KTM 125 DUKE EU Manual

SETUP INSTRUCTIONS 2021
125 DUKE
Art. no. 3214431en

INTRODUCTION
*3214431en*
3214431en
01/2021
INTRODUCTION
Perform the work described in these setup instructions before the vehicle is delivered to the customer.
Read the setup instructions in their entirety before beginning work.
All specifications contained herein 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 produc-
tion of a particular model without prior notice. KTM accepts no liability for delivery options, deviations from fig-
ures and descriptions, misprints, and other errors. The models portrayed partly contain special equipment that
does not belong to the regular scope of supply.
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.
© 2021 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)
KTM applies quality assurance processes that lead to the highest possible product quality as
defined in the ISO 9001 international quality management standard.
Issued by: TÜV Management Service
KTM Sportmotorcycle GmbH
Stallhofnerstraße 3
5230 Mattighofen, Austria
This document is valid for the following models:
125 DUKE EU (F4003U1, F4003U2)
125 DUKE B.D. EU (F4003U3, F4003U4)

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.
Indicates a voltage measurement.
Indicates a current measurement.
Indicates a resistance measurement.
Indicates the end of an activity including potential rework.
1.2 Formats used
The typographical formats used in this document are explained below.
Proprietary name Indicates a proprietary name.
Name®Indicates a protected name.
Brand™ Indicates a brand available on the open market.
Underlined terms Refer to technical details of the vehicle or indicate technical terms, which
are explained in the glossary.

SETUP 2
3
2.1 Unpacking and setting up the vehicle
A00034-10
–Remove the straps and the box.
A00035-10
–Remove the adhesive tape in the upper area of the motorcycle.
A00038-10
–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 fin-
ished work on the vehicle.
–Remove the separate enclosure and unpack it. Check the sepa-
rate enclosure for completeness.
–Check the vehicle for transport damage.
A00037-10
Warning
Danger of accidents A repaired handlebar poses a
safety risk.
If the handlebar is bent or straightened, the mate-
rial becomes fatigued. The handlebar may break as a
result.
–Change the handlebar if the handlebar is damaged
or bent.
–Position the handlebar.
Info
Make sure the cables and wiring are positioned cor-
rectly.
–Position the handlebar clamp. Mount and tighten the screws
evenly.
Guideline
Screw, handle-
bar clamp
M8 20 Nm (14.8 lbf ft)
Loctite®243™

2 SETUP
4
The lettering on the handlebar is in the middle of the han-
dlebar clamp.
A00036-10
–Position all controls in their exact positions on the handlebar.
Tighten all screws.
H03807-10
–Make sure that the clutch cable is attached to the clutch
release lever and secured.
–Check the clutch lever play. ( p. 6)
–Check the play in the throttle cable. ( p. 7)
–Mount and tighten the rear mirror on both sides.
F01045-10
–Mount rear reflector 1with spring washers 2on holding
plate 3.
–Mount the retaining plate on the license plate holder.
–Mount the license plate holder.
–Carefully loosen and remove the tension belt over the link fork.
Info
An assistant prevents the motorcycle from falling over.
–Carefully loosen and remove the tension belts around the lower
triple clamp.
The vehicle is released at the front.
–Together with an assistant, take the vehicle off the pallet.
–Remove the passenger seat. ( p. 7)
E01183-01
–Take tool set out of the separate enclosure and fasten onto the
bottom of the passenger seat using the rubber straps provided
in the tool set.
–Remove the front rider's seat. ( p. 8)
–Remove spare key and KEYCODECARD from under the seat and
keep in a safe place for the handover.

SETUP 2
5
Warning
Risk of injury Battery acid and battery gases cause
serious chemical burns.
–Keep 12 V batteries out of the reach of children.
–Wear suitable protective clothing and safety
glasses.
–Avoid contact with battery acid and battery gases.
–Keep sparks or open flames away from the 12 V
battery.
–Only charge 12 V batteries in well-ventilated
rooms.
–Rinse the affected area immediately with plenty of
water in the event of contact with the skin.
–Rinse eyes with water for at least 15 minutes and
consult a doctor immediately if battery acid and
battery gases get into the eyes.
–Fill the 12 V battery.
Info
Read the notes in the 12 V battery accessory pack.
–Charge the 12-V battery. ( p. 9)
–Install the 12-V battery. ( p. 11)
–Remove the remaining film, padding, the corrugated card-
board, and the other packaging material.
–Refuel. ( p. 13)
–Check the headlight setting. ( p. 14)
–Prepare the vehicle according to the specifications in
the KTM Dealer.net for handover to the customer.

3 WORK
6
3.1 Checking the clutch lever play
Note
Clutch damage If there is no free travel by the clutch lever, the clutch will begin to slip.
–Check the free travel of the clutch lever each time before using the motorcycle.
–Adjust the free travel of the clutch lever when necessary in accordance with the specification.
F00767-10
–Check the clutch lever for smooth operation.
–Move the handlebar to the straight-ahead position.
–Pull the clutch lever until resistance is perceptible, and deter-
mine the play in the clutch lever A.
Clutch lever play A1 … 3 mm (0.04 …
0.12 in)
» If the clutch lever play does not meet the specified value:
–Adjust play in the clutch lever. ( p. 6)
–Move the handlebar to and fro over the entire steering range.
The clutch lever play must not change.
» If the clutch lever play changes:
–Check the routing of the clutch cable.
3.2 Adjusting play in the clutch lever
F00768-10
–Move the handlebar to the straight-ahead position.
–Push back sleeve 1.
–Loosen lock nut 2.
–Adjust the play in the clutch level Aby turning adjusting
screw 3.
Guideline
Clutch lever play A1 … 3 mm (0.04 …
0.12 in)
–Tighten lock nut 2.
–Position bellows 1.

WORK 3
7
3.3 Checking the play in the throttle cable
400192-11
–Check the throttle grip for smooth operation.
–Move the handlebar to the straight-ahead position. Turn the
throttle grip back and forth slightly and determine the play in
throttle cable A.
Throttle cable play A3 … 5 mm (0.12 … 0.2 in)
» If the throttle cable play does not meet the specified value:
–Adjust the play in the throttle cable. ( p. 7)
Danger
Danger of poisoning Exhaust gases are toxic and inhal-
ing them may result in unconsciousness and death.
–Always make sure there is sufficient ventilation
when running the engine.
–Use effective exhaust extraction when starting or
running the engine in an enclosed space.
–Start the engine and let it run at idle speed. Move the handle-
bar to and fro over the entire steering range.
The idle speed must not change.
» If the idle speed changes:
–Check the throttle cable routing.
3.4 Adjusting the play in the throttle cable
F00773-10
–Move the handlebar to the straight-ahead position.
–Push back sleeve 1.
–Loosen lock nut 2.
–Adjust the play in the throttle cable by turning barrel
adjuster 3.
Guideline
Play in throttle cable 3 … 5 mm (0.12 … 0.2 in)
–Tighten lock nut 2.
–Slide on sleeve 1.
3.5 Removing the passenger seat
H01991-10
–Insert the ignition key in seat lock 1and turn it clockwise.
–Raise the rear of the seat, push it towards the rear, and lift it
off.
–Remove the ignition key from the seat lock.

3 WORK
8
3.6 Mounting the passenger seat
H01992-01
–Attach hooks 1on the passenger seat to seat mounting 2
on the subframe, and lower it at the rear while pushing for-
ward.
–Press the passenger seat downward until it clicks into place.
Warning
Danger of accidents The seat can come loose from the
anchoring if it is not mounted correctly.
–After assembly, check whether the seat is correctly
locked and cannot be pulled up.
–Finally, check that the passenger seat is correctly mounted.
3.7 Removing the front rider's seat
Preparatory work
–Remove the passenger seat. ( p. 7)
H01993-01
Main work
–Raise the rear of the front rider's seat, pull it towards the rear,
and remove it upwards.
3.8 Mounting the front rider's seat
H01994-01
Main work
–Attach the front rider's seat in area Aand lower at the rear.
–Finally, check that the front rider's seat is correctly mounted.
Finishing work
–Mount the passenger seat. ( p. 8)