Target Audience:
Owners and independent workshops seeking to maintain and repair their KTM Duke 125, 200, or 390 motorcycles.
Value Proposition:
Provides comprehensive, factory-level repair and maintenance information, offering a cost-effective alternative to official dealership service and ensuring correct repair procedures.
Manual Features:
Full factory procedures, detailed illustrations, troubleshooting guides, and extensive technical data essential for accurate servicing.
Engine Management:
Fuel injection system, ignition system, engine control unit (ECU) diagnostics, sensor data, emission control.
Engine Mechanical:
Engine disassembly and assembly, cylinder head, piston, crankshaft, camshafts, valve timing, lubrication system, cooling system.
Transmission Drivetrain:
Clutch operation and adjustment, gearbox disassembly and assembly, gear selection mechanism, final drive (chain and sprockets).
Chassis Suspension:
Frame inspection and repair, front fork (WP Suspension) overhaul and adjustments, rear shock absorber (WP Suspension) overhaul and adjustments, swingarm, steering head bearings.
Brakes:
Front and rear brake system service, hydraulic system bleeding, brake pad replacement, caliper overhaul, master cylinder inspection, ABS system (if equipped).
Electrical System:
Battery maintenance, charging system (alternator, regulator/rectifier), starter motor, lighting system (headlight, taillight, indicators), horn, wiring diagrams, fuse identification and replacement, ECU troubleshooting.
Fuel System:
Fuel tank inspection and cleaning, fuel pump operation, fuel filter replacement, injector cleaning and testing.
Bodywork Trim:
Fairing removal and installation, seat removal, fuel tank cover removal, body panel repairs, decal application.
Routine Maintenance:
Oil and filter change, air filter cleaning/replacement, spark plug inspection/replacement, chain adjustment and lubrication, brake fluid level check, coolant level check, tire pressure checks.
Troubleshooting:
Diagnostic procedures for common starting issues, engine performance problems, electrical faults, braking system issues, and suspension irregularities.
Repair Overhaul:
Detailed step-by-step instructions for engine rebuilds, gearbox repairs, suspension fork servicing, brake system overhauls, and electrical component replacement.
Diagnostics:
Guidance on using diagnostic tools (if applicable to the model year), interpreting error codes, and performing system checks.
Specifications Data:
Torque specifications for all fasteners, fluid capacities, valve clearances, ignition timing (if adjustable), electrical component resistances, and performance data.
Depth Level:
Comprehensive (from basic maintenance to full engine/chassis rebuild)
Diagram Detail:
Hundreds of detailed photos and exploded diagrams
User Level:
Suitable for professional mechanics, technicians, and experienced DIY enthusiasts
Engine Type:
Single-cylinder, 4-stroke
Cooling System:
Liquid-cooled
Bore X Stroke 125:
58 mm x 47.2 mm
Bore X Stroke 200:
65.5 mm x 57.8 mm
Bore X Stroke 390:
89 mm x 60 mm
Displacement 200:
199.5 cc
Displacement 390:
373.2 cc
Horsepower 125:
Approx. 15 hp (11 kW) @ 9,500 rpm
Horsepower 200:
Approx. 25 hp (18.4 kW) @ 10,000 rpm
Horsepower 390:
Approx. 44 hp (32 kW) @ 9,500 rpm
Torque 390:
Approx. 35 Nm (25.8 lb-ft) @ 7,250 rpm
Fuel Delivery:
Electronic Fuel Injection (EFI) by Bosch (ECU controlled)
Ignition System:
Digital ignition with variable ignition timing
Emission Control:
Euro 3 compliant (typical for these years), catalytic converter
Oil Change Interval:
Typically every 5,000 - 7,500 km or annually, whichever comes first (refer to manual for exact intervals).
Air Filter Service:
Inspection every 5,000 km, cleaning/replacement as needed.
Spark Plug Interval:
Inspection/replacement at approximately 10,000 - 15,000 km.
Valve Clearance Check:
Typically at 10,000 - 20,000 km intervals (critical procedure detailed in manual).
Engine Oil Grade:
SAE 10W-50 (or as specified by KTM, often with JASO MA/MA2 certification)
Engine Oil Capacity:
Approx. 1.5 - 1.7 liters (check manual for exact capacity with filter change).
Coolant Type:
Ethylene glycol-based coolant with corrosion inhibitors (e.g., Motorex Coolant M3.0 or equivalent).
Brake Fluid Type:
DOT 4 (typically)
Common Wear Items:
Clutch plates, chain and sprockets, brake pads, fork seals, engine mounts.
Potential Electrical Gremlins:
While generally robust, intermittent issues with sensors or wiring connections can occur; the manual's detailed wiring diagrams are invaluable here.
