KTM 125 200 Duke 2012 2013 Workshop Repair Service Manual

Name: KTM 125 200 Duke 2012 2013 Workshop Repair Service Manual
Brand: Ktm
SKU: 59028
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This manual covers the 125 Duke and 200 Duke models produced for the 2012 and 2013 model years. These lightweight naked sport motorcycles embody a 'Ready to Race' philosophy, offering...

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Typ: Motorcycle

Anbieter:

Ktm

Art.-Nr: 59028

Stichworte: 125 Duke 200 Duke 2012 2013 KTM Misc Motorcycle Motorcycles

Produktvarianten

Beschreibung

This manual covers the 125 Duke and 200 Duke models produced for the 2012 and 2013 model years. These lightweight naked sport motorcycles embody a 'Ready to Race' philosophy, offering agile handling, aggressive styling, and potent performance for their class. Designed for new riders, urban commuters, and enthusiasts seeking an economical yet engaging riding experience, these models feature a steel trellis frame, premium components like ByBre brakes and WP suspension, and a liquid-cooled, DOHC, single-cylinder engine available in 124.7cc and 199.5cc displacements. This comprehensive Workshop Repair Service Manual in English provides essential information for maintaining and repairing your 125 Duke or 200 Duke. It details routine maintenance procedures, including oil changes, filter replacements, and chain adjustments, alongside in-depth troubleshooting guides for common issues. The manual also covers complete engine disassembly and reassembly, fuel system diagnostics, transmission servicing, electrical system repairs with wiring diagrams, and chassis maintenance, including suspension and brake systems. This resource is invaluable for owners and technicians aiming to ensure the optimal performance and longevity of these motorcycles.

🏷️ 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:

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.