KTM 125 Duke EU 2012 Manual

SETUP INSTRUCTIONS 2012
125 Duke EU
125 Duke DE
200 Duke EU
Art. no. 3211886en

INTRODUCTION 1
INTRODUCTION
The work described in these setup instructions must be performed before the vehicle is delivered to the customer.
Read the setup instructions in their entirety before beginning work.
Print out the current PDI form found on the KTM DEALER.NET.
These setup instructions were written to correspond to the latest state of this series. We reserve the right to make changes in the inter-
est of technical advancement without at the same time updating this manual.
We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop are not specified here.
It is assumed that the work will be performed by a fully trained mechanic.
All specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifica-
tions, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt
these to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery
options, deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain spe-
cial equipment that does not belong to the regular scope of delivery.
© 2012 KTM-Sportmotorcycle AG, 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 AG
5230 Mattighofen, Austria

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

2 SETUP 3
2.1 Unpacking and setting up the vehicle
B00911-01
–Remove the box and the plastic packaging.
Info
To avoid damaging the motorcycle during the setup, leave the protective
film on the vehicle until you have finished.
–Check the vehicle for transport damage.
–Unpack the separate enclosure and check its contents on the basis of the enclosure
list.
B00912-01
–Position the handlebar.
The lettering on the handlebar should be situated in the middle of the handle-
bar clamp.
–Position the handlebar clamps. Mount the four screws and tighten evenly.
Guideline
Screw, handlebar clamp M8 21 Nm
(15.5 lbf ft)
B00913-01
–Mount and tighten the rear mirror on both sides.
–Position all controls in their exact positions on the handlebar. Tighten all screws.
700217-01
–Mount the reflector.
–Remove the protective plastic.
–Carefully loosen and remove the tensioning belt over the swingarm.
Info
An assistant prevents the motorcycle from falling over.
–Carefully loosen and remove the tensioning belts around the lower triple clamp.
The vehicle is released at the front.
–Take the vehicle off the pallet.
Warning
Risk of injury Battery acid and battery gases cause serious chemical burns.
–Keep batteries out of the reach of children.
–Wear suitable protective clothing and goggles.
–Avoid contact with battery acid and battery gases.
–Keep 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 con-
tact a physician.
–Fill the battery.
Info
Read the notes in the battery package.
–Recharge the battery. ( p. 6)
–Install the battery. ( p. 7)
–Refuel. ( p. 9)

2 SETUP 4
–Print out the current PDI form found on KTM DEALER.NET and perform the delivery
inspection.
–Set kilometers or miles. ( p. 9)
–Set the clock. ( p. 9)

3 WORK 5
3.1 Removing the passenger seat
B00712-01
–Insert the ignition key in seat lock 1and turn it clockwise.
–Raise the rear of the seat, push it towards the rear, and remove it upwards.
–Remove the ignition key from the seat lock.
3.2 Mounting the passenger seat
B00724-10
–Attach hooks 1on the passenger seat to brackets 2on the subframe, and lower it
at the rear while pushing forward.
–Press down the passenger seat until it clicks into place.
Warning
Danger of accidents The passenger seat can come loose from the anchoring
if it is not mounted correctly.
–After mounting the passenger seat, check that it is locked correctly by
pulling up.
–Finally, check that the passenger seat is correctly mounted.
3.3 Removing the seat
Preparatory work
–Remove the passenger seat. ( p. 5)
B00725-10
Main work
–Remove screws 1.
–Raise the rear of the seat, pull it towards the rear, and remove it upwards.
3.4 Mounting the seat
B00727-10
Main work
–Attach seat recesses Aat screws 1and lower at the rear.
–Mount and tighten screws 2.
Guideline
Screw, seat M6 11 Nm (8.1 lbf ft)

3 WORK 6
Finishing work
–Mount the passenger seat. ( p. 5)
3.5 Removing the battery
Warning
Risk of injury Battery acid and battery gases cause serious chemical burns.
–Keep batteries out of the reach of children.
–Wear suitable protective clothing and goggles.
–Avoid contact with battery acid and battery gases.
–Keep 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. 5)
–Remove the seat. ( p. 5)
B00750-10
Main work
–Pull back the negative terminal cover 1.
–Disconnect the negative cable 2of the battery.
B00751-10
–Pull back the positive terminal cover 3.
–Disconnect the positive cable 4of the battery.
–Detach rubber band 5.
–Pull the battery up and out of the battery rack.
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 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.
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.

3 WORK 7
Info
Even when there is no load on the battery, it still loses power steadily.
The charge state and the type of charge are very important for the service life of the battery.
Rapid recharging with a high charging current shortens the battery's service life.
If the charging current, charging voltage, and charging time are exceeded, electrolyte escapes through the safety valves. This
reduces the battery capacity.
If the battery is depleted from starting the vehicle repeatedly, the battery must be charged immediately.
If the battery is left in a discharged state for an extended period, it will become over-discharged and sulfate, destroying the
battery.
The battery is maintenance-free, which means that the acid level does not need to be checked.
Preparatory work
–Switch off all power consumers and switch off the engine.
–Remove the passenger seat. ( p. 5)
–Remove the seat. ( p. 5)
–Disconnect the negative cable of the battery to avoid damage to the motorcycle's
electronics.
B00752-10
Main work
–Connect the battery charger to the battery. Switch on the battery charger.
Battery charger (58429074000)
You can also use the battery charger to test rest potential and start potential of the
battery, and to test the alternator. With this device, you cannot overcharge the bat-
tery.
Info
Never remove lid 1.
Charge the battery with a maximum of 10% of the capacity specified on
battery housing 2.
–Switch off the charger after charging. Disconnect the battery.
Guideline
The charge current, charge voltage and charge time must not be exceeded.
Charge the battery regularly when the
motorcycle is not in use
3 months
Finishing work
–Mount the seat. ( p. 5)
–Mount the passenger seat. ( p. 5)
–Set the clock. ( p. 9)
3.7 Installing the battery
B00751-11
Main work
–Position the battery in the battery rack.
Info
The battery terminals must be at the top.
–Attach rubber band 1.
–Reconnect the positive cable 2of the battery.
–Position positive terminal cover 3.

3 WORK 8
B00750-11
–Connect the negative cable 4of the battery.
–Position the negative terminal cover 5.
Finishing work
–Mount the seat. ( p. 5)
–Mount the passenger seat. ( p. 5)
–Set the clock. ( p. 9)
3.8 Opening the filler cap
Danger
Fire hazard Fuel is highly flammable.
–Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no
fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
–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 between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immedi-
ately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, con-
tact a doctor 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.
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
–Do not allow fuel to get into the ground water, the ground, or the sewage system.
B00710-10
–Lift the cover 1of the filler cap and insert the ignition key in the lock.
Note
Danger of damage Ignition key breakage.
–To take pressure off of the ignition key, push down on the filler cap. Damaged
ignition keys must be replaced.
–Turn the ignition key 90° clockwise.
–Open the filler cap.
–Remove the ignition key.
3.9 Closing the filler cap
B00711-01
Warning
Fire hazard Fuel is highly flammable, poisonous and harmful to your
health.
–When closing the filler cap, ensure that it is closed correctly. Change
clothing 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.

3 WORK 9
3.10 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 imme-
diately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed,
contact a doctor immediately. Change clothing that has come into contact with fuel.
Note
Material damage Premature clogging of the fuel filter.
–In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with
the fuel system.
–Only refuel 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 get into the ground water, the ground, 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 1of the fuel filler.
Total fuel tank
capacity, approx.
10.5 l
(2.77 US gal)
Super unleaded (ROZ 95/RON 95/PON
91) ( p. 13)
–Close the filler cap. ( p. 8)
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.

3 WORK 10
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 - TIGHTENING TORQUES FOR CHASSIS 11
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 4 Nm (3 lbf ft) –
Screw, trim, subframe, bottom M4 2 Nm (1.5 lbf ft) –
Remaining screws, chassis M5 5 Nm (3.7 lbf ft) –
Screw, brake fluid reservoir of rear
brake
M5 6 Nm (4.4 lbf ft) Loctite®243™
Screw, fuel pump M5 5 Nm (3.7 lbf ft) –
Screw, fuel tank closure flange M5 3 Nm (2.2 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) Loctite®243™
Screw, windshield M5 3 Nm (2.2 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 15 Nm (11.1 lbf ft) –
Remaining screws, chassis M6 10 Nm (7.4 lbf ft) –
Screw, air filter box M6 6 Nm (4.4 lbf ft) –
Screw, bottom of rear part M6 11 Nm (8.1 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) Loctite®243™
Screw, compensating tank M6 11 Nm (8.1 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 5 Nm (3.7 lbf ft) –
Screw, fuel tank M6 11 Nm (8.1 lbf ft) –
Screw, headlight holder M6 11 Nm (8.1 lbf ft) –
Screw, headlight mask M6 11 Nm (8.1 lbf ft) –
Screw, ignition coil M6 9 Nm (6.6 lbf ft) –
Screw, license plate holder M6 14 Nm (10.3 lbf ft) –
Screw, magnetic holder on side stand M6 5 Nm (3.7 lbf ft) Loctite®243™
Screw, radiator bracket M6 6 Nm (4.4 lbf ft) –
Screw, radiator holder M6 9 Nm (6.6 lbf ft) –
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 11 Nm (8.1 lbf ft) –
Screw, shift activation M6 11 Nm (8.1 lbf ft) Loctite®243™
Screw, voltage regulator M6 10 Nm (7.4 lbf ft) –
Screw, voltage regulator holder M6 15 Nm (11.1 lbf ft) –
Remaining nuts, chassis M8 30 Nm (22.1 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 frame M8 26 Nm (19.2 lbf ft) –
Screw, foot brake lever M8 15 Nm (11.1 lbf ft) Loctite®243™
Screw, fork stub M8 15 Nm (11.1 lbf ft) –

4 TECHNICAL DATA - TIGHTENING TORQUES FOR CHASSIS 12
Screw, front brake disc M8 29 Nm (21.4 lbf ft) Loctite®243™
Screw, front wheel spindle M8 25 Nm (18.4 lbf ft) –
Screw, handlebar clamp M8 21 Nm (15.5 lbf ft) –
Screw, handrail M8 31 Nm (22.9 lbf ft) –
Screw, horn M8 21 Nm (15.5 lbf ft) –
Screw, rear brake disc M8 29 Nm (21.4 lbf ft) Loctite®243™
Screw, rear footrest bracket M8 26 Nm (19.2 lbf ft) Loctite®243™
Screw, shift lever M8 15 Nm (11.1 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®243™
Nut, mirror M10 16 Nm (11.8 lbf ft) –
Nut, turn signal M10 6 Nm (4.4 lbf ft) –
Remaining nuts, chassis M10 50 Nm (36.9 lbf ft) –
Remaining screws, chassis M10 45 Nm (33.2 lbf ft) –
Screw cap, side stand M10 34 Nm (25.1 lbf ft) –
Screw connection, engine mounting
bracket
M10 46 Nm (33.9 lbf ft) –
Nut, rear sprocket screw M10x1.25 32 Nm (23.6 lbf ft) –
Screw connection, handlebar support M10x1.25 21 Nm (15.5 lbf ft) –
Screw, front footrest bracket M10x1.25 46 Nm (33.9 lbf ft) –
Screw, side stand bracket M10x1.25 25 Nm (18.4 lbf ft) Loctite®243™
Screw, top shock absorber M10x1.25 50 Nm (36.9 lbf ft) –
Nut, rear wheel spindle M14x1.5 60 Nm (44.3 lbf ft) –
Nut, swingarm pivot M14x1.5 98 Nm (72.3 lbf ft) –
Screw, top steering head M16x1.5 52 Nm (38.4 lbf ft) –
Swingarm bearing adjusting ring M22x1 Tighten and ensure that
there is no play
–
Nut, steering head M30x1 Step 1
50 Nm (36.9 lbf ft)
2nd stage (loosen, counter-
clockwise)
2 turns
Step 3
5 Nm (3.7 lbf ft)
–

5 SUBSTANCES 13
Super unleaded (ROZ 95/RON 95/PON 91)
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.
Info
Do not use fuel containing methanol (e. g. M15, M85, M100) or more than 10 % ethanol (e. g. E15, E25, E85, E100).

*3211886en*
3211886en
08/2012
KTM-Sportmotorcycle AG
5230 Mattighofen/Austria
http://www.ktm.com
Photo: Mitterbauer/KTM