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KTM Duke 200 2012 Workshop Service Manual for Repair

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🏷️ Basic Information Identification Make: KTM Model: Duke 200 Year: 2012 Generation Generation Designation: First Generation (2011-2017) Codes Chassis Code: 200 Duke 👋 Introduction Market Position Segment: Lightweight naked sportbike,...

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Mots clés: 2012 Duke 200 KTM Misc Motorcycle Motorcycles

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Description

🏷️ Basic Information

Identification

Make:

KTM

Model:

Duke 200

Year:

2012

Generation

Generation Designation:

First Generation (2011-2017)

Codes

Chassis Code:

200 Duke

👋 Introduction

Market Position

Segment:

Lightweight naked sportbike, entry-level performance motorcycle.

Competitive Analysis

Competitors:

Honda CB250F, Yamaha FZ25, Bajaj Pulsar NS200, Suzuki Gixxer 250.

Key Features

Unique Selling Points:

Aggressive styling, premium components (WP suspension), lightweight chassis, strong performance for its class, rider-focused ergonomics.

📋 Manual Details

Coverage Areas

Vehicle Coverage:

KTM Duke 200 (2012 Model Year)

Page Count

Page Count:

264

Manual Type

Manual Type:

Workshop Service Manual

Language

Language:

English

Format

Format:

PDF

📖 Manual Coverage

Systems Covered

Powertrain:

Engine, Fuel System, Ignition System, Cooling System, Exhaust System, Transmission

Chassis:

Frame, Suspension (Front & Rear), Steering, Wheels, Tires, Brakes (Front & Rear)

Electrical:

Battery, Charging System, Lighting, Ignition, Instruments, Sensors, ECU, Wiring Diagrams

Bodywork:

Fairings, Seat, Handlebars, Footpegs, Body Panels

Procedures Included

Maintenance:

Scheduled Maintenance (Oil Changes, Filter Replacements, Spark Plug Checks, Chain Adjustments)

Repair:

Engine Overhaul, Transmission Repair, Suspension Rebuild, Brake System Service, Electrical Component Replacement

Troubleshooting:

Diagnostic procedures for common issues, fault finding, error codes

Technical Depth

Depth:

Comprehensive, covering basic maintenance to full engine and transmission rebuilds. Includes detailed specifications and diagnostic procedures.

📊 Manual Specifications

File Format

PDF Quality:

High resolution, clear text and diagrams, printable.

Print Quality

Print Readability:

Designed for clear printing with easily legible text and diagrams.

Binding Type

Binding Type:

N/A (Digital PDF Download)

Paper Type

Paper Type:

N/A (Digital PDF Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Single-cylinder, 4-stroke, liquid-cooled

Displacement:

199.5 cc

Bore X Stroke:

65.5 mm x 58.8 mm

Compression Ratio:

11.5:1

Performance

Horsepower:

25 HP (approx. at 9,500 rpm)

Torque:

19 Nm (approx. at 8,000 rpm)

Fuel System

Fuel Delivery:

Bosch electronic fuel injection (EFI)

Fuel Type:

Unleaded Petrol (Octane rating 91 or higher recommended)

Cooling System

Cooling Method:

Liquid Cooling

Ignition System

Ignition Type:

Digital CDI with electronic ignition advance

Lubrication System

Oil Type:

SAE 10W-50 or SAE 15W-50, API SG, JASO MA

Engine Management

ECU Type:

Engine Control Unit (ECU) with diagnostic capabilities

🔧 Transmission

Standard

Transmission Type:

6-speed, claw-shifted, constant mesh

Clutch Type:

Wet multi-disc clutch, hydraulically actuated

Features

Final Drive:

X-ring chain 5/8 x 1/4"

📐 Dimensions

Exterior

Length:

1970 mm

Width Handlebar:

760 mm

Height Seat Max:

1075 mm

Seat Height:

800 mm

Wheelbase:

1357 mm

Ground Clearance:

157 mm

Weights

Dry Weight:

125 kg

Kerb Weight:

137 kg

Max Gross Weight:

290 kg

Cargo

Fuel Tank Capacity:

11 Liters

🛡️ Safety Features

Ratings

ABS:

Optional (may vary by market, but generally not standard on this model year)

Active Features

Brakes Front:

Disc brake with four-piston radial fixed caliper, brake disc, floating

Brakes Rear:

Disc brake with one-piston fixed caliper, brake disc

Suspension Front:

WP APEX USD forks, 43 mm

Suspension Rear:

WP APEX monoshock absorber with linkage system

Passive Features

Lighting:

Halogen Headlight, LED Tail Light

💡 Technology Features

Infotainment

Instrument Cluster:

Digital LCD display with speedometer, tachometer, fuel gauge, gear indicator, trip meters, clock, and warning lights.

Driver Assistance

ABS:

As mentioned, typically optional or not available for the 2012 model. If equipped, it would be a Bosch ABS system.

Connectivity

Connectivity Features:

None (No Bluetooth or smartphone integration on this model year).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000 km or 6 months, whichever comes first.

Air Filter Check:

Every 5,000 km, clean or replace as needed.

Spark Plug Check:

Every 10,000 km, check gap and replace if necessary.

Chain Maintenance:

Clean and lubricate every 500 km, check and adjust tension regularly.

Fluid Specifications

Coolant Type:

Ethylene glycol-based coolant with corrosion inhibitors (e.g., Motorex Coolant M3.0 or equivalent)

Brake Fluid:

DOT 4

Fork Oil Type:

WP recommends specific suspension fluid (check manual for exact viscosity, often 4W or 5W)

Engine Oil Capacity:

1.1 Liters (without filter change), 1.2 Liters (with filter change)

Known Issues

Common Problems:

Overheating in heavy traffic (typical for this class), occasional electrical gremlins, chain wear can be rapid if not maintained.

Recall Information:

Refer to official KTM service bulletins or national vehicle safety databases for any applicable recalls for the 2012 model year.

📚 Vehicle History

Brand Heritage

Heritage Focus:

KTM has a strong heritage in off-road racing, translating to a performance-oriented and lightweight design philosophy in its street bikes.

Model Evolution

Introduction Year:

The Duke 200 was introduced in 2011 as part of KTM's expansion into smaller displacement segments, particularly for emerging markets.

Production

Manufacturing Location:

Primarily manufactured in India by Bajaj Auto Limited under license from KTM.

🏆 Awards & Recognition

Recognitions

Industry Acclaim:

While specific awards for the 2012 Duke 200 may be difficult to pinpoint, the Duke line consistently receives praise for its sharp handling, accessible performance, and 'Ready to Race' ethos.