KTM Duke 125 200 (2012) - Service Repair Manual - Wiring Diagram

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KTM DUKE 125 and 200 (2012) - WORKSHOP, SERVICE, REPAIR MANUAL


- English Service Manual and Wiring Diagram to motorcycles KTM Duke 125 200 (2012).



CONTENTS:



1 MEANS OF REPRESENTATION
- 1.1 Symbols used
- 1.2 Formats used
2 SAFETY ADVICE
- 2.1 Repair Manual
- 2.2 Safety advice
- 2.3 Degrees of risk and symbols
- 2.4 Work rules
3 IMPORTANT NOTES
- 3.1 Guarantee, warranty
- 3.2 Operating and auxiliary substances
- 3.3 Spare parts, accessories
- 3.4 Figures
4 SERIAL NUMBERS
- 4.1 Chassis number/type label
- 4.2 Key number
- 4.3 Engine number
5 MOTORCYCLE
- 5.1 Raising the motorcycle with the rear wheel stand
- 5.2 Taking the motorcycle off of the rear wheel stand
- 5.3 Raising the motorcycle with the front wheel stand
- 5.4 Taking the motorcycle off of the front wheel stand
- 5.5 Raising the motorcycle with the work stand
- 5.6 Removing the motorcycle from the work stand
- 5.7 Starting
- 5.8 Starting the motorcycle to make checks
6 FORK, TRIPLE CLAMP

- 6.1 Cleaning the dust boots of the fork legs
- 6.2 Removing fork legs
- 6.3 Installing the fork legs
- 6.4 Disassembling the fork legs
- 6.5 Checking the fork legs
- 6.6 Assembling the fork legs
- 6.7 Removing the lower triple clamp
- 6.8 Installing the lower triple clamp
- 6.9 Checking the steering head bearing play
- 6.10 Adjusting the steering head bearing play
7 HANDLEBAR, CONTROLS
- 7.1 Checking the play in the throttle cable
- 7.2 Adjusting the play in the throttle cable
- 7.3 Checking the clutch lever play
- 7.4 Adjusting the clutch cable play
8 SHOCK ABSORBER, SWINGARM
- 8.1 Adjusting the spring preload of the shock absorber
- 8.2 Removing the shock absorber
- 8.3 Installing the shock absorber
- 8.4 Removing the spring
- 8.5 Installing the spring
9 EXHAUST
- 9.1 Removing the exhaust manifold
- 9.2 Installing the exhaust manifold
- 9.3 Removing the main silencer
- 9.4 Installing the main silencer
10 AIR FILTER
- 10.1 Removing the air filter
- 10.2 Installing the air filter
11 FUEL TANK, SEAT, TRIM
- 11.1 Opening the filler cap
- 11.2 Closing the filler cap
- 11.3 Removing the seat
- 11.4 Mounting the seat
- 11.5 Removing the passenger seat
- 11.6 Mounting the passenger seat
- 11.7 Removing the fuel tank cover
- 11.8 Installing the fuel tank cover
- 11.9 Removing the fuel tank
- 11.10 Installing the fuel tank
- 11.11 Removing the front spoiler
- 11.12 Fitting front spoiler
- 11.13 Dismounting the front fender
- 11.14 Installing the front fender
- 11.15 Checking the fuel pressure
- 11.16 Changing the fuel filter
- 11.17 Replacing the fuel pump
12 WHEELS
- 12.1 Checking the tire air pressure
- 12.2 Checking the tire condition
- 12.3 Checking the brake discs
- 12.4 Front wheel
- 12.4.1 Removing the front wheel
- 12.4.2 Installing the front wheel
- 12.4.3 Removing the brake disc of the front brake
- 12.4.4 Installing the brake disc of the front brake
- 12.5 Rear wheel
- 12.5.1 Removing the rear wheel
- 12.5.2 Installing the rear wheel
- 12.5.3 Removing the brake disc of the rear brake
- 12.5.4 Installing the brake disc of the rear brake
- 12.5.5 Checking the chain tension
- 12.5.6 Adjusting the chain tension
- 12.5.7 Checking the chain, rear sprocket, and engine sprocket
- 12.5.8 Cleaning the chain
- 12.5.9 Checking the rear hub rubber dampers
13 WIRING HARNESS, BATTERY
- 13.1 Removing the battery
- 13.2 Installing the battery
- 13.3 Disconnecting the negative cable of the battery
- 13.4 Reconnecting the negative cable of the battery
- 13.5 Recharging the battery
- 13.6 Checking the charging voltage
- 13.7 Changing the fuses of individual power consumers
14 BRAKE SYSTEM
- 14.1 Checking the front brake linings
- 14.2 Changing the front brake linings
- 14.3 Checking the brake fluid level of the front brake
- 14.4 Adding front brake fluid
- 14.5 Changing the front brake fluid
- 14.6 Checking the rear brake linings
- 14.7 Changing the rear brake linings
- 14.8 Checking the free travel of foot brake lever
- 14.9 Adjusting the free travel of the foot brake lever
- 14.10 Checking the rear brake fluid level
- 14.11 Adding rear brake fluid
- 14.12 Changing the rear brake fluid
15 LIGHTING SYSTEM, INSTRUMENTS
- 15.1 Setting kilometers or miles
- 15.2 Adjusting the shift speed RPM 1
- 15.3 Adjusting the shift speed RPM 2
- 15.4 Setting the time
- 15.5 Resetting the service interval display
- 15.6 Checking the headlight setting
- 15.7 Adjusting the headlight range
- 15.8 Changing the parking light bulb
- 15.9 Changing the headlight bulb
16 ENGINE
- 16.1 Removing the engine
- 16.2 Installing the engine
- 16.3 Disassembling the engine
- 16.3.1 Preparations (125 Duke)
- 16.3.2 Draining the engine oil (125 Duke)
- 16.3.3 Removing the chain securing guide (125 Duke)
- 16.3.4 Removing the valve cover (125 Duke)
- 16.3.5 Removing the spark plug (125 Duke)
- 16.3.6 Removing the clutch cover (125 Duke)
- 16.3.7 Setting the engine to ignition top dead center (125 Duke)
- 16.3.8 Removing the starter motor (125 Duke)
- 16.3.9 Removing the timing chain tensioner (125 Duke)
- 16.3.10 Removing the camshaft (125 Duke)
- 16.3.11 Removing the cylinder head (125 Duke)
- 16.3.12 Removing the piston (125 Duke)
- 16.3.13 Removing the water pump wheel (125 Duke)
- 16.3.14 Removing the alternator cover (125 Duke)
- 16.3.15 Removing the rotor (125 Duke)
- 16.3.16 Removing the starter drive (125 Duke)
- 16.3.17 Removing the balancer shaft drive wheel (125 Duke)
- 16.3.18 Removing the gear position sensor (125 Duke)
- 16.3.19 Removing the spacer (125 Duke)
- 16.3.20 Removing the clutch basket (125 Duke)
- 16.3.21 Removing the primary gear (125 Duke)
- 16.3.22 Removing the oil pump (125 Duke)
- 16.3.23 Removing the shift shaft (125 Duke)
- 16.3.24 Removing the shift drum locating (125 Duke)
- 16.3.25 Removing the locking lever (125 Duke)
- 16.3.26 Removing the oil filter (125 Duke)
- 16.3.27 Removing the left engine case (125 Duke)
- 16.3.28 Removing the shift rails (125 Duke)
- 16.3.29 Removing the shift drum (125 Duke)
- 16.3.30 Removing the shift forks (125 Duke)
- 16.3.31 Removing the transmission shafts (125 Duke)
- 16.3.32 Removing the balancer shaft (125 Duke)
- 16.3.33 Removing the crankshaft (125 Duke)
- 16.3.34 Preparations (200 Duke)
- 16.3.35 Draining the engine oil (200 Duke)
- 16.3.36 Removing the chain securing guide (200 Duke)
- 16.3.37 Removing the valve cover (200 Duke)
- 16.3.38 Removing the spark plug (200 Duke)
- 16.3.39 Removing the clutch cover (200 Duke)
- 16.3.40 Setting the engine to ignition top dead center (200 Duke)
- 16.3.41 Removing the starter motor (200 Duke)
- 16.3.42 Removing the timing chain tensioner (200 Duke)
- 16.3.43 Removing the camshaft (200 Duke)
- 16.3.44 Removing the cylinder head (200 Duke)
- 16.3.45 Removing the piston (200 Duke)
- 16.3.46 Removing the water pump wheel (200 Duke)

- 16.3.47 Removing the alternator cover (200 Duke)
- 16.3.48 Removing the rotor (200 Duke)
- 16.3.49 Removing the starter drive (200 Duke)
- 16.3.50 Removing the balancer shaft drive wheel (200 Duke)
- 16.3.51 Removing the gear position sensor (200 Duke)
- 16.3.52 Removing the spacer (200 Duke)
- 16.3.53 Removing the clutch basket (200 Duke)
- 16.3.54 Removing the primary gear (200 Duke)
- 16.3.55 Removing the oil pump (200 Duke)
- 16.3.56 Removing the shift shaft (200 Duke)
- 16.3.57 Removing the shift drum locating (200 Duke)
- 16.3.58 Removing the locking lever (200 Duke)
- 16.3.59 Removing the oil filter (200 Duke)
- 16.3.60 Removing the left engine case (200 Duke)
- 16.3.61 Removing the shift rails (200 Duke)
- 16.3.62 Removing the shift drum (200 Duke)
- 16.3.63 Removing the shift forks (200 Duke)
- 16.3.64 Removing the transmission shafts (200 Duke)
- 16.3.65 Removing the balancer shaft (200 Duke)
- 16.3.66 Removing the crankshaft (200 Duke)
- 16.4 Work on individual parts
- 16.4.1 Work on the left section of the engine case (125 Duke)
- 16.4.2 Work on the right section of the engine case (125 Duke)
- 16.4.3 Changing the shaft seal ring of the water pump (125 Duke)
- 16.4.4 Removing the main bearing (125 Duke)
- 16.4.5 Checking the radial play of the lower conrod bearing (125 Duke)
- 16.4.6 Changing the conrod bearing (125 Duke)
- 16.4.7 Changing the balancer shaft bearing (125 Duke)
- 16.4.8 Changing the camshaft bearing (125 Duke)
- 16.4.9 Work on the cylinder head (125 Duke)
- 16.4.10 Checking the cylinder head (125 Duke)
- 16.4.11 Checking/measuring the cylinder (125 Duke)
- 16.4.12 Checking the piston ring
- 16.4.13 Checking/measuring the piston (125 Duke)
- 16.4.14 Checking the piston/cylinder mounting clearance (125 Duke)
- 16.4.15 Checking the oil pump (125 Duke)
- 16.4.16 Checking the oil pressure regulator valve (125 Duke)
- 16.4.17 Checking the clutch (125 Duke)
- 16.4.18 Preassembling the clutch (125 Duke)
- 16.4.19 Checking the shift mechanism (125 Duke)
- 16.4.20 Preassembling the shift shaft (125 Duke)
- 16.4.21 Disassembling the main shaft (125 Duke)
- 16.4.22 Dismantling the countershaft (125 Duke)
- 16.4.23 Checking the transmission (125 Duke)
- 16.4.24 Assembling the main shaft (125 Duke)
- 16.4.25 Assembling the countershaft (125 Duke)
- 16.4.26 Checking the timing assembly (125 Duke)
- 16.4.27 Changing the stator (125 Duke)
- 16.4.28 Checking the electric starter drive (125 Duke)
- 16.4.29 Checking the freewheel (125 Duke)
- 16.4.30 Work on the left section of the engine case (200 Duke)
- 16.4.31 Work on the right section of the engine case (200 Duke)
- 16.4.32 Changing the shaft seal ring of the water pump (200 Duke)
- 16.4.33 Removing the main bearing (200 Duke)
- 16.4.34 Checking the radial play of the lower conrod bearing (200 Duke)
- 16.4.35 Changing the conrod bearing (200 Duke)
- 16.4.36 Changing the balancer shaft bearing (200 Duke)
- 16.4.37 Changing the camshaft bearing (200 Duke)
- 16.4.38 Work on the cylinder head (200 Duke)
- 16.4.39 Checking the cylinder head (200 Duke)
- 16.4.40 Checking/measuring the cylinder (200 Duke)
- 16.4.41 Checking the piston ring
- 16.4.42 Checking/measuring the piston (200 Duke)
- 16.4.43 Checking the piston/cylinder mounting clearance (200 Duke)
- 16.4.44 Checking the oil pump (200 Duke)
- 16.4.45 Checking the oil pressure regulator valve (200 Duke)
- 16.4.46 Checking the clutch (200 Duke)
- 16.4.47 Preassembling the clutch (200 Duke)
- 16.4.48 Checking the shift mechanism (200 Duke)
- 16.4.49 Preassembling the shift shaft (200 Duke)
- 16.4.50 Disassembling the main shaft (200 Duke)
- 16.4.51 Dismantling the countershaft (200 Duke)
- 16.4.52 Checking the transmission (200 Duke)
- 16.4.53 Assembling the main shaft (200 Duke)
- 16.4.54 Assembling the countershaft (200 Duke)
- 16.4.55 Checking the timing assembly (200 Duke)
- 16.4.56 Changing the stator (200 Duke)
- 16.4.57 Checking the electric starter drive (200 Duke)
- 16.4.58 Checking the freewheel (200 Duke)
- 16.5 Assembling the engine
- 16.5.1 Installing the crankshaft (125 Duke)
- 16.5.2 Installing the balancer shaft (125 Duke)
- 16.5.3 Installing the transmission shafts (125 Duke)
- 16.5.4 Installing the shift forks (125 Duke)
- 16.5.5 Installing the shift drum (125 Duke)
- 16.5.6 Installing the shift rails (125 Duke)
- 16.5.7 Installing the left engine case (125 Duke)
- 16.5.8 Installing the oil filter (125 Duke)
- 16.5.9 Installing the locking lever (125 Duke)
- 16.5.10 Installing the shift drum locating (125 Duke)
- 16.5.11 Installing the shift shaft (125 Duke)
- 16.5.12 Installing the oil pump (125 Duke)
- 16.5.13 Installing the primary gear (125 Duke)
- 16.5.14 Installing the clutch basket (125 Duke)
- 16.5.15 Installing the spacer (125 Duke)
- 16.5.16 Installing the gear position sensor (125 Duke)
- 16.5.17 Installing the balancer shaft drive wheel (125 Duke)
- 16.5.18 Installing the starter drive (125 Duke)
- 16.5.19 Installing the rotor (125 Duke)
- 16.5.20 Installing the alternator cover (125 Duke)
- 16.5.21 Installing the water pump cover (125 Duke)
- 16.5.22 Installing the piston (125 Duke)
- 16.5.23 Installing the cylinder head (125 Duke)
- 16.5.24 Installing the camshafts (125 Duke)
- 16.5.25 Installing the timing chain tensioner (125 Duke)
- 16.5.26 Checking the valve clearance (125 Duke)
- 16.5.27 Adjusting the valve clearance (125 Duke)
- 16.5.28 Installing the starter motor (125 Duke)
- 16.5.29 Installing the clutch cover (125 Duke)
- 16.5.30 Installing the spark plug (125 Duke)
- 16.5.31 Installing the valve cover (125 Duke)
- 16.5.32 Installing the chain securing guide (125 Duke)
- 16.5.33 Installing the oil screen (125 Duke)
- 16.5.34 Removing the engine from the engine assembly stand (125 Duke)
- 16.5.35 Installing the crankshaft (200 Duke)
- 16.5.36 Installing the balancer shaft (200 Duke)
- 16.5.37 Installing the transmission shafts (200 Duke)
- 16.5.38 Installing the shift forks (200 Duke)
- 16.5.39 Installing the shift drum (200 Duke)
- 16.5.40 Installing the shift rails (200 Duke)
- 16.5.41 Installing the left engine case (200 Duke)
- 16.5.42 Installing the oil filter (200 Duke)
- 16.5.43 Installing the locking lever (200 Duke)
- 16.5.44 Installing the shift drum locating (200 Duke)
- 16.5.45 Installing the shift shaft (200 Duke)
- 16.5.46 Installing the oil pump (200 Duke)
- 16.5.47 Installing the primary gear (200 Duke)
- 16.5.48 Installing the clutch basket (200 Duke)
- 16.5.49 Installing the spacer (200 Duke)
- 16.5.50 Installing the gear position sensor (200 Duke)
- 16.5.51 Installing the balancer shaft drive wheel (200 Duke)
- 16.5.52 Installing the starter drive (200 Duke)
- 16.5.53 Installing the rotor (200 Duke)
- 16.5.54 Installing the alternator cover (200 Duke)
- 16.5.55 Installing the water pump cover (200 Duke)
- 16.5.56 Installing the piston (200 Duke)
- 16.5.57 Installing the cylinder head (200 Duke)
- 16.5.58 Installing the camshafts (200 Duke)
- 16.5.59 Installing the timing chain tensioner (200 Duke)
- 16.5.60 Checking the valve clearance (200 Duke)
- 16.5.61 Adjusting the valve clearance (200 Duke)
- 16.5.62 Installing the starter motor (200 Duke)
- 16.5.63 Installing the clutch cover (200 Duke)
- 16.5.64 Installing the spark plug (200 Duke)
- 16.5.65 Installing the valve cover (200 Duke)
- 16.5.66 Installing the chain securing guide (200 Duke)
- 16.5.67 Installing the oil screen (200 Duke)
- 16.5.68 Removing the engine from the engine assembly stand (200 Duke)
17 SHIFT MECHANISM
- 17.1 Adjusting the shift lever
18 WATER PUMP, COOLING SYSTEM
- 18.1 Draining the coolant
- 18.2 Filling/bleeding the cooling system
- 18.3 Checking the antifreeze and coolant level
- 18.4 Checking the coolant level
19 LUBRICATION SYSTEM
- 19.1 Oil circuit
- 19.2 Checking the engine oil level
- 19.3 Checking the engine oil pressure
- 19.4 Changing the engine oil and oil filter, cleaning the oil screen
- 19.5 Adding engine oil
20 IGNITION SYSTEM
- 20.1 Alternator - checking the stator winding
21 TECHNICAL DATA
- 21.1 Engine
- 21.1.1 125 Duke
- 21.1.2 200 Duke
- 21.2 Engine tolerance, wear limits
- 21.2.1 125 Duke
- 21.2.2 200 Duke
- 21.3 Engine tightening torques
- 21.4 Capacities
- 21.4.1 Engine oil
- 21.4.2 Coolant
- 21.4.3 Fuel
- 21.5 Chassis
- 21.6 Electrical system
- 21.7 Tires
- 21.8 Fork
- 21.9 Shock absorber
- 21.10 Chassis tightening torques
22 CLEANING/PROTECTIVE TREATMENT
- 22.1 Cleaning the motorcycle
- 22.2 Checks and maintenance steps for winter operation
23 STORAGE
- 23.1 Storage
- 23.2 Preparing for use after storage
24 SERVICE SCHEDULE
- 24.1 Service schedule
25 WIRING DIAGRAM
- 25.1 Page 1 of 8 (125 Duke, 200 Duke EU)
- 25.2 Page 2 of 8 (125 Duke, 200 Duke EU)
- 25.3 Page 3 of 8 (125 Duke, 200 Duke EU)
- 25.4 Page 4 of 8 (125 Duke, 200 Duke EU)
- 25.5 Page 5 of 8 (125 Duke, 200 Duke EU)
- 25.6 Page 6 of 8 (125 Duke, 200 Duke EU)
- 25.7 Page 7 of 8 (125 Duke, 200 Duke EU)
- 25.8 Page 8 of 8 (125 Duke, 200 Duke EU)
- 25.9 Page 1 of 8 (200 Duke 2013 COL)
- 25.10 Page 2 of 8 (200 Duke 2013 COL)
- 25.11 Page 3 of 8 (200 Duke 2013 COL)
- 25.12 Page 4 of 8 (200 Duke 2013 COL)
- 25.13 Page 5 of 8 (200 Duke 2013 COL)
- 25.14 Page 6 of 8 (200 Duke 2013 COL)
- 25.15 page 7 of 8 (200 Duke 2013 COL)
- 25.16 Page 8 of 8 (200 Duke 2013 COL)
26 SUBSTANCES
27 AUXILIARY SUBSTANCES
28 SPECIAL TOOLS
29 STANDARDS
INDEX