KTM 125 200 Duke 2012 2013 Workshop Repair Service Manual
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🏷️ Basic Information Identification Make: KTM Model: 125 Duke / 200 Duke Years Covered: 2012, 2013 👋 Introduction Market Position Segment: Lightweight naked sport motorcycles, entry-level performance segment. Target Audience: New riders, urban commuters, and those seeking agile, fun, and economical performance. Competitive Analysis Key Competitors: Yamaha MT-03, Kawasaki Z250/Z300 (depending on market), Suzuki GSX250R. Key Features Brand Philosophy: KTM's 'Ready to Race' philosophy translates to a sporty chassis and potent engine for its class. Design: Aggressive styling, trellis frame, and premium componentry (e.g., ByBre brakes, WP suspension) for its segment. 📋 Manual Details Coverage Areas Manual Type: Workshop Repair Service Manual Language: English Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Complete engine disassembly, assembly, troubleshooting, and overhaul procedures for single-cylinder, liquid-cooled engines. Fuel System: Detailed diagnostics and repair for the fuel injection system (Bosch EFI), throttle body, fuel pump, and fuel filter. Transmission: Coverage of the 6-speed constant mesh gearbox, clutch operation, maintenance, and common issues. Electrical System: Comprehensive wiring diagrams, troubleshooting guides for ignition, lighting, starter system, battery, and ECU. Chassis: Suspension (WP USD front forks, WP monoshock rear), steering, frame, and swingarm inspection and service. Brakes: Front and rear brake system service, including hydraulic lines, calipers (ByBre), discs, and bleeding procedures. Cooling System: Radiator, fan, thermostat, and coolant flow diagnostics and maintenance. Exhaust System: Service and inspection of the exhaust headers and silencer assembly. Bodywork: Panel removal, installation, and basic bodywork repair guidance. Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustment, tire pressure checks, spark plug replacement, and brake fluid checks. Troubleshooting: Diagnostic charts and procedures for common starting issues, engine performance problems, electrical faults, and braking anomalies. Engine Rebuild: Complete step-by-step instructions for engine disassembly, component inspection (piston, rings, cylinder, valves), reassembly, and torque specifications. Suspension Service: Fork seal replacement, oil changes, and shock absorber servicing. Brake System Repair: Bleeding brakes, caliper service, and pad replacement. Electrical Diagnostics: Wiring harness inspection, sensor testing, and fault code interpretation. Technical Depth Depth Level: Comprehensive; covers everything from basic owner maintenance to complete engine and chassis overhauls. Diagnostics: Advanced diagnostic procedures for fuel injection and ignition systems. Component Specs: Detailed specifications for all major components, including tolerances and wear limits. 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text content for quick information retrieval. Print Quality: High-resolution, printable pages suitable for workshop use. 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, DOHC, 4 valves Displacement 125: 124.7 cm³ (7.6 cu in) Displacement 200: 199.5 cm³ (12.2 cu in) Bore X Stroke 125: 54 mm x 54.5 mm (2.13 x 2.15 in) Bore X Stroke 200: 72 mm x 49 mm (2.83 x 1.93 in) Performance Power Output 125 Approx: 15 hp (11 kW) @ 9,500 rpm (varies by market regulations) Power Output 200 Approx: 25 hp (18.4 kW) @ 10,000 rpm Torque 125 Approx: 12 Nm (8.9 lb-ft) @ 8,000 rpm Torque 200 Approx: 19.5 Nm (14.4 lb-ft) @ 8,000 rpm Fuel System Fuel Delivery: Bosch electronic fuel injection (EFI) Fuel Type: Unleaded gasoline, minimum 91 RON Emission Control: Catalytic converter Lubrication Oil Type: API SG/SH/SJ or JASO MA/MA2; SAE 10W/50 🔧 Transmission Standard Transmission Type: 6-speed, constant mesh Optional Optional Transmission: N/A Features Clutch Type: Wet multi-disc clutch, cable-actuated Final Drive: Chain drive Transmission Oil: Refer to manual for specific type and capacity, typically SAE 75W/90 or 10W/40 gear oil. 📐 Dimensions Exterior Length Approx: 1900 - 1930 mm (74.8 - 76.0 in) Width Handlebar Approx: 760 mm (29.9 in) Height Seat Approx: 800 - 830 mm (31.5 - 32.7 in) Wheelbase Approx: 1350 - 1360 mm (53.1 - 53.5 in) Weights Dry Weight 125 Approx: 120.5 kg (265.6 lbs) Dry Weight 200 Approx: 129.5 kg (285.5 lbs) Fuel Tank Capacity: 10.5 liters (2.77 US gal) 🛡️ Safety Features Ratings ABS: Optional or standard depending on market and specific model variant (check local specifications). Active Features Brakes: Disc brakes front and rear with ByBre calipers for strong, reliable stopping power. Passive Features Frame: Steel trellis frame provides a rigid and responsive chassis. 💡 Technology Features Infotainment Instrument Cluster: Digital LCD display with tachometer, speedometer, gear indicator, fuel level, and warning lights. Driver Assistance ABS System: Bosch ABS unit, offering safety during braking. Connectivity Connectivity Features: No advanced connectivity features such as Bluetooth or smartphone integration on these specific model years. 🔧 Maintenance Service Intervals Oil Change Interval: Every 5,000 km (3,100 miles) or annually, whichever comes first. Air Filter Check: Every 5,000 km (3,100 miles) Spark Plug Replacement: Every 10,000 km (6,200 miles) Chain Cleaning Lubrication: Every 1,000 km (620 miles) and after riding in wet conditions. Valve Clearance Check: Every 10,000 km (6,200 miles) Fluid Specifications Engine Oil: API SG/SH/SJ or JASO MA/MA2; SAE 10W/50 Coolant:...
15 hp (11 kW) @ 9,500 rpm (varies by market regulations)
Power Output 200 Approx:
25 hp (18.4 kW) @ 10,000 rpm
Torque 125 Approx:
12 Nm (8.9 lb-ft) @ 8,000 rpm
Torque 200 Approx:
19.5 Nm (14.4 lb-ft) @ 8,000 rpm
Fuel System
Fuel Delivery:
Bosch electronic fuel injection (EFI)
Fuel Type:
Unleaded gasoline, minimum 91 RON
Emission Control:
Catalytic converter
Lubrication
Oil Type:
API SG/SH/SJ or JASO MA/MA2; SAE 10W/50
🔧 Transmission
Standard
Transmission Type:
6-speed, constant mesh
Optional
Optional Transmission:
N/A
Features
Clutch Type:
Wet multi-disc clutch, cable-actuated
Final Drive:
Chain drive
Transmission Oil:
Refer to manual for specific type and capacity, typically SAE 75W/90 or 10W/40 gear oil.
📐 Dimensions
Exterior
Length Approx:
1900 - 1930 mm (74.8 - 76.0 in)
Width Handlebar Approx:
760 mm (29.9 in)
Height Seat Approx:
800 - 830 mm (31.5 - 32.7 in)
Wheelbase Approx:
1350 - 1360 mm (53.1 - 53.5 in)
Weights
Dry Weight 125 Approx:
120.5 kg (265.6 lbs)
Dry Weight 200 Approx:
129.5 kg (285.5 lbs)
Fuel Tank Capacity:
10.5 liters (2.77 US gal)
🛡️ Safety Features
Ratings
ABS:
Optional or standard depending on market and specific model variant (check local specifications).
Active Features
Brakes:
Disc brakes front and rear with ByBre calipers for strong, reliable stopping power.
Passive Features
Frame:
Steel trellis frame provides a rigid and responsive chassis.
💡 Technology Features
Infotainment
Instrument Cluster:
Digital LCD display with tachometer, speedometer, gear indicator, fuel level, and warning lights.
Driver Assistance
ABS System:
Bosch ABS unit, offering safety during braking.
Connectivity
Connectivity Features:
No advanced connectivity features such as Bluetooth or smartphone integration on these specific model years.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 km (3,100 miles) or annually, whichever comes first.
Air Filter Check:
Every 5,000 km (3,100 miles)
Spark Plug Replacement:
Every 10,000 km (6,200 miles)
Chain Cleaning Lubrication:
Every 1,000 km (620 miles) and after riding in wet conditions.
Valve Clearance Check:
Every 10,000 km (6,200 miles)
Fluid Specifications
Engine Oil:
API SG/SH/SJ or JASO MA/MA2; SAE 10W/50
Coolant:
Mixture of distilled water and antifreeze (e.g., Motorex M3.0 or equivalent), typically a 50/50 mix.
Brake Fluid:
DOT 4
Known Issues
Common Faults:
Some owners have reported occasional electrical gremlins, minor leaks from engine seals under high mileage, and chain wear if not maintained diligently.
Common Issues
Diagnostic Assistance:
The manual provides detailed troubleshooting steps to identify and resolve potential issues.
📚 Vehicle History
Brand Heritage
Brand Origin:
KTM is an Austrian manufacturer known for its off-road prowess and aggressive performance motorcycles.
Model Evolution
Duke Lineup:
The Duke line represents KTM's street-focused naked motorcycles, characterized by their sharp styling and dynamic handling.
125 200 Introduction:
The 125 and 200 Duke models were introduced to cater to emerging markets and entry-level riders seeking KTM's DNA in a more accessible package.
Production
Manufacturing Location:
Primarily manufactured in India through a partnership with Bajaj Auto.
🏆 Awards & Recognition
Recognitions
Awards History:
While specific awards for these models may be limited, KTM models are consistently recognized for their performance and handling in their respective segments by motorcycle publications.
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