Model Variants:
KTM 125 Duke, KTM 200 Duke
Production Years Covered:
1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006
Chassis Codes:
Varies by specific model/variant (e.g., Duke chassis)
Engine Codes:
Varies by specific engine displacement and configuration
Overall Coverage:
Comprehensive service, maintenance, and troubleshooting for KTM 125 and 200 models from 1999-2006.
Specific Systems:
Engine, transmission, chassis, suspension, brakes, electrical system, fuel system, cooling system, exhaust system, bodywork, troubleshooting guides.
Estimated Pages:
Approximately 300-500 pages (typical for comprehensive workshop manuals).
Type:
Workshop Repair Service Manual
Language:
English (assumed for professional technical manuals sold in international markets)
Engine Mechanical:
Detailed disassembly, inspection, repair, and reassembly procedures for the engine, including cylinder head, pistons, crankshaft, connecting rods, valve train, timing system, and lubrication system.
Fuel System:
Carburetor (or early fuel injection systems) tuning, cleaning, and overhaul. Fuel pump and filter service.
Cooling System:
Radiator, coolant hoses, thermostat, water pump maintenance and repair. Coolant type and capacity specifications.
Exhaust System:
Exhaust pipe, muffler inspection, and replacement. Emission control system details.
Transmission Drivetrain:
Gearbox disassembly, inspection, and repair. Clutch service (hydraulic or cable). Chain and sprocket maintenance. Gear ratio specifications.
Chassis Frame:
Frame inspection, alignment checks, and component mounting. Swingarm and bearing service.
Suspension Front:
Front fork disassembly, seal replacement, oil type and level specifications, spring rates, damping adjustments.
Suspension Rear:
Monoshock rear suspension service, linkage maintenance, shock absorber adjustments and overhaul. Spring pre-load specifications.
Brakes Front:
Brake caliper overhaul, pad replacement, rotor inspection, brake fluid type and bleeding procedures. Master cylinder service.
Brakes Rear:
Rear brake caliper, pad, and rotor service. Rear master cylinder and fluid maintenance.
Wheels Tires:
Wheel bearing inspection and replacement, tire mounting and balancing, recommended tire pressures and sizes.
Electrical System Ignition:
Ignition system components (coil, spark plug, CDI unit), starting system (starter motor, battery), charging system (alternator, regulator/rectifier), lighting, wiring diagrams.
Electrical System Instruments:
Instrument cluster functionality, speedometer, tachometer, warning lights, and related sensors.
Bodywork Fairings:
Fairing removal and installation, seat, fuel tank, and other body panel service.
Scheduled Maintenance:
Detailed maintenance schedules for regular servicing, including oil changes, filter replacements, chain adjustments, and lubrication points.
Troubleshooting Diagnostics:
Systematic troubleshooting guides for common problems, including symptom analysis, diagnostic steps, and corrective actions. Diagnostic codes if applicable.
Engine Rebuild:
Complete engine overhaul procedures, including critical torque specifications and clearances for internal components.
Suspension Setup:
Guidance on adjusting suspension for different riding conditions and rider preferences.
Brake Bleeding:
Step-by-step instructions for safely bleeding hydraulic brake systems.
Carburetor Tuning:
Procedures for adjusting idle speed, fuel mixture, and jetting for optimal performance.
Electrical Diagnostics:
Troubleshooting electrical faults using wiring diagrams and multimeter testing.
Special Tool Identification:
Identification of specialized tools required for specific maintenance and repair tasks.
Depth:
In-depth technical information suitable for professional mechanics and experienced DIY enthusiasts. Covers everything from routine maintenance to complete component rebuilds and complex diagnostics.
Diagnostic Focus:
Emphasis on systematic fault finding and diagnosis across all major vehicle systems.
Type:
Single-cylinder, 4-stroke, Liquid-cooled (typical for Duke models of this era)
Displacement 125:
Approximately 125cc
Displacement 200:
Approximately 200cc
Bore X Stroke 125:
Specific dimensions would be detailed in the manual (e.g., ~54mm x 54.5mm)
Bore X Stroke 200:
Specific dimensions would be detailed in the manual (e.g., ~63mm x 63mm)
Compression Ratio:
Detailed in manual, typically around 11.0:1 to 12.5:1
Horsepower 125:
Approximate range of 15-18 HP (varies by region and tuning)
Horsepower 200:
Approximate range of 20-25 HP (varies by region and tuning)
Torque 125:
Approximate range of 10-12 Nm
Torque 200:
Approximate range of 15-18 Nm
Fuel Delivery 125:
Typically Carburetor (e.g., Keihin CV type, ~30-32mm throttle bore)
Fuel Delivery 200:
Typically Carburetor (e.g., Keihin CV type, ~32-35mm throttle bore)
Fuel Type Recommendation:
Unleaded gasoline, Octane rating specified in manual (typically 91+ AKI).
Fuel Tank Capacity:
Detailed in manual, likely around 10-12 liters.
Length:
Specific dimensions will vary by Duke model variant; detailed in manual.
Width:
Specific dimensions will vary by Duke model variant; detailed in manual.
Height:
Specific dimensions will vary by Duke model variant; detailed in manual.
Wheelbase:
Specific dimensions will vary by Duke model variant; detailed in manual (likely around 1350mm - 1400mm).
Ground Clearance:
Specific dimensions will vary by Duke model variant; detailed in manual.
Dry Weight 125:
Approximate range of 110-120 kg (depending on specific model/year).
Dry Weight 200:
Approximate range of 120-130 kg (depending on specific model/year).
Wet Weight:
Detailed in manual, includes all fluids.
Max Load Capacity:
Detailed in manual, typically for rider and passenger.
Crash Test Results:
N/A for motorcycles of this era. Focus is on mechanical and operational safety.
Braking System:
Disc brakes front and rear. ABS was not a common feature on these models during this period, but specific variants might exist.
Suspension Stability:
Well-engineered suspension contributes to rider control and stability.
Lighting:
Headlight, taillight, brake light, turn signals for visibility.
Warning Indicators:
Instrument cluster includes indicators for oil pressure, neutral, turn signals, high beam, and potentially engine warnings.
Oil Change:
Typically every 3,000 - 5,000 km or annually, as specified in the manual.
Oil Filter Replacement:
At every oil change or as specified.
Air Filter Cleaning Replacement:
Regular inspection and cleaning, replacement as needed (e.g., every 5,000-10,000 km depending on riding conditions).
Spark Plug Replacement:
Recommended replacement at specific mileage intervals (e.g., 10,000 - 15,000 km), check manual for exact type and gap.
Chain Lubrication Adjustment:
Frequent checks recommended, especially after wet riding (e.g., every 500-1000 km).
Valve Clearance Check:
Periodic check and adjustment required (e.g., every 10,000 - 15,000 km), critical for engine health.
Engine Oil Type:
Specific viscosity and API/JASO rating detailed in manual (e.g., Motorex or equivalent, SAE 10W-40, JASO MA/MA2).
Engine Oil Capacity:
Approximate capacity specified in the manual (e.g., 1.2 - 1.5 liters).
Coolant Type:
Specific ethylene glycol-based coolant, typically a 50/50 mix with distilled water, meeting specified standards.
Brake Fluid Type:
DOT 4 hydraulic brake fluid.
Common Wear Items:
Clutch plates, brake pads, chain and sprockets, fork seals, and wheel bearings are typical wear items that may require replacement over time.
Potential Electrical Gremlins:
As with many motorcycles of this era, occasional issues with charging systems (regulator/rectifier) or wiring connectors can arise.
Carburetor Performance:
Carburetors can require periodic cleaning and adjustment to maintain optimal performance, especially if fuel quality varies.
