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KTM Duke 200 2014 Workshop Service Manual for Repair

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🏷️ Basic Information Identification Make: KTM Model: Duke 200 Year: 2014 Market Segment: Lightweight Naked Sportbike Codes Vin Decoder Base Year: 2014 Vin Decoder Manufacturer Code: KTM (WKG) 👋 Introduction...

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Taper: Motorcycle

Distributeur:

UGS: 80981

Mots clés: 2014 Duke 200 KTM Misc Motorcycle Motorcycles

Variantes de produits

Description

🏷️ Basic Information

Identification

Make:

KTM

Model:

Duke 200

Year:

2014

Market Segment:

Lightweight Naked Sportbike

Codes

Vin Decoder Base Year:

2014

Vin Decoder Manufacturer Code:

KTM (WKG)

👋 Introduction

Market Position

Vehicle Class:

Entry-level sport naked motorcycle

Target Audience:

New riders, urban commuters, performance-oriented learners

Competitive Analysis

Key Competitors:

Yamaha MT-03, Kawasaki Z250, Honda CB300R (depending on market)

Key Features

Engine Type:

Liquid-cooled, single-cylinder, four-stroke

Suspension Brand:

WP Suspension

Braking System:

High-quality ByBre (By Brembo) components

Design Philosophy:

Sharp, aggressive styling with a focus on agility and rider engagement

📋 Manual Details

Coverage Areas

Manual Type:

Workshop Service Manual

Language:

English

Format:

PDF Download

Page Count

Total Pages:

285

Typical Page Resolution:

High (suitable for printing)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete overhaul, disassembly, assembly, component inspection, torque specifications

Fuel System:

Fuel injection system (EFI), throttle body, fuel pump, injectors, pressure regulator, diagnostic troubleshooting

Cooling System:

Radiator, fan, water pump, coolant flow, bleeding procedures

Ignition System:

ECU, ignition coils, spark plugs, timing

Exhaust System:

Catalytic converter, mufflers, lambda sensor (O2 sensor)

Transmission:

Clutch operation, gear shifting mechanism, lubrication

Chassis Frame:

Frame inspection, mounting points, subframe

Suspension Front:

WP upside-down fork service, oil change, seal replacement, spring preload adjustment (if applicable)

Suspension Rear:

WP monoshock absorber service, linkage lubrication, pre-load adjustment

Brakes Front:

Brake caliper service, pad replacement, disc inspection, hydraulic system bleeding, master cylinder

Brakes Rear:

Brake caliper service, pad replacement, disc inspection, hydraulic system bleeding, master cylinder

Wheels Tires:

Wheel bearing inspection, tire pressure, rim specifications

Electrical System:

Battery, charging system (stator, regulator/rectifier), starter motor, lighting, wiring diagrams

Instrumentation Controls:

Dashboard, switches, levers, throttle cable adjustment

Bodywork Trim:

Fairings, seat, tank cover removal and installation

Diagnostic Troubleshooting:

Fault finding procedures, error codes (if applicable), component testing

Procedures Included

Scheduled Maintenance:

Oil changes, filter replacements, chain adjustment, valve clearance checks

Repair Procedures:

Step-by-step instructions for component removal, installation, and repair

Overhaul Rebuild:

Detailed instructions for complete engine and component rebuilds

Troubleshooting Guides:

Systematic approaches to identify and resolve common problems

Diagnostic Charts:

Flowcharts and tables for diagnosing electrical and mechanical faults

Wiring Diagrams:

Complete electrical schematics for all systems

Technical Depth

Depth Level:

Comprehensive (suitable for professional technicians and advanced DIY mechanics)

Detail Level:

Highly detailed, including diagrams, illustrations, and torque specifications

📊 Manual Specifications

File Format

Format:

PDF

Searchable:

Likely searchable (depending on PDF creation)

Print Quality

Printability:

High (designed for printing essential sections)

Binding Type

Binding Type Digital:

N/A (Digital Download)

Paper Type

Paper Type Digital:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Code:

Likely variant of KTM's 199.5cc single-cylinder (e.g., LC4 variant, though simpler)

Displacement:

199.5 cc

Bore X Stroke:

63.5 mm x 62.4 mm

Compression Ratio:

12.3:1

Valve Train:

DOHC, 4 valves per cylinder

Performance

Horsepower:

Approximately 25 PS (18.4 kW) at 9000 rpm

Torque:

Approximately 19 Nm at 7250 rpm

Fuel System

Fuel Delivery:

Bosch electronic fuel injection (EFI)

Fuel Type:

Unleaded Petrol (Gasoline)

Fuel Tank Capacity:

11 Liters (2.9 US gal)

Engine Oil

Oil Capacity With Filter:

Approximately 1.1 Liters (1.16 US qt)

Recommended Oil Viscosity:

Motorex Power Synt 4T 15W-50 (or equivalent JASO MA / API SG specification)

🔧 Transmission

Standard

Transmission Type:

6-speed manual

Optional

Optional Gearbox:

N/A

Features

Clutch Type:

Wet multi-disc clutch (Mechanically operated)

Final Drive:

Chain

Transmission Oil

Transmission Oil Type:

N/A (Lubricated by engine oil)

📐 Dimensions

Exterior

Length:

Approximately 1970 mm

Width:

Approximately 800 mm (Handlebar width)

Height:

Approximately 1060 mm (seat height)

Seat Height:

Approximately 800 mm

Ground Clearance:

Approximately 170 mm

Weights

Dry Weight:

Approximately 135 kg

Curb Weight:

Approximately 145 kg (fully fueled)

Wheels Tires

Front Tire Size:

110/70-17

Rear Tire Size:

150/60-17

Wheel Bolt Pattern:

N/A (Spoked wheels with axle mounting)

Dimensions

Wheelbase:

Approximately 1367 mm

🛡️ Safety Features

Ratings

ABS Availability:

Optional (check specific model/market)

Active Features

Braking System Front:

Single disc brake with ByBre four-piston radial caliper

Braking System Rear:

Single disc brake with ByBre single-piston caliper

Suspension Type Front:

WP 43mm Upside-Down (USD) fork

Suspension Type Rear:

WP Monoshock with linkage

Passive Features

Lighting Type:

Halogen headlight, LED taillight

Frame Construction:

Steel Trellis Frame

💡 Technology Features

Infotainment

Display Type:

Digital LCD Instrument Cluster

Features Display:

Speedometer, tachometer, gear indicator, fuel gauge, odometer, trip meters, clock, service reminder

Driver Assistance

Traction Control:

N/A

Ride Modes:

N/A

Connectivity

Bluetooth:

N/A

Lighting

Headlight Technology:

Halogen

Taillight Technology:

LED

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000 km or 6 months (whichever comes first)

Oil Filter Replacement Interval:

Concurrent with oil changes

Air Filter Cleaning Interval:

Every 5,000 km (cleaning), replacement as needed

Spark Plug Replacement Interval:

Every 10,000 - 15,000 km (refer to manual for exact type and gap)

Valve Clearance Check Interval:

Every 10,000 km

Chain Lubrication Interval:

Every 500 km or after riding in rain/wet conditions

Chain Adjustment Interval:

Every 1,000 km

Fluid Specifications

Coolant Type:

Ethylene glycol based coolant with anti-corrosion additives (e.g., Motul Motocool Expert or equivalent)

Brake Fluid Type:

DOT 4

Fork Oil Type:

WP Suspension Fork Oil (e.g., WP Suspension Fluid 5W)

Known Issues

Common Wear Items:

Clutch plates, brake pads, chain and sprockets, fork seals

Potential Electrical Issues:

Loose connections, stator/regulator issues (less common than on larger models but possible)

Engine Performance Notes:

Can run slightly lean from factory, potential for exhaust modifications to improve breathing

Parts Catalog Reference

Part Number Oil Filter:

Refer to manual for specific KTM part number for 2014 Duke 200 (e.g., 77238005000)

Part Number Air Filter:

Refer to manual for specific KTM part number for 2014 Duke 200 (e.g., 90106015000)

📚 Vehicle History

Brand Heritage

Brand Origin:

Austria

Motorsport Focus:

Strong heritage in off-road and track racing

Model Evolution

Duke Lineage:

Part of KTM's highly successful Duke naked bike series, known for performance and handling

Duke 200 Introduction:

Launched globally as an accessible entry point into the Duke family, often manufactured in India by Bajaj Auto for various markets.

Production

Manufacturing Location:

Primarily India (under partnership with Bajaj Auto) for many global markets, though Austria is KTM's home base.

Production Period For Model Year:

Typically late 2013 to late 2014 for the 2014 model year.

🏆 Awards & Recognition

Recognitions

Award Category:

N/A specifically for the 2014 model year, but generally praised for performance and handling in its segment.

Ratings

Segment Performance Rating:

High (for its class, often cited as a benchmark for lightweight sporty motorcycles)

Certifications

Emissions Standard:

Meets Euro 3 or relevant regional emission standards for 2014