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OWNER’S MANUAL
2021
200 DUKE
Art. no. 3214318en
Related Manuals for KTM 200 DUKE 2021
Summary of Contents for KTM 200 DUKE 2021
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Page 1
OWNER’S MANUAL 2021 200 DUKE Art. no. 3214318en… -
Page 3
KTM accepts no liability for delivery options, deviations from fig- ures and descriptions, misprints, and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of supply. -
Page 4: Table Of Contents
TABLE OF CONTENTS 6.18 Passenger foot pegs ……19 TABLE OF CONTENTS MEANS OF REPRESENTATION …… 5 6.19 Shift lever ……..19 Symbols used ……..5 6.20 Foot brake lever ……. 19 Formats used……..5 6.21 Side stand……..20 SAFETY ADVICE……….6 COMBINATION INSTRUMENT …..
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Page 5
TABLE OF CONTENTS 10.3 Recommended work ……46 14.6 Checking the tire condition ….70 14.7 Checking tire pressure …… 71 11 TUNING THE CHASSIS ……. 47 15 ELECTRICAL SYSTEM ……… 73 11.1 Adjusting the spring preload of the shock absorber …… -
Page 6
TABLE OF CONTENTS 22.3.2 Coolant ……..101 22.3.3 Fuel ……… 101 22.4 Chassis ……… 102 22.5 Electrical system……102 22.6 Tires ……….103 22.7 Fork……….103 22.8 Shock absorber ……103 22.9 Chassis tightening torques ….103 23 SUBSTANCES ………. 107 24 AUXILIARY SUBSTANCES …… -
Page 7: Means Of Representation 1
Indicates work that requires expert knowledge and technical understanding. In the interest of your own safety, have these jobs performed by an authorized KTM workshop! Your motorcycle will be cared for there to the highest degree by specially trained experts using the special tools required.
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Page 8: Safety Advice
2 SAFETY ADVICE Use definition – intended use This vehicle has been designed and built to withstand the normal stresses and strains of road use. This vehicle is not suitable for use on race tracks or offroad. Info This vehicle is only authorized for operation on public roads in its homologated version. Misuse The vehicle must only be used as intended.
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Page 9: Tampering Warning
An appropriate driver’s license is needed to ride the vehicle on public roads. Have malfunctions that impair safety promptly eliminated by an authorized KTM workshop. Adhere to the information and warning labels on the vehicle.
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Page 10: Protective Clothing
– Always wear protective clothing that is in good condition and meets the legal regulations. In the interest of your own safety, KTM recommends that you only operate the vehicle while wearing protective clothing. Work rules Unless specified otherwise, the ignition must be turned off during all work (models with ignition lock, models with remote key) or the engine must be at a standstill (models without ignition lock or remote key).
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Page 11
The Owner’s Manual can be downloaded several times using the QR code or the link on the delivery certificate. The Owner’s Manual is also available for download from your authorized KTM dealer and on the KTM website. A printed copy can also be ordered from your authorized KTM dealer. -
Page 12: Important Notes
Manufacturer warranty, implied warranty The work prescribed in the service schedule must only be carried out in an authorized KTM workshop and con- firmed in the KTM Dealer.net, as otherwise all warranty claims will be void. Damage or secondary damage caused by tampering with and/or conversions on the vehicle are not covered by the manufacturer warranty.
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Page 13: View Of Vehicle 4
VIEW OF VEHICLE 4 View of vehicle, front left (example) S04210-10 Hand brake lever ( p. 14) Combination instrument Clutch lever ( p. 14) Front rider’s seat Passenger seat Seat lock ( p. 18) Grab handles ( p. 18) Passenger foot pegs ( p.
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Page 14: View Of Vehicle, Rear Right (Example)
4 VIEW OF VEHICLE View of vehicle, rear right (example) S04211-10 Tool set ( p. 18) Fuel tank filler cap Light switch ( p. 15) High beam flasher button ( p. 15) Turn signal switch ( p. 15) Horn button ( p.
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Page 15: Serial Numbers 5
SERIAL NUMBERS 5 Vehicle identification number The vehicle identification number is stamped on the right side of the steering head. 402408-10 Type label The type label is on the right of the frame behind the steering head. 402174-10 Engine number The engine number is stamped on the left side of the engine under the engine sprocket.
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Page 16: Controls
6 CONTROLS Clutch lever The clutch lever is fitted on the left side of the handlebar. S00656-10 Hand brake lever The hand brake lever is fitted on the right side of the handle- bar. The front brake is engaged using the hand brake lever. S00663-10 Throttle grip The throttle grip…
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Page 17: Light Switch
CONTROLS 6 Light switch The light switch is fitted on the left side of the handlebar. Possible states Low beam on – The light switch is turned downward. In this position, the low beam and the tail light are switched on. High beam on –…
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Page 18: Start Button
6 CONTROLS Start button Start button is fitted on the right side of the handlebar. Possible states • The start button is in the basic position is pressed – In this position, the starter • The start button motor is actuated. S00662-10 6.10 Ignition and steering lock…
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Page 19: Unlocking The Steering
CONTROLS 6 6.12 Unlocking the steering – Insert the ignition key into the ignition and steering lock, press in, and turn to the right. Remove the ignition key. The handlebar can now be moved again. 400731-01 6.13 Opening fuel tank filler cap Danger Fire hazard Fuel is highly flammable.
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Page 20: Closing The Fuel Tank Filler Cap
6 CONTROLS 6.14 Closing the fuel tank filler cap Warning Fire hazard Fuel is highly flammable, toxic and a health hazard. – Check that the fuel tank filler cap is locked cor- rectly after closing. – Change your clothing if fuel spills on them. –…
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Page 21: Passenger Foot Pegs
CONTROLS 6 6.18 Passenger foot pegs The passenger foot pegs can be folded up and down. Possible states Passenger foot pegs folded up – For operation without a pas- • senger. Passenger foot pegs folded down – For operation with a pas- •…
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Page 22: Side Stand
6 CONTROLS 6.21 Side stand The side stand is located on the left of the vehicle. The side stand is used for parking the motorcycle. Info The side stand must be folded up during motorcycle use. The side stand is coupled with the safety starting system; follow the riding instructions.
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Page 23: Combination Instrument 7
The malfunction indicator lamp always lights up as long as the engine is not running. If the engine is running and the malfunction indicator lamp lights up, stop (taking care not to endanger yourself or other road users in the process) and contact an authorized KTM workshop.
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Page 24: Warnings
7 COMBINATION INSTRUMENT Warnings Info All warnings that have occurred are shown automatically in succession on the display until they are no longer active. As soon as a malfunction occurs, the relevant indicator lamps light up to signal that an indication/warning note for the operating safety has been detected.
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Page 25: Indicator Lamps
If the engine is running and the malfunction indicator lamp lights up, stop (taking care not to endanger yourself or other road users in the process) and contact an authorized KTM workshop. Possible states The turn signal indicator lamp flashes green simul- taneously with the turn signal –…
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Page 26: Shift Warning Light
7 COMBINATION INSTRUMENT The immobilizer indicator lamp lights up red – Status or error message for immobilizer. The general warning lamp lights up or flashes yellow – One or more operating safety notes/warning notes have been detected. This is also shown in the display. ABS warning lamp lights up yellow –…
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Page 27: Display
COMBINATION INSTRUMENT 7 Display The tachometer shows the engine speed in revolutions per minute. The gear display shows the engaged gear. is shown in kilometers per hour km/h or in miles per Speed hour mph. The fuel level display is displayed in the area.
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Page 28: Coolant Temperature Indicator
7 COMBINATION INSTRUMENT Coolant temperature indicator The coolant temperature display is shown in segment of the display. The coolant temperature indicator consists of bars. The more bars that light up, the hotter the coolant. Note Engine failure Overheating damages the engine. –…
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Page 29: Odo Display
COMBINATION INSTRUMENT 7 7.10 ODO display – Press the MODE button briefly and repeatedly until ODO appears on the display. ODO displays the total distance covered. Info This value is retained, even if the 12-V battery is discon- nected from the vehicle or the fuse blows. Press the Next menu on the display A00975-10…
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Page 30: Fuel Range
7 COMBINATION INSTRUMENT 7.13 Fuel Range – Press the MODE button briefly and repeatedly until ODO appears on the display. – Press the SET button briefly and repeatedly until the desired menu appears. The range is shown in this menu. Info The range depends on the average fuel consumption and the fuel quantity in the fuel tank.
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Page 31: Trip 1 Display
COMBINATION INSTRUMENT 7 Press the Next menu on the display SET button briefly. Press the Next display mode in the display MODE button briefly. 7.16 TRIP 1 display – Press the MODE button briefly and repeatedly until TRIP 1 appears on the display. TRIP 1 shows the distance since the last reset, such as between two refueling stops.
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Page 32: Average Speed Trip1
7 COMBINATION INSTRUMENT 7.18 Average Speed Trip1 – Press the MODE button briefly and repeatedly until TRIP 1 appears on the display. – Press the SET button briefly and repeatedly until the desired menu appears. Average speed 1 based on TRIP 1 is shown in this menu. Press the Next menu on the display SET button…
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Page 33: Time Trip 2
COMBINATION INSTRUMENT 7 7.21 Time Trip 2 – Press the MODE button briefly and repeatedly until TRIP 2 appears on the display. – Press the SET button briefly and repeatedly until the desired menu appears. Riding time 2 based on TRIP 2 is shown in this menu. Press the Next menu on the display SET button…
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Page 34: Setting Kilometers Or Miles
7 COMBINATION INSTRUMENT 7.24 Setting kilometers or miles Info Make the setting according to the country. If you change the unit, the value ODO is retained and converted accordingly. Condition The motorcycle is stationary. – Press the MODE button briefly and repeatedly until ODO appears on the display.
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Page 35: Adjusting The Shift Speed Rpm1
COMBINATION INSTRUMENT 7 7.26 Adjusting the shift speed RPM1 Condition The motorcycle is stationary. ODO > 1,000 km (621 m). – Press the MODE button briefly and repeatedly until TRIP 1 appears on the display. – Press the MODE button for 5 seconds. The RPM1 display appears.
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Page 36: Adjusting Abs Mode
7 COMBINATION INSTRUMENT – Press the MODE button and SET button simultaneously. The RPM2 display disappears and the set shift speed RPM2 is adopted and saved. 7.28 Adjusting ABS mode Condition The motorcycle is stationary. – Press the Mode button briefly and repeatedly until the ABS display appears.
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Page 37: Preparing For Use 8
Info When using the vehicle, remember that others may feel disturbed by excessive noise. – Ensure that the pre-sales inspection work has been carried out by an authorized KTM workshop. The delivery certificate is transferred upon vehicle handover. – Read the entire Owner’s Manual before riding for the first time.
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Page 38: Running In The Engine
8 PREPARING FOR USE Running in the engine – During the running-in phase, do not exceed the specified engine speed. Guideline Maximum engine speed During the first: 1,000 km (620 mi) 7,500 rpm Info During the running-in phase, the shift warning light is set to a specified value and cannot be changed. –…
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Page 39: Riding Instructions 9
RIDING INSTRUCTIONS 9 Checks and maintenance measures when preparing for use Info Before every trip, check the condition of the vehicle and ensure that it is roadworthy. The vehicle must be in perfect technical condition when it is being operated. –…
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Page 40: Starting Off
9 RIDING INSTRUCTIONS – Unlock the steering. ( p. 17) – Sit on the vehicle, take the weight off of the side stand, and move it all the way up with your foot. – Turn the emergency OFF switch to the position –…
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Page 41
RIDING INSTRUCTIONS 9 Warning Danger of accidents If you change down at high engine speed, the rear wheel blocks and the engine races. – Do not change into a low gear at high engine speed. Warning Danger of accidents An incorrect ignition key position causes malfunctions. –… -
Page 42: Applying The Brakes
Info If unusual noises occur while riding, stop immediately (taking care not to endanger yourself or other road users in the process), switch off the engine and contact an authorized KTM workshop. – Shift into a higher gear when conditions allow (incline, road situation, etc.).
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Page 43
RIDING INSTRUCTIONS 9 Warning Danger of accidents The brake system fails in the event of overheating. If the foot brake lever is not released, the brake linings drag continuously. – Take your foot off the foot brake lever if you do not want to brake. Warning Danger of accidents Higher total weight increases the stopping distance. -
Page 44: Stopping, Parking
9 RIDING INSTRUCTIONS Stopping, parking Warning Risk of injury People who act without authorization endanger themselves and others. – Do not leave the vehicle unattended if the engine is running. – Protect the vehicle against access by unauthorized persons. – Lock the steering and remove the ignition key if you leave the vehicle unattended. Warning Danger of burns Some vehicle components become very hot when the vehicle is operated.
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Page 45: Refueling
In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the fuel system. – Refuel only with clean fuel that meets the specified standards. (Your authorized KTM workshop will be glad to help.) Note Environmental hazard Improper handling of fuel is a danger to the environment.
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Page 46
Total fuel tank 13.4 l Super unleaded capacity, approx. (3.54 US gal) (ROZ 95) p. 108) (KTM 200 Duke EU/AR/CO/MY/PH) Total fuel tank Gasohol 95 E20 capacity, approx. (RON 95) p. 108) (200 DUKE TH) –… -
Page 47: Service Schedule 10
Different service intervals may apply in your country, depending on the local operating conditions. Individual service intervals and scopes may change in the course of technical developments. The most up-to-date service schedule can always be found on KTM Dealer.net. Your authorized KTM dealer will be happy to advise you.
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Page 48: Recommended Work
15,000 km (9,300 mi) every 7,500 km (4,650 mi) after 1,000 km (620 mi) ○ ● ● ● ● Make a service entry in KTM Dealer.net. ○ One-time interval ● Periodic interval 10.3 Recommended work every 48 months every 12 months…
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Page 49: Tuning The Chassis 11
TUNING THE CHASSIS 11 11.1 Adjusting the spring preload of the shock absorber Warning Danger of accidents Modifications to the suspension setting may seriously alter the handling characteris- tic. – Ride slowly to start with after making adjustments to get the feel of the new handling characteristic. Info The spring preload defines the initial status of the spring operation on the shock absorber.
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Page 50
11 TUNING THE CHASSIS Info After the nuts have been tightened, the bearings of the shift rod must be central and aligned identically to each other in order to ensure freedom of movement in the bearing shells. – Check the shift lever to ensure it is functioning properly and can move freely. -
Page 51: Service Work On The Chassis 12
SERVICE WORK ON THE CHASSIS 12 12.1 Raising the motorcycle with rear lifting gear Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. – Mount the supports of the lifting gear. –…
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Page 52: Taking The Motorcycle Off The Front Lifting Gear
12 SERVICE WORK ON THE CHASSIS – Move the handlebar to the straight-ahead position. Position the lifting gear. Mounting pin (69329965030) Front wheel work stand, large (69329965100) Info Always raise the motorcycle at the rear first. – Lift the motorcycle at the front. 402345-01 12.4 Taking the motorcycle off the front lifting gear…
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Page 53: Removing The Passenger Seat
SERVICE WORK ON THE CHASSIS 12 Main work – Push protection caps of both fork legs downward. – Push dust boots of both fork legs downward. Info The dust boots remove dust and coarse dirt particles from the inside fork tubes. Over time, dirt can accumu- late behind the dust boots.
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Page 54: Mounting The Passenger Seat
12 SERVICE WORK ON THE CHASSIS 12.7 Mounting the passenger seat – Attach hooks on the passenger seat to seat mounting on the subframe, and lower it at the rear while pushing for- ward. – Press the passenger seat downward until it clicks into place. Warning Danger of accidents The seat can come loose from the anchoring if it is not mounted correctly.
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Page 55: Checking For Chain Dirt Accumulation
SERVICE WORK ON THE CHASSIS 12 12.10 Checking for chain dirt accumulation – Check the chain for coarse dirt accumulation. » If the chain is very dirty: – Clean the chain. ( p. 53) 400678-01 12.11 Cleaning the chain Warning Danger of accidents Lubricants on the tires reduces the road grip.
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Page 56: Checking The Chain Tension
12 SERVICE WORK ON THE CHASSIS 12.12 Checking the chain tension Warning Danger of accidents Incorrect chain tension damages components and results in accidents. If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel bearings wear more quickly. Some components may break if overloaded. If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket.
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Page 57: Checking The Chain, Rear Sprocket, And Engine Sprocket
SERVICE WORK ON THE CHASSIS 12 Main work – Loosen nut – Loosen nuts – Adjust the chain tension by turning adjusting screws left and right. Guideline Chain tension 5 … 7 mm (0.2 … 0.28 in) Turn the adjusting screws on the left and right so that the markings on the left and right chain adjusters are in…
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Page 58
12 SERVICE WORK ON THE CHASSIS – Shift the transmission into neutral. – Pull on the lower chain section with the specified weight Guideline Weight, chain wear measure- 15 kg (33 lb.) ment – Measure distance of 20 chain rollers in the lower chain section. -
Page 59: Removing The Front Spoiler
SERVICE WORK ON THE CHASSIS 12 12.15 Removing the front spoiler – Remove screws – Take off the front spoiler. S04212-10 12.16 Fitting front spoiler – Position the front spoiler. Mount and tighten screws Guideline Screw, front spoiler M6x9 9 Nm (6.6 lbf ft) rear S04212-10 12.17…
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Page 60: 13 Brake System
Do not make any changes to the suspension travel. – Only use spare parts on the brake system which have been approved and recommended by KTM. – Only use tires/wheels approved by KTM with the corre- sponding speed index. – Maintain the specified tire pressure. –…
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Page 61: Checking The Brake Discs
Warning Danger of accidents Worn-out brake discs reduce the braking effect. – Make sure that worn-out brake discs are replaced immediately. (Your authorized KTM workshop will be glad to help.) – Check the front and rear brake disc thickness at multiple…
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Page 62: Adding Front Brake Fluid
– Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) – Move the brake reservoir mounted on the handlebar into a hori- zontal position.
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Page 63: Checking The Front Brake Linings
Checking the front brake linings Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Damaged brake discs reduce the braking effect.
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Page 64: Checking The Rear Brake Fluid Level
Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) – Position the vehicle upright.
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Page 65
BRAKE SYSTEM 13 Note Environmental hazard Hazardous substances cause environmental damage. – Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations. Info Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid. -
Page 66: Checking The Rear Brake Linings
Checking the rear brake linings Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Damaged brake discs reduce the braking effect.
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Page 67: Adjusting The Free Travel Of The Foot Brake Lever
BRAKE SYSTEM 13 13.10 Adjusting the free travel of the foot brake lever Warning Danger of accidents The brake system fails in the event of overheating. If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear brake.
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Page 68: 14 Wheels, Tires
14 WHEELS, TIRES 14.1 Removing the front wheel Preparatory work – Raise the motorcycle with the rear lifting gear. ( p. 49) – Lift the motorcycle with the front lifting gear. ( p. 49) Main work – Remove screws and push the fender to the side. –…
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Page 69: Removing Rear Wheel
WHEELS, TIRES 14 – Clean the thread of the wheel spindle and screw – Position the front wheel and insert the wheel spindle. The brake linings are correctly positioned. – Mount and tighten screw Guideline Screw, front wheel 25 Nm (18.4 lbf ft) spindle –…
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Page 70: Installing The Rear Wheel
14 WHEELS, TIRES Main work – Remove screw and pull wheel speed sensor out of the hole. – Remove nut and washer. – Remove chain adjuster – Holding the rear wheel, withdraw wheel spindle with the washer and chain adjuster –…
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Page 71: Checking Rear Hub Damping Rubber Pieces
WHEELS, TIRES 14 – Clean the contact areas on the brake caliper bracket and link fork. – Mount the damping rubber pieces and rear sprocket carrier on the rear wheel. – Position the rear wheel. The brake linings are correctly positioned. –…
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Page 72: Checking The Tire Condition
Warning Danger of accidents If a tire bursts while riding, the vehicle becomes uncontrollable. – Ensure that damaged or worn tires are replaced immediately. (Your authorized KTM workshop will be glad to help.) Warning Danger of crashing Different tire tread patterns on the front and rear wheel impair the handling charac- teristic.
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Page 73: Checking Tire Pressure
DOT number. The first two digits indicate the week of manufacture and the last two digits the year of manu- facture. KTM recommends that the tires be changed after 5 H01144-10 years at the latest, regardless of the actual state of wear.
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Page 74
14 WHEELS, TIRES – Mount the protection cap. -
Page 75: Electrical System 15
ELECTRICAL SYSTEM 15 15.1 Removing the 12-V battery Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep 12 V batteries out of the reach of children. – Wear suitable protective clothing and safety glasses. – Avoid contact with battery acid and battery gases.
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Page 76: Charging The 12-V Battery
15 ELECTRICAL SYSTEM – Position negative cable and mount and tighten the screw. V01273-11 Finishing work – Mount the front rider’s seat. ( p. 52) – Mount the passenger seat. ( p. 52) – Set the clock. ( p. 32) 15.3 Charging the 12-V battery Warning…
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Page 77: Changing The Abs Fuses
ELECTRICAL SYSTEM 15 Main work – Connect a battery charger to the 12-V battery. Switch on the battery charger. Battery charger (58429074000) In addition, this battery charger can be used to test the open- circuit voltage, the starting ability of the 12-V battery, and the alternator.
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Page 78
15 ELECTRICAL SYSTEM To change the fuse of the ABS hydraulic unit: – Take off the protection cap and remove fuse Info A faulty fuse has a burned-out fuse wire Warning Fire hazard Incorrect fuses overload the electrical S04216-10 system. – Only use fuses with the required ampere value. -
Page 79: Changing The Fuses Of Individual Electrical Power Consumers
ELECTRICAL SYSTEM 15 15.5 Changing the fuses of individual electrical power consumers Info The fuse box with the main fuse and the fuses of the individual electrical power consumers is located under the passenger seat. Preparatory work – Remove the passenger seat. ( p.
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Page 80: Changing The Headlight Bulb
15 ELECTRICAL SYSTEM – Check the function of the electrical power consumer. – Close the fuse box cover. Finishing work – Mount the passenger seat. ( p. 52) 15.6 Changing the headlight bulb Note Damage to reflector Grease on the reflector reduces the light intensity. Grease on the bulb will evaporate due to the heat and be deposited on the reflector.
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Page 81: Checking The Headlight Setting
ELECTRICAL SYSTEM 15 – Plug in connector – Mount protection cap – Swivel the headlight mask upward. K00793-10 – Mount screw Info Screw also secures the headlight. Ensure the screw is always screwed in far enough. – Check that the lighting is functioning properly. G04938-10 Finishing work –…
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Page 82: Adjusting The Headlight Range
15 ELECTRICAL SYSTEM 15.8 Adjusting the headlight range Main work – Turn adjusting screw to adjust the headlight range. Info Turn clockwise to increase the headlight range; turn counterclockwise to reduce the headlight range. If you have a payload, you may have to correct the headlight range.
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Page 83: Cooling System 16
COOLING SYSTEM 16 16.1 Cooling system Water pump in the engine ensures forced circulation of the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap . Heat expansion causes excess coolant to flow into compensating tank .
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Page 84: Checking The Antifreeze And Coolant Level
16 COOLING SYSTEM Condition The engine is cold. – Stand the motorcycle upright on a horizontal surface. – Check the coolant level in the compensating tank The coolant level must be between MIN and MAX. » If the coolant level does not match the specified value: –…
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Page 85: Draining The Coolant
COOLING SYSTEM 16 – Stand the motorcycle upright on a horizontal surface. – Remove the cap of the compensating tank – Check the coolant antifreeze. −25 … −45 °C (−13 … −49 °F) » If the antifreeze in the coolant does not match the speci- fied value: –…
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Page 86: Filling/Bleeding The Cooling System
16 COOLING SYSTEM Warning Danger of poisoning Coolant is toxic and a health hazard. – Keep coolant out of the reach of children. – Do not allow coolant to come into contact with the skin, the eyes and clothing. – Consult a doctor immediately if coolant is swallowed. –…
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Page 87: Changing The Coolant
COOLING SYSTEM 16 – Loosen bleeder screw Guideline 3 turns – Tilt the vehicle slightly to the right. – Pour in the coolant until it emerges without bubbles at the bleeder screw, and then mount and tighten the bleeder screw immediately.
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Page 88
16 COOLING SYSTEM Warning Danger of poisoning Coolant is toxic and a health hazard. – Keep coolant out of the reach of children. – Do not allow coolant to come into contact with the skin, the eyes and clothing. – Consult a doctor immediately if coolant is swallowed. –… -
Page 89
COOLING SYSTEM 16 Danger Danger of poisoning Exhaust gases are toxic and inhal- ing them may result in unconsciousness and death. – Always make sure there is sufficient ventilation when running the engine. – Use effective exhaust extraction when starting or running the engine in an enclosed space. -
Page 90: 17 Tuning The Engine
17 TUNING THE ENGINE 17.1 Checking the play in the throttle cable – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Turn the throttle grip back and forth slightly and determine the play in throttle cable 3 ……
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Page 91: Adjusting Play In The Clutch Lever
TUNING THE ENGINE 17 – Check the clutch lever for smooth operation. – Move the handlebar to the straight-ahead position. – Pull the clutch lever until resistance is perceptible, and deter- mine the play in the clutch lever 1 … 3 mm (0.04 … Clutch lever play 0.12 in) »…
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Page 92: 18 Service Work On The Engine
18 SERVICE WORK ON THE ENGINE 18.1 Checking the engine oil level Condition The engine is at operating temperature. Preparatory work – Stand the motorcycle upright on a horizontal surface. Main work – Check the engine oil level. Info After switching off the engine, wait one minute before checking the level.
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Page 93
SERVICE WORK ON THE ENGINE 18 – Remove screws . Take off oil filter cover with the O- ring. – Pull oil filter out of the oil filter housing. – Allow the engine oil to drain completely. – Thoroughly clean the parts and the sealing surface. S04242-10 –… -
Page 94: Adding Engine Oil
Info In order to achieve optimal engine oil performance, it is 401955-10 not advisable to mix different engine oils. KTM recommends changing the engine oil where neces- sary. – Mount and tighten the filler plug together with the O-ring. Danger Danger of poisoning Exhaust gases are toxic and inhal-…
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Page 95: Cleaning, Care 19
CLEANING, CARE 19 19.1 Cleaning the motorcycle Note Material damage Components become damaged or destroyed if a pressure cleaner is used incorrectly. The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc. Pressure which is too high causes malfunctions and destroys components. –…
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Page 96: Checks And Maintenance Steps For Winter Operation
19 CLEANING, CARE – Push back the sleeves of the handlebar controls to allow any water that has penetrated to evaporate. – After the motorcycle has cooled down, lubricate all moving parts and pivot points. – Clean the chain. ( p.
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Page 97: Storage 20
– Store vehicle in a dry location that is not subject to large fluc- tuations in temperature. Info KTM recommends jacking up the motorcycle. – Raise the motorcycle with the rear lifting gear. ( p. 49) – Lift the motorcycle with the front lifting gear. ( p.
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Page 98: Preparing For Use After Storage
20 STORAGE 20.2 Preparing for use after storage – Take the motorcycle off the front lifting gear. ( p. 50) – Remove the rear of the motorcycle from the lifting gear. p. 49) – Install the 12-V battery. p. 73) –…
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Page 99: Troubleshooting 21
Carry out start procedure. ( p. 37) – Malfunction in the electronic Read out the fault memory using the fuel injection KTM diagnostics tool. – Engine has too little power Air filter is very dirty Change the air filter. –…
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Page 100
21 TROUBLESHOOTING Faults Possible cause Action – Time is not (correctly) dis- Fuse 8 is blown Change the fuses of individual electri- played cal power consumers. ( p. 77) – Set the clock. ( p. 32) – 12 V battery discharged Ignition was not switched off Charge the 12-V battery. -
Page 101: Technical Data 22
TECHNICAL DATA 22 22.1 Engine Design 1-cylinder 4-stroke engine, water-cooled Displacement 200 cm³ (12.2 cu in) Stroke 49 mm (1.93 in) Bore 72 mm (2.83 in) Compression ratio 11,5:1 Control DOHC, four valves controlled via cam lever, chain drive Intake valve diameter 28.5 mm (1.122 in) Exhaust valve diameter 24 mm (0.94 in)
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Page 102: Engine Tightening Torques
22 TECHNICAL DATA 22.2 Engine tightening torques Oil nozzle 6 Nm (4.4 lbf ft) Loctite ® 243™ Screw, engine vent plate 7 Nm (5.2 lbf ft) Loctite ® 243™ Screw, retaining bracket 6 Nm (4.4 lbf ft) Loctite ® 243™ Screw, retaining bracket, stator 8 Nm (5.9 lbf ft) Loctite…
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Page 103: Capacities
22.3.3 Fuel Total fuel tank capacity, approx. 13.4 l (3.54 US gal) Super unleaded (ROZ 95) p. 108) (KTM 200 Duke EU/AR/CO/MY/PH) Total fuel tank capacity, approx. Gasohol 95 E20 (RON 95) p. 108) (200 DUKE TH) Fuel reserve, approx.
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Page 104: Chassis
22 TECHNICAL DATA 22.4 Chassis Frame Lattice frame of steel tubes, powder-coated WP Suspension Fork WP Suspension Shock absorber Brake system front Disc brake with 4-piston brake caliper rear Disc brake with single-pot brake caliper, floating Brake discs — diameter front 300 mm (11.81 in) rear…
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Page 105: Tires
110/70 R 17 M/C 54S TL 150/60 R 17 M/C 66S TL MRF REVZ‑C1 MRF REVZ‑C1 The tires specified represent one of the possible series production tires. Additional information is available in the Service section under: KTM.COM 22.7 Fork Fork article number F20123401O Fork…
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Page 106
22 TECHNICAL DATA Screw, brake fluid reservoir for rear 8 Nm (5.9 lbf ft) Loctite ® 243™ brake Screw, brake hose clamp 7 Nm (5.2 lbf ft) Screw, chain sliding guard 7 Nm (5.2 lbf ft) Screw, combination instrument 7 Nm (5.2 lbf ft) Screw, compensating tank 5 Nm (3.7 lbf ft) Screw, damper block… -
Page 107
TECHNICAL DATA 22 Screw, engine bearer 22 Nm (16.2 lbf ft) Screw, foot brake lever 16 Nm (11.8 lbf ft) Loctite ® 243™ Screw, fork stub 15 Nm (11.1 lbf ft) Screw, front brake disc 30 Nm (22.1 lbf ft) Loctite ®… -
Page 108
22 TECHNICAL DATA Screw, steering head, top M16x1.5 49 Nm (36.1 lbf ft) Loctite ® 243™ Lambda sensor M18x1.5 19 Nm (14 lbf ft) Adjusting ring, link fork bearing M22x1 Tighten and ensure that there is no play Nut, steering head M30x1 1st stage 45 Nm (33.2 lbf ft) -
Page 109: Substances 23
SUBSTANCES 23 Brake fluid DOT 4 / DOT 5.1 Standard/classification – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that exhibits the corresponding properties. Recommended supplier Castrol – REACT PERFORMANCE DOT 4 MOTOREX ®…
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Page 110
23 SUBSTANCES Engine oil (SAE 10W/40) Standard/classification – JASO T903 MA2 ( p. 110) – SAE ( p. 110) (SAE 10W/40) Guideline – Use only engine oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties. -
Page 111: Auxiliary Substances 24
AUXILIARY SUBSTANCES 24 Chain cleaner Recommended supplier MOTOREX ® – Chain Clean Fuel additive Recommended supplier MOTOREX ® – Fuel Stabilizer Long-life grease Recommended supplier MOTOREX ® – Bike Grease 2000 Motorcycle cleaner Recommended supplier MOTOREX ® – Moto Clean Perfect finish and high gloss polish for paints Recommended supplier MOTOREX…
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Page 112: 25 Standards
25 STANDARDS JASO T903 MA2 Different technical development directions required a separate specification for motorcycles – the JASO T903 MA2 standard. Earlier, engine oils from the automobile industry were used for motorcycles because there was no separate motor- cycle specification. Whereas long service intervals are demanded for automobile engines, the focus for motorcycle engines is on high performance at high engine speeds.
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Page 113: Index Of Special Terms 26
INDEX OF SPECIAL TERMS 26 Anti-lock braking system Safety system that prevents locking of the wheels when driving straight ahead without the influence of lateral forces On-board diagnosis Vehicle system, which monitors the specified parame- ters of the vehicle electronics…
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Page 114: 27 List Of Abbreviations
27 LIST OF ABBREVIATIONS Art. no. Article number circa compare e.g. for example etc. et cetera i.a. inter alia number poss. possibly…
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Page 115: List Of Symbols 28
Malfunction indicator lamp lights up yellow – The OBD has detected a malfunction in the vehicle electronics. Come safely to a halt, and contact an authorized KTM workshop. The general warning lamp lights up or flashes yellow – One or more operating safety notes/warning notes have been detected.
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Page 116: Index
INDEX Clutch lever play INDEX checking ……88 12-V battery Combination instrument ….21-34 charging .
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Page 117
INDEX Kilometers or miles adjusting ……32 Figures ……10 Filling up fuel . -
Page 118
INDEX Safe operation ……7 Use definition ……6 Seat lock . -
Page 119
*3214318en* 3214318en 01/2022 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KISKA/KTM KTM.COM…
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KTM 200 Duke Service Repair Manuals on Motor Era
Motor Era offers service repair manuals for your KTM 200 Duke — DOWNLOAD your manual now! KTM 200 Duke service repair manuals
Complete list of KTM 200 Duke motorcycle service repair manuals:
1998-2005 KTM 400-660 LC4 Motorcycle Workshop Repair Service Manual BEST DOWNLOAD
KTM 2003-2007 950 ADVENTURE, 990 ADVENTURE, 990 SUPER DUKE, 950 SUPERMOTO, 950 SUPER ENDURO WORKSHOP REPAIR & SERVICE MANUAL #❶ QUALITY!
2003-2007 KTM 950 ADVENTURE, 990 ADVENTURE, 990 SUPER DUKE, 950 SUPERMOTO, 950 SUPER ENDURO Motorcycle Workshop Repair Service Manual
KTM 1290 Super Duke R Motorcycle Complete Workshop Service Repair Manual 2014 2015 2016
KTM 1290 Super Duke R 2014-2016 Service Repair Workshop Manual Download PDF
KTM 950 Adventure, 990 Super Duke Motorcycle Workshop Service Repair Manual 2003-2005 (En-De-Fr-It-Es) (203MB, 2,500+ Pages, Searchable, Printable, Bookmarked, iPad-ready PDF)
KTM 400-660 LC4 Motorcycle Service & Repair Manual 1998-2003
KTM 125 200 Duke 2012 2013 Workshop Service Repair Manual
KTM 125 200 Duke 2012 2013 Service Repair Workshop Manual
KTM 125 200 Duke 2012 2013 Factory Service Repair Manual PDF
KTM 125 200 Duke 2012 2013 Workshop Repair Service Manual
KTM 200 Duke 2012 Workshop Service Repair Manual
KTM 200 Duke 2013 Workshop Service Repair Manual
KTM 200 Duke 2014 Workshop Service Repair Manual
KTM 200 Duke 2012 Service Repair Workshop Manual
KTM 200 Duke 2013 Service Repair Workshop Manual
KTM 200 Duke 2014 Service Repair Workshop Manual
KTM 200 Duke 2012 Workshop Repair Service Manual PDF
KTM 200 Duke 2013 Workshop Repair Service Manual PDF
KTM 200 Duke 2014 Workshop Repair Service Manual PDF
KTM 200 Duke 2012 Factory Service Repair Manual PDF
KTM 200 Duke 2013 Factory Service Repair Manual PDF
KTM 200 Duke 2014 Factory Service Repair Manual PDF
KTM 200 Duke 2012 Service Repair Manual PDF
KTM 125 200 Duke 2012 Service Repair Manual PDF
KTM 200 Duke 2013 Service Repair Manual PDF
KTM 200 Duke 2014 Service Repair Manual PDF
KTM 125 200 Duke 2013 Service Repair Manual PDF
Ktm 200 Duke COL Motorcycle 2013 2014 Workshop Service Repai
Ktm 200 Duke EU Motorcycle 2013 2014 Workshop Service Repair
Ktm 200 Duke MAL Motorcycle 2013 2014 Workshop Service
KTM 200 Duke 2012 Workshop Repair Service Manual
KTM 200 Duke 2013 Workshop Repair Service Manual
KTM 200 Duke 2014 Workshop Repair Service Manual
KTM 200 Duke 2012 Workshop Service Manual for Repair
KTM 200 Duke 2013 Workshop Service Manual for Repair
KTM 200 Duke 2014 Workshop Service Manual for Repair
KTM Duke 200 2012 Workshop Service Manual for Repair
KTM Duke 200 2013 Workshop Service Manual for Repair
KTM Duke 200 2014 Workshop Service Manual for Repair
KTM Duke 125-200-390 2011-2014 Motorcycle Workshop Repair Service Manual
2013 KTM 125 Duke EU, 200 Duke EU, 200 Duke MAL, 200 Duke 2014 COL MOTORCYCLE SERVICE & REPAIR MANUAL — DOWNLOAD!
2013 KTM 125 Duke EU, 200 Duke EU, 200 Duke MAL, 200 Duke 2014 COL MOTORCYCLE SERVICE REPAIR MANUAL DOWNLOAD
2012 KTM 125 Duke EU, 125 Duke DE, 200 Duke EU, 200 Duke 2013 COL Motorcycle Service Repair Manual Download
2012 KTM 125 Duke EU, 125 Duke DE, 200 Duke EU, 200 Duke 2013 COL MOTORCYCLE SERVICE & REPAIR MANUAL — DOWNLOAD!
2013 KTM 125 Duke EU, 200 Duke EU, 200 Duke MAL, 200 Duke 20
2012 KTM 125 Duke EU, 125 Duke DE, 200 Duke EU, 200 Duke 201
2011-2014 KTM Duke 125-200-390 Motorcycle Workshop Repair & Service Manual [COMPLETE & INFORMATIVE for DIY REPAIR] ☆ ☆ ☆ ☆ ☆
KTM 125 Duke 200 Duke Motorcycle Complete Workshop Service Repair Manual 2013 2014
KTM 125 Duke 200 Duke 2013-2014 Factory Service Repair Workshop Manual Download
KTM 125 Duke 200 Duke 2013-2014 Service Repair Workshop Manual Download Pdf
KTM 125 DUKE 200 DUKE BIKE WORKSHOP SERVICE REPAIR MANUAL
KTM 125 200 Duke Complete Workshop Service Repair Manual 2012 2013 2014 2015 2016
KTM 125 200 Duke Complete Workshop Service Repair Manual 2013 2014
KTM 125 DUKE 200 DUKE BIKE FACTORY WORKSHOP SERVICE MANUAL
KTM 125 DUKE 200 DUKE BIKE WORKSHOP SERVICE REPAIR MANUAL
KTM Duke 125 200 390 Motorcycle Complete Workshop Service Repair Manual 2011 2012 2013 2014
2012 KTM 125/200 DUKE, SERVICE REPAIR MANUAL
2013 KTM 125/200 DUKE, SERVICE REPAIR MANUAL
KTM DUKE 2 Owners Manual 2003
KTM 125 DUKE 200 DUKE BIKE WORKSHOP SERVICE REPAIR MANUAL
KTM 125 DUKE 200 DUKE BIKE WORKSHOP SERVICE REPAIR MANUAL
KTM MOTORBIKE ALL MODELS WORKSHOP REPAIR SERVICE MANUAL