Reduced braking efficiency caused by worn brake linings Change worn brake linings immediately Your authorized KTM workshop will be glad to help Note Danger of accidents Reduced braking efficiency caused by damaged brake discs Ifthe brake linings are not changed in time the steel brake lining carriers grind on the brake disc The braking effect is greatly reduced and the brake discs are destroyed Check the brake linings regularly 12 BRAKE SYSTEM 96 C
41. ces Check the front and rear tires for cuts run in objects and other damage Ifthe tires exhibit cuts run in objects or other damage Change the tires Check the depth of the tread e Info Note local national regulations concerning the minimum tread depth 400602 10 Minimum tread depth 22mm 2 0 08 in 13 WHEELS TIRES 110 Ifthe tread depth is less than the minimum permissible depth Change the tires Check the age of the tires e Info The tire s date of the manufacture is usually part of the tire markings and is indicated by the last four digits of the DOT marking The first two digits refer to the week of manufacture and last two digits refer to the year of manufacture KTM recommends that the tires are changed regardless of the actual wear at the latest after 5 years Ifa tire is more than 5 years old Change the tires 13 7 Checking the tire air pressure e Info Low tire air pressure leads to abnormal wear and overheating of the tire Correct tire air pressure ensures optimal riding comfort and maximum tire service life Remove the dust cap Check tire air pressure when the tires are cold Tire air pressure solo 20 bar CS psi 2 0 bar 29 psi Tire air pressure with passenger full payload 2 0 bar 29 psi 2 2 bar 32 psi 400695 01 13 WHEELS TIRES If the tire air pressure does not meet specifications Correct the tire air pressure Mount the dust cap
42. cket facing upwards and insert the wheel spindle in the hub To check the play Q hold the rear wheel tight and try to rotate the rear sprocket e Info Measure the play on the outside of the rear sprocket Play in rubber dampers rear wheel lt 5 mm lt 0 2 in f play O is larger than the specified value Change all rubber dampers in the rear hub Finishing work Install the rear wheel amp p 105 Take the motorcycle off of the rear wheel stand p 75 13 13 6 A A A WHEELS TIRES 109 Checking the tire condition Warning Danger of accidents Uncontrollable vehicle handling in the event of a flat tire Inthe interest of safety replace damaged or worn tires immediately Your authorized KTM workshop will be glad to help Warning Danger of crashing Poor vehicle handling due to different tire tread patterns on front and rear wheels The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle Warning Danger of accidents Uncontrollable handling characteristic due to non approved and or non recommended tires wheels Only tires wheels approved by KTM and with the corresponding speed index should be used Info The type condition and air pressure of the tires all have a major impact on the riding behavior of the motorcycle Worn tires have a negative effect on riding behavior especially on wet surfa
43. cle off of the front wheel stand p 77 Take the motorcycle off of the rear wheel stand p 75 N Recharge the battery p 114 Install the battery p 113 Set the clock p 46 Refuel p 69 i P udi gr ue O O Perform checks and maintenance steps when preparing for use p 59 Take a test ride 401059 01 20 TROUBLESHOOTING Faults 154 Action Possible cause Engine does not crank vvhen the elec tric starter button is pressed Engine turns only if the clutch lever is drawn Engine turns but does not start Engine has too little power Engine overheats Operating error Battery discharged Fuse 1 2 3 or 4 is blown No ground connection present The vehicle is in gear The vehicle is in gear and the side stand is folded out Operating error Defect in fuel injection system Air filter is very dirty Fuel filter is very dirty Defect in fuel injection system Too little coolant in cooling system Radiator fins very dirty Foam formation in cooling system Thermostat defective Fuse 5 blown Go through the steps of starting the engine p 60 Recharge the battery 4 p 114 Change the fuses of individual power consumers p 118 Check the ground connection Shift gear to neutral Shift gear to neutral Go through the steps of starting the engine p 60 Read out the
44. consumption 1 average fuel consumption 2 MENU ina 40 6 11 14 Average fuel consumption 2 service menu 4 6 11 15 Service range MEN U aaa aa ana aaa kk esen 42 6 11 16 Range riding time menu eese 43 6 11 17 Total distance menu ODO 44 TABLE OF CONTENTS 6 11 18 Distance menu 1 TRIP 1 aaa aa aaa nana anen eese 44 6 11 19 Distance menu 2 TRIP 2 aaa ke 45 6 11 20 Setting kilometers or miles 45 OLI TL Seting the TING sa pk med e rne 46 6 11 22 Adjusting the shift speed RPM 1 47 6 11 23 Adjusting the shift speed RPM 2 47 6 12 Opening the filler Capite tuned kk 48 6 13 Closing the filler Cap sea ne dh ts 50 bold Seat TOD Ka sarda binema nd e e ne 50 Go AAA aw AN ae AW ley n A War S das 51 616 Grab Mame snc vetere ERR e e baud 51 6 17 Passenger footrests sn rep kk sas 52 Ole SNTE EVE acess sh i 52 6 19 Foot brake lever eis E ue a 53 6201 SIGS SHAM U eta ht A Me AA nA b y AN EUR PUDE 54 Tr PREPARING E OR USE anesor de kin Dateien 55 7 1 AQVICE OD TSt USE sa end ts ad 55 TEL Running in the engine esee 56 eS Loading the vehicle ocococococonoccconcnronoronorononono 57 G RIDING INSTRUCTTONS nad 59 8 1 Checks and maintenance when preparing for A l kax e EA 59 B 2 LAKIM e os atti ate Eon tl et e ta ott eu 60 8 3 Se hose Sur kd 62 8 4 SMILE KAN su uan yalan
45. cover 14 ELECTRICAL SYSTEM 114 Connect the negative cable of the battery Position the negative terminal cover Finishing work Mount the seat p 80 Mount the passenger seat p 79 Set the clock p 46 a Warning S 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 the battery away from sparks or open flames Charge only in well ventilated areas 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 14 q ELECTRICAL SYSTEM 115 Warning Environmental hazard The battery contains elements that are harmful to the environment Do not discard batteries with the household trash Dispose of a defective battery in an environmentally compatible manner Give the battery to your KTM dealer or to a recycling center that accepts used batteries 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 electroly
46. cycle is stationary Alternative 2 e The ignition is on e The motorcycle is moving Press the SET button briefly and repeatedly until the desired info display appears The average fuel consumption 2 in km L or miles L and the distance to the next service are displayed in this menu e Info E The average fuel consumption 2 is displayed after several 100 meters of travel after the ignition is switched on If the ignition was switched off for over 60 minutes the display of the average fuel consumption 2 is reset to O Press the SET button Next display mode on the info display briefly 6 CONTROLS 42 6 11 15 Service range menu Condition Alternative 1 e The ignition is on e The motorcycle is stationary Alternative 2 e The ignition is on e The motorcycle is moving Press the SET button briefly and repeatedly until the desired info display appears This menu shows the distance to the next service and the range e Info The range depends on the average fuel consumption and the fuel quantity in the fuel tank The range is displayed after several 100 meters of travel after the ignition is switched on If the ignition was switched off for over 60 minutes the display of the range and riding time is reset to O Press the SET button Next display mode on the info display briefly 6 CONTROLS 43 6 11 16 Range riding time menu Condition Alternative 1 e The ignition is on e he motorcycle is statio
47. dents Unstable handling characteristics due to slipped baggage Check the way your baggage is fixed regularly 1 PREPARING FOR USE 58 f you carry any baggage make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight distribu tion between the front and rear wheels Do not exceed the overall maximum permitted weight and the axle loads Guideline Maximum permissible overall weight 335 kg 739 Ib Maximum permissible front axle load 125 kg 276 Ib Maximum permissible rear axle load 210 kg 463 Ib 8 RIDINGINSTRUCTIONS 8 1 Checks and maintenance when preparing for use e Info Before every trip check the condition of the vehicle and ensure that it is roadworthy The vehicle must be in perfect technical condition when used Check the engine oil level p 143 Check the brake fluid level of the front brake p 93 Check the rear brake fluid level p 98 Check the front brake linings p 95 Check the rear brake linings p 101 Check the brake system function Check the coolant level p 134 Check for chain dirt accumulation p 81 Check the chain tension p 82 Check the tire condition p 109 Check the tire air pressure p 110 Check the settings of all controls and ensure that they can be operated smoothly Check the functioning of the electrical equipment Check t
48. e 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 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 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 3 IMPORTANT NOTES 14 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 The figures contained in the manual may depict special equipment In the interest
49. e and routing without sharp bends 4 Check that the throttle cables are undamaged routed without sharp bends and set correctly 4 Change the air filter Clean the air filter box Check the screws and nuts for tightness Change the front brake fluid 4 Change the rear brake fluid Check the headlight setting p 127 Check that the radiator fan is functioning properly Final check Check the vehicle for roadworthiness and take a test ride Read out the fault memory using the KTM diagnostics tool after a test ride Make the service entry in KTM DEALER NET and in the service record 4 One time interval Periodic interval 10 TUNING THE CHASSIS 73 10 1 Adjusting the spring preload of the shock absorber 4 VVarning A Danger of accidents Modifications to the suspension settings can seriously alter the vehicle s ride behavior Following modifications ride slowly at first to get the feel of the new ride behavior e Info l The spring preload defines the initial situation of the spring process on the shock absorber The best spring preload setting is achieved when it is set for the weight of the rider and that of any baggage and a passenger thus ensuring an ideal compromise between maneuverability and stability Turn adjusting ring to adjust the spring preload Guideline Hook wrench T106S e Info The spring preload can be set to 10 different positions 10 TUNING THE CHASSIS 74 e In
50. e chain sliding guard is loose Tighten the chain sliding guard 87 11 SERVICE VVORK ON THE CHASSIS 88 Position the chain guard and tighten screw O Guideline Screw chain guard EJOT PT9 4 Nm 3 Ibf ft Tighten screw Q Guideline Screw chain guard EJOT PT9 4 Nm 3 Ibf ft Tighten screw O Guideline SHME 11 SERVICE VVORK ON THE CHASSIS 89 Remove screws Remove screws Take off the front spoiler B00771 10 11 SERVICE VVORK ON THE CHASSIS 9 O Position the front spoiler Mount screws but do not tighten yet Mount and tighten screws Guideline Remaining screws chassis 10 Nm 7 4 Ibf ft Tighten screw O Guideline Remaining screws chassis 10 Nm 7 4 Ibf ft BOO771 10 12 BRAKE SYSTEM 12 1 ABS antilock brake system 401687 10 91 The ABS unit which consists of a hydraulic unit ABS control unit and return pump is installed under the seat A wheel speed sensor is located at the front and rear wheels 1 VVarning Danger of accidents Functional limitations of the ABS The rear wheel may only be spun with the front brake applied burn out if the ABS is switched off lf the vehicle has been modified such as shortened or lengthened spring deflec tions different rim diameters different tires the wrong tire air pressure differ ent brake linings etc the ABS will not function optimally Optimal f
51. e o aa id roca 38 range riding time menu o o oo coco nooo o 43 riding timelaverage speed menu 39 service range men 3 333 e i 42 total distance menu ODO 44 Naimi NOTES Es anio IEA X M al A AN aci alav c c OR a 29 Goolant ei ia an ee daa kaka e al ae WAM aa kun iki AR ee 136 Goolant level CHECKING san And divan Yol fe de Re at Q dd a ra A cedat 132 134 Cooling SISTE berri ew a 131 filling bleeding cu ra aeui RC date Ca die toe UR PERI 137 Customer service llle 14 E Electric starter button 2 000 ee eee 26 Emergency OFF switch lt lt lt ees 25 Engine KONI Wi ats xb Sh a naci B Gath wee ae arte 56 Engine number s e yt Cte m e tot afar A Gat KIIR De 20 Engine oil adding 178 GC aa ao a ica e Sane ded A de 143 Engine oil level CHECKINS PC 143 Engine sprocket CHECKING raid SU oa a IUE OC Sea Et s DIRE 85 Environment sic x be Ys AE RE RU X 11 F DD nd A e 14 Filler cap CLOSINGS a ar cite ec reg atur aC e an EC o fede AS 50 OPENS er e 408 4 VA A Ay a 48 Filling up NUSE e ee 69 Foot brake lever caia kk kk kK CROP ace COO e toe ci 53 free travel adjusting kk kK RR cee ee k 97 free travel checking kk kK KERIK a es 96 Front spoiler Stalne ura iaa Ld tod eae apes ERU HH HH me ede 90 FOMOVING atin nien e aaa era ee a we eke eas 89 Front wheel WSEAS spad a os read e E it ae ae 103
52. e regulations 17 SERVICE WORK ON THE ENGINE 144 e Info Drain the engine oil only when the engine is warm Preparatory work Remove the front spoiler p 89 Stand the motorcycle on its side stand on a horizontal surface Main work Place a suitable container under the engine Remove the oil drain plug with the O ring Remove oil screen with the O ring Completely drain the engine oil Clean the oil drain plug and oil screen thoroughly Position oil screen and mount and tighten oil drain plug with the O ring Guideline Oil drain plug 125 Duke M24 20 Nm 14 8 Ibf ft Oil drain plug 200 Duke EU MAL M24 20 Nm 14 8 Ibf ft 17 SERVICE WORK ON THE ENGINE 145 Remove screws Remove the oil filter cover with the O ring Pull oil filter O out of the oil filter housing Circlip pliers reverse 51012011000 Completely drain the engine oil Thoroughly clean the parts and sealing area Insert oil filter Oil the O ring of the oil filter cover Mount oil filter cover Mount and tighten the screws Guideline Screw oil filter cover 125 M5 8 Nm Loctite9 243 Duke 5 9 Ibf ft Screw oil filter cover M5 8 Nm Loctite 243 200 Duke EU MAL 5 9 Ibf ft e Info Too little engine oil or poor quality engine oil results in premature wear to the engine B00776 10 17 SERVICE WORK ON THE ENGINE 146 Remove the oil filler plu
53. ehicle while wearing protective clothing 2 1 VVork rules Special tools are necessary for certain tasks The tools are not contained in the vehicle but can be ordered under the number in parenthe ses 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 per tain to the disposal of an end of life motorcycle Your authorized KTM dealer will be glad to advise you 2 SAFETY ADVICE 12 2 9 Owner s Manual It is important that yo
54. f the new season When refueling for the last time before taking the motorcycle out of service add fuel additive Fuel additive p 173 Make sure the tank is empty to the point where the Low Fuel Level message lights up so that you can fill up with fresh fuel when you put the motorcycle back into operation Clean the motorcycle p 148 Change the engine oil and oil filter clean the oil screen 4 p 143 Check the antifreeze and coolant level p 132 401058 01 Check the tire air pressure p 110 Remove the battery p 112 Recharge the battery 4 p 114 Guideline Storage temperature of battery without D 958 019252 95 F direct sunlight Store the vehicle in a dry location that is not subject to large fluctuations in tempera ture e Info KTM recommends jacking up the motorcycle 19 STORAGE 153 Raise the motorcycle with the rear wheel stand p 75 Raise the motorcycle with the front wheel stand p 76 Cover the motorcycle with a tarp or similar cover that is permeable to air Info Do not use non porous materials since they prevent humidity from escaping thus causing corrosion Avoid running the engine for a short time only Since the engine cannot warm up properly the water vapor produced during combustion condenses and causes valves and exhaust system to rust 19 2 Preparing for use after storage Take the motorcy
55. fault memory using the KTM diag nostics tool A Change the air filter A Check the fuel pressure 4 Read out the fault memory using the KTM diag nostics tool Check the cooling system for leakage Check the coolant level p 134 Drain the coolant p 136 Fill bleed the cooling system amp p 137 Check the thermostat W4 Change the fuses of individual power consumers p 118 20 TROUBLESHOOTING 155 Faults Possible cause Action Engine overheats Defect in radiator fan system Check the radiator fan system A The engine diagnosis warning Defect in fuel injection system Read out the fault memory using the KTM diag lamp MIL lights up red nostics tool 4 Engine dies during the trip Lack of fuel Refuel p 69 Fuse 1 2 3 or 4 is blown Change the fuses of individual power consumers p 118 The ABS warning lamp lights up ABS fuse is blown Change the ABS fuses p 117 Large difference in wheel speeds of the Stop the vehicle switch off the ignition and front and rear wheels start it again Malfunction in ABS Read out the ABS fault memory using the KTM diagnostics tool 4 High oil consumption Engine vent hose bent Route the vent hose without bends or change it if necessary Engine oil level too high Check the engine oil level p 143 Engine oil too thin low viscosity Change the engine oil and oil filter cle
56. fly and repeatedly until the desired info display appears In this menu the average speed and the average fuel consumption 1 are displayed in L 100 km or L 100 miles 6 CONTROLS e Info The average fuel consumption 1 is displayed after several 100 meters of travel after the ignition is switched on If the ignition was switched off for over 60 minutes the display of the average speed and average fuel consumption 1 is reset to O Press the SET button Next display mode on the Info display briefly 6 11 13 Average fuel consumption 1 average fuel consumption 2 menu gt A Condition Alternative 1 e The ignition is on e The motorcycle is stationary Alternative 2 e The ignition is on e he motorcycle is moving Press the SET button briefly and repeatedly until the desired info display appears In this menu the average fuel consumption 1 in L 100 km or L 100 miles and the aver age fuel consumption 2 in km L or miles L are displayed e Info The average fuel consumption 1 and 2 are displayed after several 100 meters of travel after the ignition is switched on If the ignition was switched off for over 60 minutes the display of the average fuel consumption 1 and 2 is reset to O Press the SET button Next display mode on the info display briefly 6 CONTROLS 41 6 11 14 Average fuel consumption 2 service menu SF f Condition Alternative 1 e The ignition is on e The motor
57. fo The adjustment range of the shift lever is limited B00780 10 Loosen nuts Adjust the shift lever by turning shift rod Guideline Shift rod adjustment range Q 100 112 mm 3 94 4 41 in e info Make the same adjustments on both sides At least five screw threads must be screwed into the seating Check adjusting angle Guideline Adjusting angle shift rod deflector shift lever Tighten nuts Info I After the nuts have been tightened the bearings of the shift rod must be cen trally and identically aligned to each other in order to ensure freedom of move ment in the bearing shells Check the shift lever to ensure it is functioning properly and can move freely 11 SERVICE VVORK ON THE CHASSIS 75 Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface Mount the support of the wheel stand Insert the adapter in the rear wheel stand Adapter 61029055130 Rear wheel stand 61029055400 Stand the motorcycle upright align the lifting gear with the swingarm and the adapters and lift the motorcycle Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface 11 SERVICE VVORK ON THE CHASSIS 76 Secure the motorcycle against falling over Remove the rear wheel stand and lean the vehicle on the side stand O Remove the s
58. g with the O ring from the clutch cover and fill up with engine oil Engine oil After oil change 1 2 1 3 qt External temper Engine oil approx ature 0 50 C SAE 15W 50 32 122 F 7 p 171 External tempera Engine oil ture 10 40 C SAE 10W 40 14 104 F e p 171 Install and tighten the oil filler plug with the O ring 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 Start the engine and check that it is oil tight Finishing work Fit the front spoiler p 90 Check the engine oil level p 143 e Info Too little engine oil or poor quality engine oil results in premature wear to the engine 17 SERVICE VVORK ON THE ENGINE 147 Main vvork Remove the oil filler plug with the O ring from the clutch cover and fill up with engine oil Engine oil SAE 15W 50 p 171 Engine oil SAE 10W A0 p 171 e Info For optimal performance of the engine oil do not mix different types of engine oil If appropriate change the engine oil Install and tighten the oil filler plug with O ring Danger A Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and or dea
59. ger of accidents Reduced braking effect caused by damaged brake discs Always lay the wheel down in such a way that the brake discs are not dam aged Pull the rear wheel back and take it out of the swingarm e Info Do not operate the foot brake when the rear wheel is removed e KA ik e l z O d y z J j B01393 10 MASI Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary 13 WHEELS TIRES Warning 106 Danger of accidents No braking effect when operating the rear brake After installing the rear wheel always operate the foot brake until the pressure point is reached Main work Check the rear hub rubber dampers p 107 Check the wheel bearing for damage and wear Ifthe wheel bearing is damaged or worn Change the wheel bearing Clean and grease the shaft seal rings and mating surfaces Q of the spacers Long life grease p 174 Clean the thread of the wheel spindle and nut 6 Clean the fixing locations on the brake caliper support and swingarm Install the rubber damper and rear sprocket carrier on the rear wheel Position the rear wheel Y The brake linings are correctly positioned Push the rear wheel as far forward as possible and place the chain on the rear sprocket 13
60. h the express written permission of the copyright owner DEAR KTM CUSTOMER 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 TUV Management Service TUV 150 9001 REG NO 12 100 6061 KTM Sportmotorcycle AG 5230 Mattighofen Austria TABLE OF CONTENTS 1 MEANS OF REPRESENTATIO N citan vendi tenis 1 1 4 SVIRIDOIS USDQ sc lan Gulo waa eie a ta yan akar n nC 1 2 FORMAT SHU SO adi d tpe vi iva va rever a Vewra Xu kuraya Kera Yen SAFETY ADVIC Enaren ad 8 2 1 Use definitio sa on E ER ER ELIO RUE 8 2 2 OCT CV lC vn canst so l ox utet Eis c k ye ne xe dort 8 2 2 Degrees of risk and symbols aaa aaa aaa anen eee pere 9 2 4 Tamp ring Warming noi at kani prin n pe ace aka e 9 2 5 Sale oper ON succum cede o atus ius tu v We ken ada 10 2 6 Protective Clothing enveri si xuy duat HERO TIR SR e a rs 11 2 1 VO UOS rd 11 2 8 ER V T ON TO li u eee a panned ewl 11 2 9 Owners Mantas osht or pda 12 IMPORTANT NOTES da E chee ee trad coe 13 3 1 Guarantee warranty sess 13 3 2 Operating and auxiliary substances 13 2 3 Spare parts accessories aaa aaa neper 13 3 4 SEE E A E E ey e E EM ME 13 3 5 FISUOS adiac tu Poe jer Erebi celu edo Erbe 14 3 6 CUSTOMIEL S V C nave nike hi a Rete mcer Puta dene avout 14 VIE NGOR VET
61. hat baggage is correctly secured Sit on the motorcycle and check the rear mirror setting Check the fuel level 8 RIDINGINSTRUCTIONS 60 8 2 Starting Danger A 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 Caution Danger of accidents If the vehicle is operated with a discharged battery or without a battery electronic components and safety equipment may be damaged Never operate the vehicle with a discharged battery or without a battery Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear Note Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine Always warm up the engine at low engine speeds 8 RIDINGINSTRUCTIONS Sit on the vehicle take the weight off of the side stand and move up all the way Turn the emergency OFF svvitch to the position O Switch on the ignition by turning the ignition key to the position O Y After you switch on the ignition you can hear the fuel pump working for about two G B00782 10 61 seconds The function check
62. heck the brake linings for minimum thickness Q Minimum thickness Q gt 1 mm 20 04 in Ifthe minimum thickness is less than specified Change the front brake linings 4 Check the brake linings for damage and cracking If there is wear or tearing N fi FA y Change the front brake linings 4 S 073510 A Warning A Danger of accidents Brake system failure If there is no free travel on the foot brake lever pressure builds up on the rear brake circuit The rear brake can fail due to over heating Adjust the free travel on foot brake lever according to specifications 12 BRAKE SYSTEM 97 Disconnect spring O Move the foot brake lever back and forth between the end stop and the contact to the foot brake cylinder piston and check free travel Q Guideline Free travel at foot brake lever 3 5 mm 0 12 0 2 in If the free travel does not meet specifications Adjust the free travel of the foot brake lever 4 p 97 Reconnect spring O B00735 10 CAT Warning Danger of accidents Brake system failure If there is no free travel on the foot brake lever pressure builds up on the rear brake circuit The rear brake can fail due to over heating Adjust the free travel on foot brake lever according to specifications 12 BRAKE SYSTEM 98 Disconnect spring O Release nut and use screw to adjust the specified free travel Q Guideli
63. igital ignition adjustment Alternator 12 V 238 W 21 1 2 200 Duke EU MAL Displacement 200 em 12 2 cu in 49 mm 1 93 in 72 mm 2 83 n Valve diameter intake 28 5 mm 1 122 in Valve diameter exhaust 24 mm 0 94 in Valve clearance intake cold 0 08 0 12 mm 0 0031 0 0047 in Valve clearance exhaust cold 0 13 0 17 mm 0 0051 0 0067 in 21 TECHNICAL DATA 159 Crankshaft bearing Two ball bearings 1 L ring 1 tapered compression piston ring 1 oil scraper ring Ignition Contactless controlled fully electronic ignition with digital ignition adjustment 21 TECHNICAL DATA 160 21 2 Engine tightening torques inde head serw O wn eo rn JE TT Not water pump ir js E Pug water pump dran T Seen alternator cover im ameo JET Seren camshaft bearing bridge j e wn t rej JE o Seven cu cover ME A JE TT M6 M6 Screvv retaining bracket shaft seal ring 11 Nm 8 1 Ibf ft Loctite 243 clutch cover Screw shift drum locating me 12 Nm 8 9 Ibf ft Loctite 243 21 TECHNICAL DATA 161 Screw timing chain tensioner 12 Nm 8 9 Ibf ft Screw timing chain tensioning rail A 12 Nm 8 9 Ibf ft Loctite 2437M oren ve coer we iz Gur DENN Nut vm Nut conrod bearing 125 Duke 125 Duke MI JA Nm 24 Nm 17 7 Ibf ft 0 7 Ibf ft ET HER 200 Duke EU MAL Nt ehaust rlange CO PATAS Seren balarcer saf gear we E Stud ematten wa RBA O Cylinder head screw M10 S
64. increases the value The SET button decreases the value Do not activate the two buttons for approx 15 seconds Y The display RPM 2 goes out and the set speed is stored e Info Upon delivery the speed of RPM 2 is set to 11000 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 Fuel in the fuel tank expands when warm and can escape if the tank is overfilled See the notes on refueling 6 CONTROLS 49 Warning A Danger of poisoning Fuel is poisonous and a health hazard Avoid contact between fuel and skin eyes and clothing Do not inhale fuel vapors If fuel gets into your eyes rinse immediately with water and contact a doctor Wash affected skin areas immediately with soap and water If fuel is swallowed contact a doc tor immediately Change clothing that has come into contact with fuel Store fuel in a suitable canister according to regulations and keep it out of the reach of children gg Warning AN 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 Lift the cover of the filler cap and insert the ignition key in the lock Note Danger of damage Ignition key breakage To take pressu
65. it gets into your eyes rinse immediately with water and contact a doctor Wash affected skin areas immediately with soap and water If coolant is swallowed contact a doctor immediately Change clothes that have come into contact with coolants Keep coolant out of the reach of children Condition The engine is cold Preparatory work Remove the front spoiler p 89 15 COOLING SYSTEM 137 Main work Stand the motorcycle upright Place a suitable container under the engine Remove screw O Remove the radiator cap Completely drain the coolant Mount screw O with a new seal ring and tighten it Guideline Plug water pump drain hole 125 Duke water pump drain hole Plug water pump drain hole 125 Duke Duke M6 8 Nm 8 Nm 5 9 Ibf ft 9 Ibf ft B00768 10 Plug water pump drain hole ee Nm 5 9 Ibf ft 200 Duke EU MAL 15 5 Filling bleeding the cooling system 4 Warning Danger of poisoning Coolant is poisonous and a health hazard Avoid contact between coolant and skin eyes and clothing If it gets into your eyes rinse immediately with water and contact a doctor Wash affected skin areas immediately with soap and water If coolant is swallowed contact a doctor immediately Change clothes that have come into contact with coolants Keep coolant out of the reach of children 15 COOLING SYSTEM 138 Remove radiator cap O Remove bleeder screv Q Tilt the vehicle slightly
66. k the brake linings regularly Check the brake linings for minimum thickness Q Minimum thickness Q gt 1 mm 20 04 in If the minimum thickness is less than specified Change the rear brake linings 4 Check the brake linings for damage and cracking If there is wear or tearing Change the rear brake linings 4 13 WHEELS TIRES 13 1 Removing the front wheel 4 102 Preparatory work Raise the motorcycle with the rear wheel stand X p 75 Raise the motorcycle with the front wheel stand p 76 Main work Remove screws O and push the fender to the side Remove screw and pull wheel speed sensor out of the hole Loosen screws O and screw O Unscrew screw about six turns and press your hand on the screw to push the wheel spindle out of the axle clamp Remove screw Warning Danger of accidents Reduced braking effect caused by damaged brake discs Always lay the wheel down in such a way that the brake discs are not dam aged Holding the front wheel withdraw the wheel spindle Take the front wheel out of the fork e Info Do not pull the hand brake lever when the front wheel is removed 13 WHEELS TIRES 103 u Warning A Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Main work Check the wheel
67. km 620 mi 7 500 rpm e Tip During the running in phase set the shift warning light to the specified engine speed Adjust the shift speed RPM 1 p 47 Adjust the shift speed RPM 2 p 47 Avoid fully opening the throttle 1 1 3 A A A A A A PREPARING FOR USE 57 Loading the vehicle Warning Danger of accidents Unstable handling characteristics Do not exceed the maximum permitted weight and axle loads The overall weight consists of motorcycle operational and with a full tank driver and passenger with protective clothing and helmet baggage Warning Danger of accidents Unstable handling characteristics due to incorrect mounting of suitcase and or tank rucksack Mount and secure suitcase and tank rucksack according to the manufacturer s instructions Warning Danger of accidents Risk of breakage of suitcase system f you have fitted suitcases on your motorcycle read the manufacturer s specifications concerning the maximum payload Warning Danger of accidents Poor visibility for other road users due to slipped baggage lf the tail light is covered you are less visible to traffic behind you especially in the dark Check that your baggage is fixed properly at regular intervals Warning Danger of accidents Changed handling characteristics and longer stopping distance with excessive payload Adapt your speed according to your payload Warning Danger of acci
68. l drugs and certain medications or physically or mentally impaired Danger PN 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 11 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 v
69. lasher button in neutral position e High beam flasher button pressed In this position the headlight flasher high beam is actuated P 2D B00705 10 6 CONTROLS 25 The turn signal switch O is fitted on the left side of the handlebar Possible states EEE 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 The emergency OFF switch 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 igni tion circuit is closed B00707 10 6 CONTROLS 26 The electric starter button O is fitted on the right side of the handlebar Possible states e Electric starter button in basic position e Electric starter button pressed In this position the electric starter is actuated B00708 10 The ignition steering lock is in front of the upper triple clamp Possible states Ignition OFF In this position the ignition circuit is interrupted
70. nary Alternative 2 e The ignition is on e he motorcycle is moving Press the SET button briefly and repeatedly until the desired info display appears The range and the riding time are displayed in this menu e Info The range depends on the average fuel consumption and the fuel quantity in the fuel tank The range is displayed after several 100 meters of travel after the ignition is switched on If the ignition was switched off for over 60 minutes the display of the range and riding time is reset to O Press the SET button Next display mode on the info display briefly 6 CONTROLS 6 11 17 Total distance menu ODO 6 11 18 Distance menu 1 TRIP 1 44 Condition Alternative 1 e The ignition is on e The motorcycle is stationary Alternative 2 e The ignition is on e The motorcycle is moving Press the MODE button briefly and repeatedly until ODO appears on the display ODO shows the total distance covered e Info This value is retained even if the battery is disconnected and or the fuse blows Press the MODE but Next display mode on the display ton Condition Alternative 1 e The ignition is on e The motorcycle is stationary Alternative 2 e The ignition is on e The motorcycle is moving Press the MODE button briefly and repeatedly until TRIP 1 appears on the display TRIP 1 shows the distance covered since the last reset For example the distance from one refueling st
71. ne Free travel at foot brake lever 3 5mm 0 12 0 2 in e Info The range of adjustment is limited Hold screw and tighten nut Attach spring O A Warning A4 Danger of accidents Failure of the brake system Ifthe brake fluid level falls below the MIN mark this indicates a leakage in the brake system or worn out brake linings Check the brake system and do not continue riding Your authorized KTM workshop will be glad to help 12 BRAKE SYSTEM VVarning Danger of accidents Reduced braking efficiency due to old brake fluid Change the brake fluid of the front and rear brake according to the service schedule Your authorized KTM vvorkshop vvill be glad to help Stand the vehicle upright Check the brake fluid level in the brake fluid reservoir If the fluid level reaches the MIN mark Add rear brake fluid 4 p 99 12 9 Adding rear brake fluid 4 Warning Danger of accidents Failure of the brake system 99 Ifthe brake fluid level falls below the MIN mark this indicates a leakage in the brake system or worn out brake linings Check the brake system and do not continue riding Your authorized KTM workshop will be glad to help Warning Skin irritation Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and keep out of the reach of children Wear suitable protective clothing and goggles If brake fluid comes into co
72. ng of fuel is a danger to the environment Do not allow fuel to get into the ground water the ground or the sewage system Switch off the engine Open the filler cap p 48 Fill the fuel tank with fuel up to the lower edge O of the fuel filler Total fuel tank 11 2 9 US gal Super unleaded ROZ 95 RON 95 PON capacity approx 91 p 172 Close the filler cap p 50 A B00719 10 9 SERVICE SCHEDULE 71 9 1 Service schedule Every 10 000 km 6 214 mi or every 2 years Every 5 000 km 3 107 mi or annually Once after 1 000 km 621 4 mi Change the engine oil and oil filter clean the oil screen p 143 Check the shock absorber and fork for leaks Perform a fork and shock absorber service if needed and depending on vehicle use Check the Eum tension X p 82j Grease all moving parts e g side stand hand lever chain and check for smooth operation Clean the dust boots of the fork legs Check the brake fluid level of the front brake p 93 Check the steering head bearing play O e e 9 SERVICE SCHEDULE 72 O Every 10 000 km 6 214 mi or every 2 years Every 5 000 km 3 107 mi or annually Once after 1 000 km 621 4 mi Change the spark plugs 4 Check the valve clearance Check all hoses e g fuel cooling bleeder drainage etc and bellows for cracking leaks and correct routing A Check the antifreeze and coolant level p 132 Check the cables for damag
73. ntact with the eyes flush the eyes thoroughly with water and consult a physician immediately 12 BRAKE SYSTEM 100 VVarning Danger of accidents Reduced braking efficiency due to old brake fluid Change the brake fluid of the front and rear brake according to the service schedule Your authorized KTM vvorkshop vvill be glad to help VVarning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations e Info Avoid contact between brake fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container Stand the vehicle upright Remove screw cap O with membrane Add brake fluid to level Q Brake fluid DOT 4 DOT 5 1 p 170 Refit screw cap with membrane e Info Clean up overflowed or spilt brake fluid immediately with water 12 BRAKE SYSTEM 101 12 10 Checking the rear brake linings Warning Danger of accidents Reduced braking efficiency caused by worn brake linings Change worn brake linings immediately Your authorized KTM workshop will be glad to help Note Danger of accidents Reduced braking efficiency caused by damaged brake discs If the brake linings are not changed in time the steel brake lining carriers grind on the brake disc The braking effect is greatly reduced and the brake discs are destroyed Chec
74. of clarity some components may be shown disassembled or may not be shown at all It is not always necessary to disassem ble the component to perform the activity in question Please follow the instructions in the text 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 15 4 VIEW OF VEHICLE 16 4 1 View of vehicle front left example BO1385 10 4 QO Q0 NI O of Bl O N H ea Im O VIEW OF VEHICLE Function buttons p 32 Indicator lamps p 33 Rear mirror Clutch lever p 22 Seat Passenger seat Seat lock p 50 Grab handles p 51 Engine number p 20 Side stand p 54 Shift lever p 52 17 4 VIEW OF VEHICLE 18 4 2 View of vehicle rear right example BO1386 10 4 QO QO A O Oo S WIP PM MI NMI Im O VIEW OF VEHICLE Tool set p 51 Light switch p 24 High beam flasher button p 24 Turn signal switch p 25 Horn button p 23 lgnition steering lock p 26 Emergency OFF switch p 25 Throttle grip X p 23 Hand brake lever p 22 Electric starter button p 26 Chassis number type label p 20 Passenger footrests p 52 Foot brake lever p 53 19 9 SERIAL NUMBERS 20 5 1 Chassis number type tar 55 0 The
75. op to the next TRIP 1 is always running and counts up to 999 9 6 CONTROLS 6 11 19 Distance menu 2 TRIP 2 p T 5 6 11 20 Setting kilometers or miles e Info Make the country specific setting 45 Press the SET button Display of TRIP 1 is reset for 5 10 seconds Press the MODE but Next display mode on the display ton Condition Alternative 1 e The ignition is on e he motorcycle is stationary Alternative 2 e The ignition is on e he motorcycle is moving Press the MODE button briefly and repeatedly until TRIP 2 appears on the display TRIP 2 shows the distance covered since the last reset For example the distance from one refueling stop to the next TRIP 2 is always running and counts up to 999 9 Press the SET button Display of TRIP 2 is reset for 5 10 seconds Press the MODE but Next display mode on the display ton Condition The ignition is on 6 CONTROLS 46 The motorcycle is stationary Press the MODE button briefly and repeatedly until ODO appears on the display Press the MODE button for 5 10 seconds Y The display changes from km h to mph or from mph to km h 6 11 21 Setting the time Condition The ignition is on The motorcycle is stationary Press the MODE button briefly and repeatedly until ODO appears on the display Press the MODE and SET buttons for 5 10 seconds Y The time display begins to flash Set the hours displa
76. orward 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 Preparatory work Remove the passenger seat p 78 Main work Remove screws O Raise the rear of the seat pull it towards the rear and remove it upwards 11 SERVICE VVORK ON THE CHASSIS 80 11 8 Mounting the seat P Main work Attach seat recesses Q at screws and lower at the rear Mount and tighten screws Guideline Nn 8 1 FT BOO727 10 Finishing work Mount the passenger seat p 79 11 SERVICE VVORK ON THE CHASSIS 11 9 Checking for chain dirt accumulation Check the chain for coarse dirt accumulation Ifthe chain is very dirty Clean the chain p 81 400678 01 11 10 Cleaning the chain VVarning Danger of accidents Oil or grease on the tires reduces their grip Remove oil and grease vvith a suitable cleaning material VVarning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Warning Environmental hazard Hazardous substances cause environmental damage Oil grea
77. ositions of the 6 forward gears in the figure The neutral or idle position is between the first and second gears First gear is used for starting off or for steep inclines The operating temperature is reached when 4 bars of the temperature indicator B00716 10 light up 8 8 9 RIDING INSTRUCTIONS 65 Accelerate only up to a speed suitable for the road surface and weather conditions Par ticularly in bends do not shift and accelerate very carefully To shift down brake if necessary and close the throttle at the same time Pull the clutch lever and shift into a lower gear release the clutch lever slowly and open the throttle or shift again Switch off the engine if you expect to be standing for a long time Ifthe engine diagnosis warning lamp lights up during a trip stop immediately switch off the engine and contact an authorized KTM workshop Applying the brakes Warning Danger of accidents Reduced braking efficiency due to a wet or dirty brake system Clean or dry a dirty or wet brake system by riding and braking gently Warning Danger of accidents Reduced braking efficiency caused by spongy pressure point of front or rear brake Check the brake system and do not continue riding Your authorized KTM workshop will be glad to help Warning Danger of accidents Failure of brake system Ifthe foot brake lever is not released the brake linings drag continuously The rear
78. ottle cable 4 9 p 141 Danger 400192 10 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 Start the engine and let it run idle Move the handlebar to and fro over the entire steer ing range The idle speed must not change Ifthe idle speed changes Check the throttle cable routing 16 TUNING THE ENGINE 141 16 2 Adjusting the play in the throttle cable 4 Move the handlebar to the straight ahead position Push back sleeve Loosen lock nut Adjust the play in the throttle cable by turning adjusting screw 9 Guideline Throttle cable play 3 5 mm 0 12 0 2 in Tighten lock nut Slide on sleeve 16 3 Checking the clutch lever play Check the clutch lever for smooth operation Move the handlebar to the straight ahead position Lightly pull the clutch lever and ascertain the clutch lever play Q Clutch lever play 1 3 mm 0 04 0 12 in If the clutch lever play does not meet specifications Adjust the clutch cable play p 142 Note B00729 10 Clutch damage If there is no play on the clutch lever the clutch will begin to slip When operating the motorcycle always check the clutch lever play
79. ow Battery appears on the info display if the battery voltage falls below the specified value Battery voltage 10 80 V 6 CONTROLS 31 Service Not Reset appears on the info display for 10 seconds when the ignition is switched on and the distance Interval between service appointments has been exceeded or the service interval display was not reset during a service appointment GONTROLS Function buttons 401685 12 32 You can change the display mode with the MODE button QO Possible display modes are total distance traveled TRIP 1 distance 1 ODO and distance 2 TRIP 2 Pressing and holding the SET button QY resets the distance 1 TRIP 1 and distance 2 TRIP 2 functions to 0 0 and briefly pressing the SET button changes the info display to the next display mode The ABS can be switched off using button 9 6 CONTROLS 33 6 11 5 Indicator lamps Possible states The turn signal indicator light flashes green simultaneously with the turn signal The turn signal is switched on The engine diagnosis warning lamp MIL lights up red The OBD on board diagnosis has detected an emission or safety critical error The shift warning lights up flashes red The set shift speed has been reached The idling speed indicator lamp lights up green The transmission is Shifted to idle The high beam indicator lamp lights up blue The high beam is switched on The immobilizer indicator lamp lights up or fl
80. r the vehicle Warning Danger of accidents Uncontrollable handling characteristic due to non approved and or non recommended tires wheels Only tires wheels approved by KTM and with the corresponding speed index should be used Warning Danger of accidents Reduced road grip with new tires New tires have a smooth rolling surface and therefore cannot provide full road grip The entire rolling surface must be rough ened in the first 200 kilometers 124 3 miles by moderate riding at alternating angles The full grip levels are not achieved until the tires have been run in Info When using your vehicle remember that others may feel disturbed by excessive noise 1 PREPARING FOR USE 56 Make sure that the pre delivery inspection work has been carried out by an authorized KTM workshop Y You receive a delivery certificate and the service record at vehicle handover Before your first trip read the entire operating instructions carefully Get to know the controls Get used to handling the motorcycle on a suitable piece of land before making a longer trip Try also to ride as slowly as possible to get a better feel for the vehicle Hold the handlebar firmly with both hands and keep your feet on the footrests when riding Run the engine in X p 56 7 2 Running in the engine During the running in phase do not exceed the specified engine speed Guideline Maximum engine speed During the first 1 000
81. raking should be completed before you enter into a bend Braking should always be completed before you go into a bend Change down to a lower gear appropriate to your road speed On long downhill stretches use the braking effect of the engine Change down one or two gears but do not over rev the engine In this way you have to brake far less and the brakes do not overheat 8 RIDINGINSTRUCTIONS 67 8 6 Stopping parking VVarning Risk of misappropriation Usage by unauthorized persons Never leave the vehicle while the engine Is running Secure the vehicle against use by unauthorized persons If you leave the vehicle lock the steering and remove the Ignition key 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 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 Note Material damage Damage and destruction of components by excessive load The side stand is
82. ray p 175 18 2 Checks and maintenance steps for winter operation Info If the motorcycle is used in the winter salt can be expected on the roads Precautions need to be taken against road salt corrosion If the vehicle was operated in road salt clean it with cold water after riding Warm water would enhance the corrosive effects of salt Clean the motorcycle p 148 Clean the brakes e Info ll After EVERY trip on salted roads thoroughly wash the brake calipers and brake linings with cold water and dry carefully This should be done after the parts are cooled down and while they are installed After riding on salted roads thoroughly wash the motorcycle with cold water and dry it well 401060 01 reat the engine swingarm and all other bright and zinc plated parts except for the brake discs with a wax based corrosion inhibitor 18 CLEANING CARE 151 e Info Corrosion inhibitor is not permitted to come in contact with the brake discs as this would greatly reduce the braking force Clean the chain p 81 19 19 1 STORAGE 152 Storage Info If you want to garage the motorcycle for a longer period take the following steps Before storing the motorcycle check all parts for function and wear If service repairs or replacements are necessary you should do this during the storage period less workshop overload In this way you can avoid long workshop waiting times at the start o
83. re off of the ignition key push down on the filler cap Damaged igni tion keys must be replaced Turn the ignition key 90 clockwise Open the filler cap RENE BOO710 10 Remove the ignition key 6 CONTROLS 50 VVarning Fire hazard Fuel is highly flammable poisonous and harmful to your health When closing the filler cap ensure that it is closed correctly Change cloth ing that came into contact with fuel Immediately clean skin that came into contact with fuel using soap and water Close the filler cap Push down the filler cap until the lock engages The seat lock is located to the left of the seat It can be locked with the ignition key B00712 01 6 CONTROLS 51 6 45 Toolset 00 The tool set Q is located under the passenger seat The grab handles are used for moving the motorcycle around If you carry a passenger the passenger can hold onto the grab handles during the trip B00717 10 6 CONTROLS 52 6 17 Passenger fo otrests The passenger footrests can be folded in and out Possible states e Passenger footrests folded up For operation without a passenger e Passenger footrests folded down For operation with a passenger Shift lever is mounted on the left side of the engine B00715 10 6 GONTROLS B00716 10 The gear positions can be seen in the photograph The neutral or idle position is between the first and second gears
84. sating tank 15 COOLING SYSTEM 13 Screw off radiator cap IY Check the coolant antifreeze 2044 945 C 19 49 F Ifthe coolant antifreeze does not meet specifications Correct the coolant antifreeze Check the coolant level in the radiator The radiator must be completely filled Ifthe coolant level does not meet specifications Correct the coolant level and find out the cause of the loss Alternative 1 Coolant p 170 Alternative 2 Coolant mixed ready to use p 170 If you had to add more coolant than the specified amount gt 0 20 gt 0 21 qt Fill bleed the cooling system p 137 Mount the radiator cap 15 3 Checking the coolant level Warning Danger of scalding During motorcycle operation the coolant gets very hot and is under pressure Do not remove the radiator cap radiator hoses or other cooling system components when the engine is hot Allow the engine and cooling system to cool down In case of scalding rinse immediately with lukewarm water 15 COOLING SYSTEM 13 Warning Danger of poisoning Coolant is poisonous and a health hazard OI Avoid contact between coolant and skin eyes and clothing If it gets into your eyes rinse immediately with water and contact a doctor Wash affected skin areas immediately with soap and water If coolant is swallowed contact a doctor immediately Change clothes that have come into contac
85. se filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations 81 11 SERVICE VVORK ON THE CHASSIS 82 e Info The service life of the chain depends largely on its maintenance Clean the chain regularly Rinse off loose dirt with a soft jet of water Remove old grease remains with chain cleaner Chain cleaner p 173 After drying apply chain spray Chain lube for road use p 173 400725 01 11 11 Checking the chain tension Warning Danger of accidents Danger caused by incorrect chain tension Ifthe chain tension is too high the components of the secondary power train chain engine sprocket rear sprocket bearings in transmission and rear wheel are under additional load Apart from premature wear in extreme cases the chain can rupture or the countershaft of the transmission can break On the other hand if the chain is loose it can fall off the engine sprocket or the rear sprocket and block the rear wheel or damage the engine Check the chain tension and correct if necessary 11 SERVICE VVORK ON THE CHASSIS 83 Lean the motorcycle on the side stand Shift gear to neutral In the area of chain sliding guard press the chain upward toward the swingarm and determine chain tension Q Info I The upper chain section must be taut Chain wear is not always even so you should repeat this measurement at differ ent chain positions
86. sures are not taken Note Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken Warning it Identifies 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 pur chaser 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 10 Removal or puncturing of the main silencer baffles header pipes or any other components which conduct exhaust gases Removal or puncturing of any part of the intake system Lack of proper maintenance BW N mm Replacing any moving part of the vehicle or parts of the exhaust or intake system with parts other than those specified by the manu facturer 2 5 Safe operation Danger A Danger of accidents Danger arising from the rider s judgement being impaired Do not operate the vehicle while under the influence of alcoho
87. t moderate speed until the tires reach operating temperature and optimal road grip Is ensured VVarning Danger of accidents Reduced road grip with new tires New tires have a smooth rolling surface and therefore cannot provide full road grip The entire rolling surface must be rough ened in the first 200 kilometers 124 3 miles by moderate riding at alternating angles The full grip levels are not achieved until the tires have been run in 8 RIDINGINSTRUCTIONS 64 VVarning Danger of accidents Unstable handling characteristics due to slipped baggage Check the way your baggage Is fixed regularly Warning Danger of accidents Lack of roadworthiness After a fall check the vehicle as usual before preparing for use Note Engine failure Overheating of engine If the coolant temperature warning lamp lights up stop and switch off the engine Allow the engine to cool down and check the coolant level in the radiator and top up if necessary If you continue with the coolant temperature warning lamp alight you may have engine failure e Info If you hear unusual noises while riding stop immediately switch off the engine and contact an authorized KTM workshop When conditions allow incline road situation etc you can shift into a higher gear Release the throttle while simultaneously pulling the clutch lever shift into the next gear release the clutch and open the throttle e Info You can see the p
88. t with coolants Keep coolant out of the reach of children Condition The engine is cold Stand the motorcycle upright on a horizontal surface Check the coolant level in the compensating tank O The coolant level must be between MIN and MAX If the coolant level does not meet specifications Correct the coolant level Alternative 1 Coolant p 170 Alternative 2 Coolant mixed ready to use p 170 Screw off radiator cap and check the coolant level in the radiator The radiator must be completely filled Ifthe coolant level does not meet specifications Correct the coolant level and find out the cause of the loss Alternative 1 Coolant p 170 15 COOLING SYSTEM 136 Alternative 2 Coolant mixed ready to use p 170 f you had to add more coolant than the specified amount 0 201 0 21 qt Fill bleed the cooling system p 137 Mount the radiator cap 15 4 Draining the coolant 4 Warning Danger of scalding During motorcycle operation the coolant gets very hot and is under pressure Do not remove the radiator cap radiator hoses or other cooling system components when the engine is hot Allow the engine and cooling system to cool down In case of scalding rinse immediately with lukewarm water Warning Danger of poisoning Coolant is poisonous and a health hazard Avoid contact between coolant and skin eyes and clothing If
89. te 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 78 Remove the seat p 79 Disconnect the negative cable of the battery to avoid damage to the motorcycle s elec tronics 14 ELECTRICAL SYSTEM 116 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 bat tery and to test the alternator With this device you cannot overcharge the battery e Info Never remove lid Charge the battery with a maximum of 10 of the capacity specified on battery housing Q 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 r 1 motorcycle is not in use HIIN BO1395 10 Finishing vvork Mount the seat p 80 Mount the passenger seat p 79
90. tep 1 Thread is oiled head flat is 20 Nm 14 8 lb ft greased Step 2 40 Nm 29 5 Ibf ft er pressure sensor LE TEN EA Water temperature sensor o Oi JET ET Mia TT TT NDS Nat primary gear m AmO S o maine LO omas E 21 TECHNICAL DATA 162 21 3 Capacities 21 3 1 Engine oil Engine oil First filling 1 5 I 1 6 qt External temperature 0 Engine oil SAE 15W 50 5O 6 32 122 F p 171 External temperature 10 Engine oil SAE 10W 40 40 C 14 104 F p 171 After oil change approx 1 21 1 3 qt External temperature O Engine oil SAE 15W 50 D T 32 122 F p 171 External temperature 10 Engine oil SAE 10W 40 40 C 14 104 F p 171 21 3 2 Coolant Coolant 1 I 1 at Coolant p 170 Coolant mixed ready to use p 170 21 3 3 Fuel Total fuel tank capacity approx 11 2 9 US gal Super unleaded ROZ 95 RON 95 PON 91 p 172 Fuel reserve approx 1 5 I 1 6 qt 21 TECHNICAL DATA 163 21 4 Chassis Brake system Suspension travel Brake discs vvear limit Tire air pressure solo Tire air pressure with passenger full payload 21 TECHNICAL DATA 164 Chain 5 8 x 114 520 O ring Steering head angle 65 Wheelbase 1 361215 mm 53 58 0 59 in Seat height unloaded 800 mm 31 5 in Ground clearance unloaded 1 0 mm 6 69 in Weight without fuel approx 125 Duke 127 kg 280 Ib Weight without fuel approx 200 Duke
91. th 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 Start the engine and check that it is oil tight Finishing work Check the engine oil level p 143 18 CLEANING CARE 148 18 1 Cleaning the motorcycle Note Material damage Damage and destruction of components by high pressure cleaning equipment When cleaning the vehicle with a pressure cleaner do not point the water jet directly onto electrical components connectors cables bearings etc Maintain a minimum distance of 60 cm between the nozzle of the pressure cleaner and the component Excessive pres sure can cause malfunctions or destroy these parts Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info If you clean the motorcycle regularly its value and appearance will be maintained over a long period Avoid direct sunshine on the motorcycle during cleaning Seal the exhaust system to keep water out First remove coarse dirt particles with a gentle spray of water Spray very dirty areas with a normal motorcycle cleaner and then clean with a paint brush Motorcycle cleaner p 174 401061 01 18 CLEANING CARE 149 e Info Use warm water containing norm
92. to the right Pour in coolant until it emerges without bubbles at the vent hole and then mount and tighten the bleeder screw immediately Alternative 1 Coolant p 170 Alternative 2 Coolant mixed ready to use p 170 Fill the radiator completely with coolant Mount the radiator cap Rest the vehicle on the side stand Danger A 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 15 COOLING SYSTEM 139 Start the engine and let it run warm Stop the engine and allow it to cool down When the engine is cool check the coolant level in the radiator and if necessary add coolant Remove the cap of the compensating tank and add coolant until the coolant level is up to the MAX mark Mount the cap of the compensating tank Fit the front spoiler p 90 16 TUNING THE ENGINE 140 16 1 Checking the play in the throttle cable Check the throttle grip for smooth operation Move the handlebar to the straight ahead position Move the throttle grip backwards and forwards to ascertain the play in the throttle cable Throttle cable play 3 5 mm 0 12 0 2 in If the throttle cable play does not meet specifications Adjust the play in the thr
93. u read this Owner s Manual carefully and completely before making your first trip The Owner s Manual contains use ful 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 13 3 1 Guarantee 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 Additional information on the guarantee or warranty and the procedures involved can be found in the service record 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 th
94. unction ing of the ABS Is only ensured if the brake system only contains spare parts and tires that have been approved and or recommended by KTM Service work and repairs must be performed properly Your authorized KTM workshop will be glad to help The ABS is a safety system that prevents locking of the wheels when the vehicle is traveling straight ahead without the action of lateral forces Warning Danger of accidents Rolling over of the vehicle Itis not always possible to prevent rolling over of the vehicle in extreme riding situations e g luggage loaded with a high center of gravity varying road sur faces steep descents full braking without disengaging the gear Adapt your riding style to the road conditions and your riding ability The ABS operates with two independent brake circuits front and rear brakes During nor mal operation the brake system operates like a conventional brake system without ABS When the ABS control unit detects the tendency of a wheel to lock the ABS begins regu lating the braking pressure The control process causes the hand and foot brake levers to vibrate slightly 12 BRAKE SYSTEM 92 The ABS warning lamp must light up briefly after the ignition is switched on and should then go out after starting off If it does not go out after starting off or if it lights up while riding this indicates a fault in the ABS system In this case the ABS is no longer enabled and the wheels may lock
95. upport of the wheel stand B00714 10 11 3 Raising the motorcycle with the front wheel stand Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface Preparatory work Raise the motorcycle with the rear wheel stand p 75 Condition Remove cap C00196 10 11 SERVICE VVORK ON THE CHASSIS 7 Move the handlebar to the straight ahead position Attach the lifting gear to the steering stem Adapter 61029955620 Front wheel stand 61029055500 e Info Always raise the rear of the motorcycle first C00197 01 Raise the front of the motorcycle 11 4 Taking the motorcycle off of the front wheel stand Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface Secure the motorcycle against falling over Remove the front wheel stand BO1388 01 11 SERVICE VVORK ON THE CHASSIS EN i W Mount cap O 11 5 Removing the passenger seat Insert the ignition key in seat lock and turn it clockwise Remove the ignition key from the seat lock BOO712 01 Raise the rear of the seat push it towards the rear and remove it upwards 78 11 SERVICE VVORK ON THE CHASSIS 79 11 6 Mounting the passenger seat A Attach hooks on the passenger seat to brackets on the subframe and lower it at q the rear while pushing f
96. utton You do not need to shift into neutral Warning Danger of accidents Abrupt load alterations can cause the vehicle to get out of control Avoid abrupt load alterations and sudden braking actions and adapt your speed to the road conditions Warning Danger of accidents f you change down at high engine speed the rear wheel can lock up Do not change into a low gear at high engine speed The engine races and the rear wheel can lock up Pb gt gt RIDING INSTRUCTIONS 63 Warning Danger of accidents Malfunctions caused by incorrect ignition key position Do not change the ignition key position during a journey Warning Danger of accidents Distraction from traffic activity by adjustments to the vehicle Make all adjustments when the vehicle is at a standstill Warning Risk of injury Falling off of the passenger The passenger must be able to hold himself or herself properly on the passenger seat to hold onto the rider or to hold onto the handrails and place his or her feet onto the passenger footrests Note the regulations governing the minimum age of passengers in your country Warning Danger of accidents Danger of accidents caused by dangerous driving Comply with traffic regulations and ride defensively and foresightedly to detect sources of danger early on Warning Danger of accidents Reduced road grip with cold tires On every journey take the first miles carefully a
97. w 6 Guideline For a motorcycle with rider and with luggage and a passenger if applicable the light dark boundary must be exactly on the lower mark applied in Checking headlight adjustment TS e Info y Y n f j Turn clockwise to increase the headlight range turn counterclockwise to reduce i 3 A the headlight range A w v f A MMMNNRY FKFMFFRMFFFFZFZFR FZFRMNYKMRYM gt NNYYRYFMFEYFYY N NR FFNNYNRK hNNKFRMYFYM N FRYFYKKFFPN N Nr BF M yF lt PyPFIMI I FESRIx xxnsIH NMN Fold the headlight mask up Mount and tighten screws Guideline Screw headlight mask 11 Nm 8 1 Ibf ft Mount expanding rivets 6 on both sides 14 ELECTRICAL SYSTEM Finishing work Check the headlight setting p 127 130 15 COOLING SYSTEM 131 Water pump in the engine circulates the coolant The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap Heat expansion causes excess coolant to flow into compensating tank When the temperature falls this surplus coolant is sucked back into the cooling system This ensures that operating the vehicle at the specified coolant temperature will not result in a risk of malfunctions 125 C 257 F FEA A A In gt 15 COOLING SYSTEM 132 The coolant is cooled by the air stream and a radiator fan O which is controlled by a ther moswitch The lower the speed the less the cooling effect
98. x Racing Fork Oil According to DIN EN 228 ROZ 95 RON 95 PON 91 Guideline Only use unleaded super fuel that matches or is equivalent to the specified fuel grade Fuel with an ethanol content of up to 10 E10 fuel is safe to use e Info Do not use fuel containing methanol e g M15 M85 M100 or more than 10 ethanol e g E15 E25 E85 E100 23 AUXILIARY SUBSTANCES 173 Guideline KTM recommends Motorex products Supplier Motorex Chain Clean Guideline KTM recommends Motorex products Supplier Motorex Chainlube Road Guideline KTM recommends Motorex products Supplier Motorex Protect amp Shine Guideline KTM recommends Motorex products Supplier Motorex Fuel Stabilizer 23 AUXILIARY SUBSTANCES 174 Guideline KTM recommends Motorex products Supplier Motorex Moto Polish Guideline KTM recommends Motorex products Supplier Motorex Bike Grease 2000 Guideline KTM recommends Motorex products Supplier Motorex Moto Clean 900 Guideline KTM recommends Motorex products Supplier Motorex Clean amp Polish 23 AUXILIARY SUBSTANCES 175 Guideline KTM recommends Motorex products Supplier Motorex Joker 440 Synthetic 24 STANDARDS 176 JASO T903 MA Different technical development directions required a new specification for 4 stroke motorc
99. y using the MODE button Set the minutes display using the SET button Press the MODE and SET buttons for 5 10 seconds Y The time is set 6 CONTROLS 6 11 22 Adjusting the shift speed RPM 1 6 11 23 Adjusting the shift speed RPM 2 41 Gondition The ignition is on The motorcycle is stationary Press the MODE button briefly and repeatedly until TRIP 2 appears on the display Press the MODE button for 5 10 seconds Y The display RPM 1 appears e Info The engine speed can be set at intervals of 50 RPM 1 is the engine speed above which the shift vvarning light starts to flash Set the speed with the MODE and SET buttons e Info The MODE button increases the value The SET button decreases the value Do not activate the two buttons for approx 15 seconds Y The display RPM 1 goes out and the set speed is stored e Info Upon delivery the speed of RPM 1 is set to 10000 Gondition The ignition is on The motorcycle is stationary 6 CONTROLS 48 Press the MODE button briefly and repeatedly until TRIP 2 appears on the display Press the SET button for 5 10 seconas Y The display RPM 2 appears e Info The engine speed can be set at intervals of 50 RPM 2 is the engine speed above which the shift warning light lights up con stantly The speed RPM 2 must always be higher than the speed RPM 1 Set the speed with the MODE and SET buttons e Info The MODE button
100. ycles the JASO T903 MA Standard Ear lier engine oils from the automobile industry were used for 4 stroke motorcycles because there was no separate motorcycle specification Whereas long service intervals are demanded for automobile engines high performance at high engine speeds are in the foreground for motorcycle engines In most motorcycles the gearbox and the clutch are lubricated with the same oil as the engine The JASO MA Stan dard meets these special requirements The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to their viscos ity The viscosity describes only one property of oil and says nothing about quality A ABS n me eda 91 Accessories Ex ny KK KIRI uas n en dae bok ee 13 Antifreeze CT CO KIT a rad d use Kl ana ior ao SEG 132 Antilock brake system I VIRI KIRI KIIR 91 Auxiliary substances aa 13 B O s IMMAMMMMIMMJMDMD J JJ RAE dra pe RR 51 Battery S eaa a E E ek ad dV EU 113 TECOS eaa ia A HH en 114 A A 112 Brake discs CIBC ID una ex pa ari do cia earn Sets 92 Brake fluid front brake adding caer ace c IC ERUS 94 rear brake adding Lanata Soph a aos KI KIRI On Use alto i KIRIV 99 Brake fluid level front brake checking lees 93 rear brake checking RI RIK RI ee eee 98 Brake linings front brake checking 0 0 eee RI KIRI KIIR es 95 rear brake checking kk KRI KIR

OWNER`S MANUAL 2013 125 Duke EU 200 Duke EU 200 Duke MAL

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