This manual covers the 125 Duke and 200 Duke models produced between 1999 and 2003, featuring the robust LC4 engine. These lightweight sport motorcycles are known for their agile handling and aggressive styling, reflecting a performance-oriented heritage. Designed for new riders and urban commuters, the Duke series offers a sporty and responsive riding experience, making them a popular choice in the naked sportbike segment. Their engineering quality and reliability are hallmarks of a commitment to delivering capable and engaging motorcycles. This comprehensive workshop service and repair manual provides essential information for maintaining and servicing your 125 Duke or 200 Duke. It details procedures for engine, transmission, fuel, electrical, chassis, suspension, and brake systems, including routine maintenance, troubleshooting, and complete repair instructions. With technical specifications, diagnostic guidance, and insights into common wear items, this manual is an invaluable resource for owners and technicians alike, ensuring the optimal performance and longevity of your vehicle. 🏷️ Basic Information Identification Make: KTM Model: 125 Duke / 200 Duke Covered Years: 1999, 2000, 2001, 2002, 2003 Codes Engine Code Primary: LC4 (125/200 variants) Chassis Code Primary: Not explicitly stated, typically model specific designations for the Duke series 👋 Introduction Market Position Segment: Lightweight sport motorcycles, often categorized as naked bikes or entry-level performance bikes. Target Audience: New riders, urban commuters, riders seeking agile and sporty performance in a compact package. Competitive Analysis Key Competitors: Yamaha MT-03 (if applicable to the specific market), Kawasaki Z250/Z300 (depending on region/year), Honda CB300R. Key Features Ride Dynamics: Known for sharp handling, agile chassis, and a responsive engine, reflecting KTM's 'Ready to Race' philosophy even in smaller displacements. Design Philosophy: Aggressive, modern styling with exposed trellis frame (typical KTM design language). 📋 Manual Details Coverage Areas Language: English (assumed, standard for international service manuals) Manual Type: Workshop Service Manual / Repair Manual Market Coverage: Likely global, catering to the KTM 125/200 Duke models sold internationally during the specified years. Page Count Page Count: 158 pages Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Comprehensive coverage of LC4 engine assembly, disassembly, inspection, and repair. Includes top-end (cylinder, piston, valves), bottom-end (crankshaft, connecting rod, bearings), lubrication system, cooling system (if applicable to 125/200 variants of that era), and timing. Transmission: Detailed procedures for gearbox inspection, repair, and maintenance. Includes gear selection, clutch operation, and related components. Fuel System: Coverage of carburetor system (likely Keihin or similar for this era), fuel delivery, and related adjustments. Electrical System: Wiring diagrams, component testing (ignition, lighting, starter), troubleshooting guides for electrical faults. Chassis And Suspension: Front fork service and adjustment, rear shock absorber maintenance, wheel bearing inspection, steering head bearing service, swingarm service. Brakes: Front and rear brake system maintenance, including hydraulic system bleeding, pad replacement, caliper service, and rotor inspection. Cooling System: Radiator, fan (if equipped), coolant hoses, and thermostat service. (Note: The 125/200 Duke models of this era might be air-cooled depending on the specific variant; the manual would clarify this.) Procedures Included Maintenance: Regular service checks, oil changes, filter replacements, chain adjustment, spark plug replacement, air filter cleaning/replacement. Troubleshooting: Diagnostic procedures for common performance issues, starting problems, electrical faults, and mechanical malfunctions. Repair: Step-by-step instructions for component disassembly, repair, reassembly, and calibration for all major vehicle systems. Technical Specifications: Torque specifications for critical fasteners, engine clearances, fluid capacities, tire pressures, electrical component specifications. Engine Disassembly Reassembly: Complete step-by-step instructions for engine removal, disassembly, inspection of internal components (piston, rings, valves, crankshaft), and reassembly with torque specifications. Suspension Rebuild: Detailed guide for servicing front forks (oil change, seal replacement) and rear shock absorber maintenance. Electrical Diagnostics: Troubleshooting charts and procedures for ignition system, lighting, starting system, and battery charging system issues, often referencing wiring diagrams. Technical Depth Depth: Comprehensive, covering from routine maintenance to major engine and transmission rebuilds. Suitable for professional mechanics and experienced DIY enthusiasts. Diagnostic Tools: Information may include specifics on required special tools for certain procedures, though often emphasizes standard mechanic tools. 📊 Manual Specifications File Format File Format: PDF Searchable Text: Likely searchable if scanned from an original digital source, but depends on the quality of the PDF. Printable: Yes, standard PDF functionality. Print Quality Resolution: Dependent on original source scan quality. Assumed to be legible for repair purposes. Binding Type Binding: N/A (Digital download) Paper Type Paper Type: N/A (Digital download) ⚙️ Engine Specifications Primary Engine Engine Type: Single-cylinder, 4-stroke, Liquid-cooled (or Air-cooled depending on specific 125/200 variant of the era) LC4 engine. Displacement 125: Approximately 125cc Displacement 200: Approximately 200cc Bore Stroke Approx 125: Specific figures would be in the manual, but typical for this class might be around 54mm bore x 54.5mm stroke. Bore Stroke Approx 200: Specific figures would be in the manual, but typical for this class might be around 65mm bore x 57.2mm stroke. Performance Horsepower 125: Typically in the 15-18...