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KTM
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200 DUKE EU
KTM 200 DUKE EU Repair Manual
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28
SPECIAL
TOOLS
252
Bleeder
cover
201490-10
Art.
no.:
00029013000
Bleeding
device
201491-10
Art.
no.:
00029013100
Bleed
syringe
400058-01
Art.
no.:
50329050000
Circlip
pliers
reverse
400059-01
Art.
no.:
51012011000
Valve
spring
compressor
400101-01
Art.
no.:
59029019000
253
255
Table of Contents
Default Chapter
4
Table of Contents
4
1 Means of Representation
8
Symbols Used
8
Formats Used
8
2 Safety Advice
9
Repair Manual
9
Degrees of Risk and Symbols
9
Work Rules
9
3 Important Notes
10
Guarantee, Warranty
10
Operating and Auxiliary Substances
10
Spare Parts, Accessories
10
Figures
10
4 Serial Numbers
11
Chassis Number/Type Label
11
Key Number
11
Engine Number
11
5 Motorcycle
12
Raising the Motorcycle with the Rear Wheel Stand
12
Taking the Motorcycle off of the Rear Wheel Stand
12
Raising the Motorcycle with the Front Wheel Stand
12
Taking the Motorcycle off of the Front Wheel Stand
13
Raising the Motorcycle with the Work Stand
13
Removing the Motorcycle from the Work Stand
14
Starting
15
Starting the Motorcycle to Make Checks
16
6 Fork, Triple Clamp
17
Cleaning the Dust Boots of the Fork Legs
17
Removing Fork Legs
17
Installing the Fork Legs
18
Disassembling the Fork Legs
19
Checking the Fork Legs
21
Assembling the Fork Legs
22
Removing the Lower Triple Clamp
24
Installing the Lower Triple Clamp
26
Checking the Steering Head Bearing Play
28
Adjusting the Steering Head Bearing Play
29
7 Handlebar, Controls
30
Checking the Play in the Throttle Cable
30
Adjusting the Play in the Throttle Cable
30
Checking the Clutch Lever Play
30
Adjusting the Clutch Cable Play
31
8 Shock Absorber, Swingarm
32
Adjusting the Spring Preload of the Shock Absorber
32
Removing the Shock Absorber
32
Installing the Shock Absorber
32
Removing the Spring
33
Installing the Spring
33
9 Exhaust
35
Removing the Exhaust Manifold
35
Installing the Exhaust Manifold
36
Removing the Main Silencer
37
Installing the Main Silencer
38
10 Air Filter
39
Removing the Air Filter
39
Installing the Air Filter
39
11 Fuel Tank, Seat, Trim
40
Opening the Filler Cap
40
Closing the Filler Cap
40
Removing the Seat
40
Mounting the Seat
41
Removing the Passenger Seat
41
Mounting the Passenger Seat
41
Removing the Fuel Tank Cover
41
Installing the Fuel Tank Cover
44
Removing the Fuel Tank
46
Installing the Fuel Tank
48
Removing the Front Spoiler
49
Fitting Front Spoiler
49
Dismounting the Front Fender
50
Installing the Front Fender
50
Checking the Fuel Pressure
50
Changing the Fuel Filter
52
Replacing the Fuel Pump
53
12 Wheels
55
Checking the Tire Air Pressure
55
Checking the Tire Condition
55
Checking the Brake Discs
56
Front Wheel
56
Removing the Front Wheel
56
Installing the Front Wheel
56
Removing the Brake Disc of the Front Brake
57
Installing the Brake Disc of the Front Brake
57
Rear Wheel
58
Removing the Rear Wheel
58
Installing the Rear Wheel
58
Removing the Brake Disc of the Rear Brake
59
Installing the Brake Disc of the Rear Brake
59
Checking the Chain Tension
60
Adjusting the Chain Tension
60
Checking the Chain, Rear Sprocket, and Engine Sprocket
61
Cleaning the Chain
62
Checking the Rear Hub Rubber Dampers
63
13 Wiring Harness, Battery
64
Removing the Battery
64
Installing the Battery
64
Disconnecting the Negative Cable of the Battery
65
Reconnecting the Negative Cable of the Battery
65
Recharging the Battery
65
Checking the Charging Voltage
66
Changing the Fuses of Individual Power Consumers
67
14 Brake System
68
Checking the Front Brake Linings
68
Changing the Front Brake Linings
68
Checking the Brake Fluid Level of the Front Brake
70
Adding Front Brake Fluid
70
Changing the Front Brake Fluid
71
Checking the Rear Brake Linings
72
Changing the Rear Brake Linings
73
Checking the Free Travel of Foot Brake Lever
74
Adjusting the Free Travel of the Foot Brake Lever
75
Checking the Rear Brake Fluid Level
75
Adding Rear Brake Fluid
76
Changing the Rear Brake Fluid
76
15 Lighting System, Instruments
78
Setting Kilometers or Miles
78
Adjusting the Shift Speed RPM 1
78
Adjusting the Shift Speed RPM 2
78
Setting the Time
79
Resetting the Service Interval Display
79
Checking the Headlight Setting
79
Adjusting the Headlight Range
80
Changing the Parking Light Bulb
81
Changing the Headlight Bulb
82
16 Engine
84
Removing the Engine
84
Installing the Engine
87
Disassembling the Engine
92
Preparations (125 Duke)
92
Draining the Engine Oil (125 Duke)
92
Removing the Chain Securing Guide
93
Duke)
93
Removing the Valve Cover (125 Duke)
93
Removing the Spark Plug (125 Duke)
93
Removing the Clutch Cover (125 Duke)
93
Setting the Engine to Ignition Top Dead Center (125 Duke)
94
Removing the Starter Motor (125 Duke)
94
Removing the Timing Chain Tensioner
95
Duke)
95
Removing the Camshaft (125 Duke)
95
Removing the Cylinder Head (125 Duke)
96
Removing the Piston (125 Duke)
96
Removing the Water Pump Wheel
97
Duke)
97
Removing the Alternator Cover (125 Duke)
98
Removing the Rotor (125 Duke)
98
Removing the Starter Drive (125 Duke)
99
Removing the Balancer Shaft Drive Wheel (125 Duke)
99
Removing the Gear Position Sensor
100
Duke)
100
Removing the Spacer (125 Duke)
101
Removing the Clutch Basket (125 Duke)
101
Removing the Primary Gear (125 Duke)
102
Removing the Oil Pump (125 Duke)
102
Removing the Shift Shaft (125 Duke)
103
Removing the Shift Drum Locating
103
Duke)
103
Removing the Locking Lever (125 Duke)
103
Removing the Oil Filter (125 Duke)
103
Removing the Left Engine Case
104
Duke)
104
Removing the Shift Rails (125 Duke)
105
Removing the Shift Drum (125 Duke)
105
Removing the Shift Forks (125 Duke)
105
Removing the Transmission Shafts
105
Duke)
105
Removing the Balancer Shaft (125 Duke)
106
Removing the Crankshaft (125 Duke)
106
Preparations (200 Duke)
106
Draining the Engine Oil (200 Duke)
106
Removing the Chain Securing Guide
107
Duke)
107
Removing the Valve Cover (200 Duke)
107
Removing the Spark Plug (200 Duke)
107
Removing the Clutch Cover (200 Duke)
107
Setting the Engine to Ignition Top Dead Center (200 Duke)
108
Removing the Starter Motor (200 Duke)
108
Removing the Timing Chain Tensioner
109
Duke)
109
Removing the Camshaft (200 Duke)
109
Removing the Cylinder Head (200 Duke)
110
Removing the Piston (200 Duke)
110
Removing the Water Pump Wheel
111
Duke)
111
Removing the Alternator Cover
112
Duke)
112
Removing the Rotor (200 Duke)
112
Removing the Starter Drive (200 Duke)
113
Removing the Balancer Shaft Drive Wheel (200 Duke)
113
Duke)
114
Removing the Spacer (200 Duke)
115
Removing the Clutch Basket (200 Duke)
115
Removing the Primary Gear (200 Duke)
116
Removing the Oil Pump (200 Duke)
116
Removing the Shift Shaft (200 Duke)
117
Removing the Shift Drum Locating
117
Duke)
117
Removing the Locking Lever (200 Duke)
117
Removing the Oil Filter (200 Duke)
117
Removing the Left Engine Case
118
Duke)
118
Removing the Shift Rails (200 Duke)
119
Removing the Shift Drum (200 Duke)
119
Removing the Shift Forks (200 Duke)
119
Removing the Transmission Shafts
119
Duke)
119
Removing the Balancer Shaft (200 Duke)
120
Removing the Crankshaft (200 Duke)
120
Work on Individual Parts
120
Work on the Left Section of the Engine Case (125 Duke)
120
Work on the Right Section of the Engine Case (125 Duke)
121
Changing the Shaft Seal Ring of the Water Pump (125 Duke)
121
Removing the Main Bearing (125 Duke)
122
Checking the Radial Play of the Lower Conrod Bearing (125 Duke)
123
Changing the Conrod Bearing (125 Duke)
124
Changing the Balancer Shaft Bearing
125
Duke)
125
Changing the Camshaft Bearing
125
Work on the Cylinder Head (125 Duke)
126
Checking the Cylinder Head (125 Duke)
127
Checking/Measuring the Cylinder
127
Duke)
127
Checking the Piston Ring End Gap
128
Duke)
128
Checking/Measuring the Piston
128
Checking the Piston/Cylinder Mounting Clearance (125 Duke)
129
Checking the Oil Pump (125 Duke)
129
Checking the Oil Pressure Regulator Valve (125 Duke)
129
Checking the Clutch (125 Duke)
130
Preassembling the Clutch (125 Duke)
131
Checking the Shift Mechanism
132
Duke)
132
Preassembling the Shift Shaft (125 Duke)
133
Disassembling the Main Shaft
133
Duke)
133
Dismantling the Countershaft (125 Duke)
134
Checking the Transmission (125 Duke)
134
Assembling the Main Shaft (125 Duke)
135
Assembling the Countershaft (125 Duke)
136
Checking the Timing Assembly
138
Duke)
138
Changing the Stator (125 Duke)
138
Checking the Electric Starter Drive
139
Duke)
139
Checking the Freewheel (125 Duke)
140
Work on the Left Section of the Engine Case (200 Duke)
140
Work on the Right Section of the Engine Case (200 Duke)
141
Changing the Shaft Seal Ring of the Water Pump (200 Duke)
141
Removing the Main Bearing (200 Duke)
142
Checking the Radial Play of the Lower Conrod Bearing (200 Duke)
143
Changing the Conrod Bearing (200 Duke)
144
Changing the Balancer Shaft Bearing
145
Duke)
145
Changing the Camshaft Bearing
145
Work on the Cylinder Head (200 Duke)
146
Checking the Cylinder Head (200 Duke)
147
Checking/Measuring the Cylinder
147
Duke)
147
Checking the Piston Ring End Gap
148
Duke)
148
Checking/Measuring the Piston
148
Checking the Piston/Cylinder Mounting Clearance (200 Duke)
149
Checking the Oil Pump (200 Duke)
149
Checking the Oil Pressure Regulator Valve (200 Duke)
149
Checking the Clutch (200 Duke)
150
Preassembling the Clutch (200 Duke)
151
Checking the Shift Mechanism
152
Duke)
152
Preassembling the Shift Shaft (200 Duke)
153
Disassembling the Main Shaft
153
Duke)
153
Dismantling the Countershaft (200 Duke)
154
Checking the Transmission (200 Duke)
154
Assembling the Main Shaft (200 Duke)
155
Assembling the Countershaft (200 Duke)
156
Checking the Timing Assembly
158
Duke)
158
Changing the Stator (200 Duke)
158
Checking the Electric Starter Drive
159
Duke)
159
Checking the Freewheel (200 Duke)
160
Assembling the Engine
160
Installing the Crankshaft (125 Duke)
160
Installing the Balancer Shaft (125 Duke)
160
Duke)
161
Installing the Shift Forks (125 Duke)
161
Installing the Shift Drum (125 Duke)
161
Installing the Transmission Shafts (125 Duke)
161
Installing the Shift Rails (125 Duke)
162
Installing the Left Engine Case
162
Duke)
162
Installing the Oil Filter (125 Duke)
163
Installing the Locking Lever (125 Duke)
163
Installing the Shift Drum Locating
163
Duke)
163
Installing the Shift Shaft (125 Duke)
164
Installing the Oil Pump (125 Duke)
164
Installing the Primary Gear (125 Duke)
165
Installing the Clutch Basket (125 Duke)
165
Installing the Spacer (125 Duke)
166
Installing the Gear Position Sensor
166
Duke)
166
Installing the Balancer Shaft Drive Wheel (125 Duke)
167
Installing the Starter Drive (125 Duke)
168
Installing the Rotor (125 Duke)
169
Installing the Alternator Cover (125 Duke)
169
Installing the Water Pump Cover
169
Duke)
169
Installing the Piston (125 Duke)
170
Installing the Cylinder Head (125 Duke)
171
Installing the Camshafts (125 Duke)
172
Installing the Timing Chain Tensioner
173
Duke)
173
Checking the Valve Clearance (125 Duke)
174
Adjusting the Valve Clearance (125 Duke)
174
Installing the Starter Motor (125 Duke)
174
Installing the Clutch Cover (125 Duke)
175
Installing the Spark Plug (125 Duke)
175
Installing the Valve Cover (125 Duke)
176
Installing the Chain Securing Guide
176
Duke)
176
Installing the Oil Screen (125 Duke)
176
Removing the Engine from the Engine Assembly Stand (125 Duke)
177
Installing the Crankshaft (200 Duke)
177
Installing the Balancer Shaft (200 Duke)
177
Installing the Transmission Shafts
178
Duke)
178
Installing the Shift Forks (200 Duke)
178
Installing the Shift Drum (200 Duke)
178
Installing the Shift Rails (200 Duke)
179
Installing the Left Engine Case
179
Duke)
179
Installing the Oil Filter (200 Duke)
180
Installing the Locking Lever (200 Duke)
180
Installing the Shift Drum Locating
180
Duke)
180
Installing the Shift Shaft (200 Duke)
181
Installing the Oil Pump (200 Duke)
181
Installing the Primary Gear (200 Duke)
182
Installing the Clutch Basket (200 Duke)
182
Installing the Spacer (200 Duke)
183
Installing the Gear Position Sensor (200 Duke)
183
Installing the Balancer Shaft Drive Wheel (200 Duke)
184
Installing the Starter Drive (200 Duke)
185
Installing the Rotor (200 Duke)
186
Installing the Alternator Cover (200 Duke)
186
Installing the Water Pump Cover (200 Duke)
186
Installing the Piston (200 Duke)
187
Installing the Cylinder Head (200 Duke)
188
Installing the Camshafts (200 Duke)
189
Installing the Timing Chain Tensioner (200 Duke)
190
Checking the Valve Clearance (200 Duke)
191
Adjusting the Valve Clearance (200 Duke)
191
Installing the Starter Motor (200 Duke)
191
Installing the Clutch Cover (200 Duke)
192
Installing the Spark Plug (200 Duke)
192
Installing the Valve Cover (200 Duke)
193
Installing the Chain Securing Guide (200 Duke)
193
Installing the Oil Screen (200 Duke)
193
Removing the Engine from the Engine Assembly Stand (200 Duke)
194
17 Shift Mechanism
195
Adjusting the Shift Lever
195
18 Water Pump, Cooling System
196
Draining the Coolant
196
Filling/Bleeding the Cooling System
196
Checking the Antifreeze and Coolant Level
197
Checking the Coolant Level
198
19 Lubrication System
200
Oil Circuit
200
Checking the Engine Oil Level
200
Checking the Engine Oil Pressure
200
Changing the Engine Oil and Oil Filter, Cleaning the Oil Screen
202
Adding Engine Oil
203
20 Ignition System
204
Alternator - Checking the Stator Winding
204
21 Technical Data
205
Engine
205
125 Duke
205
Engine Tolerance, Wear Limits
206
125 Duke
206
200 Duke
207
Engine Tightening Torques
207
Capacities
208
Engine Oil
208
Coolant
208
Fuel
208
Chassis
209
Electrical System
209
Tires
210
Fork
210
Shock Absorber
210
Chassis Tightening Torques
210
22 Cleaning/Protective Treatment
213
Cleaning the Motorcycle
213
Checks and Maintenance Steps for Winter Operation
214
23 Storage
215
Preparing for Use after Storage
215
24 Service Schedule
216
25 Wiring Diagram
218
125 Duke, 200 Duke EU)
218
125 Duke, 200 Duke EU)
220
125 Duke, 200 Duke EU)
222
125 Duke, 200 Duke EU)
224
125 Duke, 200 Duke EU)
226
125 Duke, 200 Duke EU)
228
125 Duke, 200 Duke EU)
230
125 Duke, 200 Duke EU)
232
200 Duke 2013 COL)
234
200 Duke 2013 COL)
236
200 Duke 2013 COL)
238
200 Duke 2013 COL)
240
200 Duke 2013 COL)
242
200 Duke 2013 COL)
244
200 Duke 2013 COL)
246
200 Duke 2013 COL)
248
26 Substances
250
27 Auxiliary Substances
252
28 Special Tools
254
29 Standards
263
Index
264
Other manuals for KTM 200 DUKE EU
Owner's Manual
185 pages
Setup Instructions
16 pages
5
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KTM 200 DUKE EU Specifications
General
Brand
KTM
Model
200 DUKE EU
Category
Motorcycle
Language
English
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