KTM 125 Duke 2016 Manual

SETUP INSTRUCTIONS 2016
125 Duke
200 Duke
Art. no. 3213457en

INTRODUCTION 1
*3213457en*
3213457en
07/2016
INTRODUCTION
The work described in these setup instructions must be performed before the vehicle is delivered to the customer.
Read the setup instructions in their entirety before beginning work.
These setup instructions were written to correspond to the latest state of this series. We reserve the right to make changes in the interest
of technical advancement without at the same time updating this manual.
We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop are not specified here. It
is assumed that the work will be performed by a fully trained mechanic.
All specifications are non-binding. KTM Sportmotorcycle GmbH specifically reserves the right to modify or delete technical specifications,
prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt these to
local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery options, devi-
ations from illustrations and descriptions, misprints, and other errors. The models portrayed partly contain special equipment that does not
belong to the regular scope of supply.
© 2016 KTM Sportmotorcycle GmbH, Mattighofen Austria
All rights reserved
Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright owner.
ISO 9001(12 100 6061)
According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead to
the maximum possible quality of the products.
Issued by: TÜV Management Service
KTM Sportmotorcycle GmbH
5230 Mattighofen, Austria
This document is valid for the following models:
125 Duke EU (F4003P1, F4003P2, F4003P3, F4003P4)
200 Duke EU (F4103P1, F4103P2)
200 Duke AR (F4142P1, F4142P2, F4142P3, F4142P4)
200 Duke ASIA (F4188P1, F4188P2)
200 Duke 2017 BR (F4140P1, F4140P2)
200 Duke CN (F4187P1)
200 Duke 2017 CO (F4141P3, F4141P4)
200 Duke MY (F4189P1, F4189P2)
200 Duke TH (F4183P1, F4183P2)

1 MEANS OF REPRESENTATION 2
1.1 Symbols used
The meaning of specific symbols is described below.
Indicates an expected reaction (e.g. of a work step or a function).
Indicates an unexpected reaction (e.g. of a work step or a function).
Indicates a page reference (more information is provided on the specified page).
Indicates information with more details or tips.
Indicates the result of a testing step.
Denotes a voltage measurement.
Denotes a current measurement.
Denotes a resistance measurement.
1.2 Formats used
The typographical formats used in this document are explained below.
Proprietary name Identifies a proprietary name.
Name®Identifies a protected name.
Brand™ Identifies a trademark.
Underlined terms Refer to technical details of the vehicle or indicate technical terms, which are explained
in the glossary.

2 SETUP 3
2.1 Unpacking and setting up the vehicle
S00786-10
–Remove the straps and box.
S00790-10
–Remove the adhesive tape in the upper area of the motorcycle.
S00789-10
–Roll down the film at the sides.
Info
To avoid damaging the motorcycle during unpacking, leave the other films
on the vehicle until you have finished work on the vehicle.
–Remove the separate enclosure and unpack it. Check the separate enclosure for
completeness.
–Check the vehicle for transport damage.
B00912-01
–Position the handlebar.
The lettering on the handlebar is situated in the middle of the handlebar
clamp.
–Position the handlebar clamps. Mount and tighten the screws evenly.
Guideline
Screw, handlebar clamp M8 21 Nm
(15.5 lbf ft)
Loctite®243™
B00913-01
–Mount and tighten the rear mirror on both sides.
–Position all controls in their exact positions on the handlebar. Tighten all screws.
700217-01
–Mount the reflector.
–Remove the protective plastic.
–Carefully loosen and remove the tensioning belt over the swingarm.
Info
An assistant prevents the motorcycle from falling over.
–Carefully loosen and remove the tensioning belts around the lower triple clamp.
The vehicle is released at the front.

2 SETUP 4
–Take the vehicle off the pallet.
Warning
Risk of injury Battery acid and battery gases cause serious chemical burns.
–Keep batteries out of the reach of children.
–Wear suitable protective clothing and goggles.
–Avoid contact with battery acid and battery gases.
–Keep sparks and open flames away from the battery. Only charge in
well-ventilated rooms.
–In the event of skin contact, rinse with large amounts of water. If battery
acid gets in the eyes, rinse with water for at least 15 minutes and con-
tact a physician.
–Fill the battery.
Info
Read the notes in the battery package.
–Recharge the battery. ( p. 6)
–Install the battery. ( p. 7)
–Refuel. ( p. 9)
–Prepare the vehicle according to the specifications in the KTM Dealer.net for han-
dover to the customer.
–Set kilometers or miles. ( p. 10)
–Set the clock. ( p. 10)

3 WORK 5
3.1 Removing the passenger seat
B00712-01
–Insert the ignition key in seat lock and turn it clockwise.
–Raise the rear of the seat, push it towards the rear, and remove it upwards.
–Remove the ignition key from the seat lock.
3.2 Mounting the passenger seat
B00724-10
–Attach hooks on the passenger seat to brackets on the subframe, and lower
it at the rear while pushing forward.
–Press down the passenger seat until it clicks into place.
Warning
Danger of accidents The passenger seat can come loose from the anchoring
if it is not mounted correctly.
–After mounting the passenger seat, check that it is locked correctly by
pulling up.
–Finally, check that the passenger seat is correctly mounted.
3.3 Removing the seat
Preparatory work
–Remove the passenger seat. ( p. 5)
B00725-10
Main work
–Remove screws .
–Raise the rear of the seat, pull it towards the rear, and remove it upwards.
3.4 Mounting the seat
B00727-10
Main work
–Attach seat recesses at screws and lower at the rear.
–Mount and tighten screws .
Guideline
Screw, seat M6 10 Nm (7.4 lbf ft)

3 WORK 6
Finishing work
–Mount the passenger seat. ( p. 5)
3.5 Removing the battery
Warning
Risk of injury Battery acid and battery gases cause serious chemical burns.
–Keep batteries out of the reach of children.
–Wear suitable protective clothing and goggles.
–Avoid contact with battery acid and battery gases.
–Keep sparks and open flames away from the battery. Only charge in well-ventilated rooms.
–In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least
15 minutes and contact a physician.
Preparatory work
–Remove the passenger seat. ( p. 5)
–Remove the seat. ( p. 5)
B00750-10
Main work
–Pull back the negative terminal cover .
–Disconnect negative cable from the battery.
B00751-10
–Pull back the positive terminal cover .
–Disconnect positive cable from the battery.
–Detach rubber band .
–Pull the battery up and out of the battery holder.
Info
Never operate the motorcycle with a discharged battery or without a battery.
In both cases, electrical components and safety devices can be damaged.
The vehicle is therefore no longer roadworthy.
3.6 Recharging the battery
Warning
Risk of injury Battery acid and battery gases cause serious chemical burns.
–Keep batteries out of the reach of children.
–Wear suitable protective clothing and goggles.
–Avoid contact with battery acid and battery gases.
–Keep sparks and open flames away from the battery. Only charge in well-ventilated rooms.
–In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least
15 minutes and contact a physician.
Warning
Environmental hazard Batteries contain environmentally-hazardous materials.
–Do not dispose of batteries as household waste.
–Dispose of batteries at a collection point for used batteries.
Warning
Environmental hazard Hazardous substances cause environmental damage.
–Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regu-
lations.

3 WORK 7
Info
Even when there is no load on the battery, it discharges steadily.
The charging level and the method of charging are very important for the service life of the battery.
Rapid recharging with a high charging current shortens the service life of the battery.
If the charging current, charging voltage, and charging time are exceeded, the battery will be destroyed.
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 sulfated, destroying the
battery.
The battery is maintenance-free, i.e., the acid level does not have to be checked.
Preparatory work
–Remove the passenger seat. ( p. 5)
–Remove the seat. ( p. 5)
–Disconnect the negative cable of the battery.
311910-10
Main work
–Connect the battery charger to the battery. Set the battery charger.
Alternative 1
Battery charger XCharge-professional EU (00029095050)
Alternative 2
Battery charger XCharge-professional US (00029095051)
Alternative 3
Battery charger XCharge-professional GB (00029095052)
Alternative 4
Battery charger XCharge-professional CH (00029095053)
Info
Follow the instructions of the charger and the manual.
–Disconnect the battery charger after charging the battery.
Guideline
The charging current, charging voltage, and charging time must not be exceeded.
Charge the battery regularly when the
motorcycle is not in use
3 months
Finishing work
–Mount the seat. ( p. 5)
–Mount the passenger seat. ( p. 5)
–Set the clock. ( p. 10)
3.7 Installing the battery
B00751-11
Main work
–Position the battery in the battery holder.
Guideline
The terminals of the battery must face upwards.
(125 Duke)
Battery (FTZ-7)
(200 Duke)
Battery (FTZ-9)
–Reconnect rubber band .
–Position the positive cable and mount and tighten the screw.
–Position positive terminal cover .

3 WORK 8
B00750-11
–Position the negative cable and mount and tighten the screw.
–Position the negative terminal cover .
Finishing work
–Mount the seat. ( p. 5)
–Mount the passenger seat. ( p. 5)
–Set the clock. ( p. 10)
3.8 Opening the filler cap
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
–Do not refuel the vehicle in the vicinity of open flames or lit cigarettes.
–Switch off the engine for refueling.
–Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
–If any fuel is spilled, wipe it off immediately.
–Observe the specifications for refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–Avoid skin, eye and clothing contact with fuel.
–Immediately consult a doctor if you swallow fuel.
–Do not inhale fuel vapors.
–In case of skin contact, rinse the affected area with plenty of water.
–Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
–Change your clothing in case of fuel spills on them.
–Keep fuels correctly in a suitable canister, and out of the reach of children.
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
–Do not allow fuel to enter the groundwater, the soil, or the sewage system.
B00710-10
–Lift the cover of the filler cap and insert the ignition key in the lock.
Note
Danger of damage Ignition key breakage.
–To take pressure off of the ignition key, push down on the filler cap. Damaged
ignition keys must be replaced.
–Turn the ignition key 90° clockwise.
–Open the filler cap.
–Remove the ignition key.

3 WORK 9
3.9 Closing the filler cap
B00711-01
Warning
Fire hazard Fuel is highly flammable, poisonous and harmful to your
health.
–After closing the filler cap, ensure that it is locked properly. Change
clothing that has been contaminated with fuel. Immediately clean con-
taminated areas on the skin with soap and water.
–Close the filler cap.
–Push down the filler cap until the lock engages.
3.10 Refueling
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
–Do not refuel the vehicle in the vicinity of open flames or lit cigarettes.
–Switch off the engine for refueling.
–Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
–If any fuel is spilled, wipe it off immediately.
–Observe the specifications for refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–Avoid skin, eye and clothing contact with fuel.
–Immediately consult a doctor if you swallow fuel.
–Do not inhale fuel vapors.
–In case of skin contact, rinse the affected area with plenty of water.
–Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
–Change your clothing in case of fuel spills on them.
Note
Material damage Inadequate fuel quality causes the fuel filter to quickly become clogged.
In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the
fuel system.
–Refuel only with clean fuel that meets the specified standards.
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
–Do not allow fuel to enter the groundwater, the soil, or the sewage system.
B00719-10
–Switch off the engine.
–Open the filler cap. ( p. 8)
–Fill the fuel tank with fuel up to the lower edge of the fuel filler.
Total fuel tank
capacity, approx.
11 l (2.9 US gal) Super unleaded (ROZ 95/RON 95/PON
91) ( p. 14) (125 Duke, 200 Duke
EU/AR/ASIA/CN/CO/MY)
Gasohol 95 E20 (RON 95) ( p. 14)
(200 Duke TH)
Super unleaded, type C (ROZ
95/RON 95/PON 91) ( p. 14)
(200 Duke 2017 BR)
–Close the filler cap. ( p. 9)

3 WORK 10
3.11 Setting the time
Condition
The ignition is on.
The motorcycle is stationary.
401303-01
–Press the MODE button briefly and repeatedly until ODO appears on the display.
–Press the MODE and SET buttons for 5 - 10 seconds.
The time display begins to flash.
–Set the hours display using the MODE button.
–Set the minutes display using the SET button.
–Press the MODE and SET buttons for 5 - 10 seconds.
The time is set.
3.12 Setting kilometers or miles
Info
Make the country-specific setting.
Condition
The ignition is on.
The motorcycle is stationary.
401303-01
–Press the MODE button briefly and repeatedly until ODO appears on the display.
–Press the MODE button for 5 - 10 seconds.
The display changes from km/h to mph or from mph to km/h.

4 TECHNICAL DATA 11
4.1 Chassis tightening torques
Exhaust clamp - 19 Nm (14 lbf ft) –
Helmet holder screw EJOT PT®3 Nm (2.2 lbf ft) –
Screw, chain guard EJOT PT®4 Nm (3 lbf ft) –
Screw, headlight EJOT PT®4 Nm (3 lbf ft) –
Remaining screws, chassis M4 4 Nm (3 lbf ft) –
Screw, EFI control unit M4 5 Nm (3.7 lbf ft) –
Screw, license plate lamp M4 2 Nm (1.5 lbf ft) –
Screw, trim, subframe, bottom M4 5 Nm (3.7 lbf ft) –
Remaining nuts, chassis M5 5 Nm (3.7 lbf ft) –
Remaining screws, chassis M5 5 Nm (3.7 lbf ft) –
Screw, ABS hose clamp (125 Duke) M5 6 Nm (4.4 lbf ft) –
Screw, brake line holder, rear M5 7 Nm (5.2 lbf ft) Loctite®243™
Screw, chain guard M5 4 Nm (3 lbf ft) Loctite®243™
Screw, fuel pump M5 5 Nm (3.7 lbf ft) –
Screw, fuel tank closure flange M5 5 Nm (3.7 lbf ft) –
Screw, fuel tank cover M5 4 Nm (3 lbf ft) –
Screw, fuel tank trim M5 5 Nm (3.7 lbf ft) –
Screw, license plate holder M5 11 Nm (8.1 lbf ft) –
Screw, rollover sensor M5 6 Nm (4.4 lbf ft) Loctite®243™
Screw, side stand switch M5 5 Nm (3.7 lbf ft) Loctite®243™
Screw, spoiler M5 5 Nm (3.7 lbf ft) –
Screw, subframe cover, bottom M5 5 Nm (3.7 lbf ft) –
Screw, tail end lower part M5 6 Nm (4.4 lbf ft) –
Screw, tail light M5 5 Nm (3.7 lbf ft) –
Screw, windshield M5 3 Nm (2.2 lbf ft) –
Clutch cable retaining bracket screw M6 6 Nm (4.4 lbf ft) –
Damping rubber frame screw M6 7 Nm (5.2 lbf ft) –
Nut, foot brake lever adjustment M6 9 Nm (6.6 lbf ft) –
Nut, radiator M6 5 Nm (3.7 lbf ft) –
Remaining nuts, chassis M6 10 Nm (7.4 lbf ft) –
Remaining screws, chassis M6 10 Nm (7.4 lbf ft) –
Screw, ABS module (125 Duke) M6 7 Nm (5.2 lbf ft) –
Screw, air filter box M6 6 Nm (4.4 lbf ft) –
Screw, air filter box lid M6 3 Nm (2.2 lbf ft) –
Screw, brake fluid reservoir of rear
brake
M6 9 Nm (6.6 lbf ft) –
Screw, cable holder, side stand switch M6 9 Nm (6.6 lbf ft) Loctite®243™
Screw, chain sliding guard M6 9 Nm (6.6 lbf ft) –
Screw, compensating tank M6 13 Nm (9.6 lbf ft) –
Screw, foot brake cylinder M6 9 Nm (6.6 lbf ft) Loctite®243™
Screw, front fender M6 11 Nm (8.1 lbf ft) –
Screw, front seat fixing M6 6 Nm (4.4 lbf ft) –
Screw, front spoiler M6 9 Nm (6.6 lbf ft) –
Screw, fuel tank M6 13 Nm (9.6 lbf ft) –
Screw, headlight holder M6 11 Nm (8.1 lbf ft) –
Screw, headlight mask M6 11 Nm (8.1 lbf ft) Loctite®243™
Screw, ignition coil M6 9 Nm (6.6 lbf ft) –
Screw, license plate holder M6 12 Nm (8.9 lbf ft) Loctite®243™
Screw, lower rear panel M6 5 Nm (3.7 lbf ft) –
Screw, magnetic holder on side stand M6 5 Nm (3.7 lbf ft) Loctite®243™
Screw, main silencer M6 10 Nm (7.4 lbf ft) –

4 TECHNICAL DATA 12
Screw, radiator bracket M6 6 Nm (4.4 lbf ft) –
Screw, radiator holder M6 9 Nm (6.6 lbf ft) –
Screw, rear ABS sensor wheel
(125 Duke)
M6 8 Nm (5.9 lbf ft) Loctite®243™
Screw, rear splash protector M6 9 Nm (6.6 lbf ft) –
Screw, rollover sensor holder M6 11 Nm (8.1 lbf ft) –
Screw, seat M6 10 Nm (7.4 lbf ft) –
Screw, shift lever linkage M6 11 Nm (8.1 lbf ft) Loctite®243™
Screw, tail end lower part, front M6 11 Nm (8.1 lbf ft) –
Screw, voltage regulator M6 10 Nm (7.4 lbf ft) –
Screw, voltage regulator holder M6 11 Nm (8.1 lbf ft) –
Screw, wheel speed sensor holder
(125 Duke)
M6 8 Nm (5.9 lbf ft) –
Silent block retaining bracket screw M6 7 Nm (5.2 lbf ft) –
Nut, rear sprocket M8 27 Nm (19.9 lbf ft) Loctite®243™
Remaining nuts, chassis M8 25 Nm (18.4 lbf ft) –
Remaining screws, chassis M8 25 Nm (18.4 lbf ft) –
Screw, bottom triple clamp M8 15 Nm (11.1 lbf ft) –
Screw, engine bearer on engine M8 25 Nm (18.4 lbf ft) –
Screw, engine bearer on frame M8 26 Nm (19.2 lbf ft) –
Screw, foot brake lever M8 16 Nm (11.8 lbf ft) Loctite®243™
Screw, fork stub M8 15 Nm (11.1 lbf ft) –
Screw, front brake disc M8 30 Nm (22.1 lbf ft) Loctite®243™
Screw, front wheel spindle M8 26 Nm (19.2 lbf ft) –
Screw, handlebar clamp M8 21 Nm (15.5 lbf ft) Loctite®243™
Screw, handrail M8 32 Nm (23.6 lbf ft) –
Screw, horn M8 7 Nm (5.2 lbf ft) –
Screw, main silencer M8 24 Nm (17.7 lbf ft) –
Screw, passenger footrest bracket M8 26 Nm (19.2 lbf ft) Loctite®243™
Screw, rear brake disc M8 30 Nm (22.1 lbf ft) Loctite®243™
Screw, shift lever M8 16 Nm (11.8 lbf ft) Loctite®243™
Screw, top triple clamp M8 11 Nm (8.1 lbf ft) –
Screw, front brake caliper M8x1 30 Nm (22.1 lbf ft) Loctite®204™
Banjo bolt, brake line M10 24 Nm (17.7 lbf ft) –
Fitting side stand M10 35 Nm (25.8 lbf ft) Loctite®243™
Fitting, engine mounting bracket M10 45 Nm (33.2 lbf ft) –
Nut mirror image left M10 16 Nm (11.8 lbf ft) –
Remaining nuts, chassis M10 45 Nm (33.2 lbf ft) –
Remaining screws, chassis M10 45 Nm (33.2 lbf ft) –
Fitting, bottom shock absorber M10x1.25 45 Nm (33.2 lbf ft) –
Fitting, handlebar support M10x1.25 21 Nm (15.5 lbf ft) –
Nut, mirror, right M10LHx1.25 16 Nm (11.8 lbf ft) –
Nut, turn signal M10x1.25 6 Nm (4.4 lbf ft) –
Screw, front footrest bracket M10x1.25 47 Nm (34.7 lbf ft) Loctite®243™
Screw, front footrest bracket / engine
bearer
M10x1.25 47 Nm (34.7 lbf ft) –
Screw, side stand bracket M10x1.25 25 Nm (18.4 lbf ft) Loctite®243™
Screw, top shock absorber M10x1.25 51 Nm (37.6 lbf ft) Loctite®243™
Stud, rear sprocket M10x1.25 50 Nm (36.9 lbf ft) –
Nut, rear wheel spindle M14x1.5 90 Nm (66.4 lbf ft) –
Nut, swingarm pivot M14x1.5 100 Nm (73.8 lbf ft) –
Screw, top steering head M16x1.5 53 Nm (39.1 lbf ft) Loctite®243™
Lambda sensor M18x1.5 19 Nm (14 lbf ft) –

4 TECHNICAL DATA 13
Swingarm bearing adjusting ring M22x1 Tighten and ensure that
there is no play
–
Nut, steering head M30x1 Step 1
55 Nm (40.6 lbf ft)
2nd stage (loosen, counter-
clockwise)
2 turns
Step 3
5 Nm (3.7 lbf ft)
–

5 SUBSTANCES 14
Gasohol 95 E20 (RON 95)
Standard/classification
–Gasohol 95 E20 (RON 95)
Guideline
–Only use super unleaded fuel that matches or is equivalent to the specifications.
–Super unleaded fuel with an ethanol content of 19 to 20% is permissible.
Info
Do not use fuel made of methanol (e. g. M15, M85, M100).
Do not use fuel with less than 19% ethanol (e. g. E10).
Do not use fuel with more than 20% ethanol (e. g. E30, E85, E100).
Super unleaded (ROZ 95/RON 95/PON 91)
Standard/classification
–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.
Info
Do not use fuel containing methanol (e. g. M15, M85, M100) or more than 10 % ethanol (e. g. E15, E25, E85, E100).
Super unleaded, type C (ROZ 95/RON 95/PON 91)
Standard/classification
–Beschluss Nr. 57 der ANP (Agência Nacional do Petróleo) (ROZ 95/RON 95/PON 91)
Guideline
–Only use super unleaded fuel that matches or is equivalent to the following specifications.
–Super unleaded fuel with an ethanol content of 19 to 27 % is permissible.
Info
Do not use fuel made of methanol (e. g. M15, M85, M100).
Do not use fuel with less than 19 % ethanol (e. g. E10).
Do not use fuel with more than 27 % ethanol (e. g. E30, E85, E100).

*3213457en*
3213457en
07/2016
KTM Sportmotorcycle GmbH
5230 Mattighofen/Austria
http://www.ktm.com
Photo: Mitterbauer/KTM