KTM 200 DUKE 2021 Page 67 Owner'S Manual Download

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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.

–

Set the free travel on the foot brake lever in accordance with the specification.

A00634-11

–

Detach spring

–

Release nut

and use screw

to adjust the specified free

travel

Guideline

Free travel at foot brake lever 3 … 5 mm (0.12 … 0.2 in)

Info

The range of adjustment is limited.

–

Hold screw

and tighten nut

–

Attach spring

Summary of Contents for 200 DUKE 2021

Page 1: ...OWNER S MANUAL 2021 200 DUKE Art no 3214318en...

Page 2: ......

Page 3: ...ifying reasons to adapt these to local conditions as well as to stop produc tion of a particular model without prior notice KTM accepts no liability for delivery options deviations from fig ures and d...

Page 4: ...g the fuel tank filler cap 18 6 15 Seat lock 18 6 16 Tool set 18 6 17 Grab handles 18 6 18 Passenger foot pegs 19 6 19 Shift lever 19 6 20 Foot brake lever 19 6 21 Side stand 20 7 COMBINATION INSTRUME...

Page 5: ...oot brake lever 65 14 WHEELS TIRES 66 14 1 Removing the front wheel 66 14 2 Installing the front wheel 66 14 3 Removing rear wheel 67 14 4 Installing the rear wheel 68 14 5 Checking rear hub damping r...

Page 6: ...ires 103 22 7 Fork 103 22 8 Shock absorber 103 22 9 Chassis tightening torques 103 23 SUBSTANCES 107 24 AUXILIARY SUBSTANCES 109 25 STANDARDS 110 26 INDEX OF SPECIAL TERMS 111 27 LIST OF ABBREVIATIONS...

Page 7: ...ed experts using the special tools required Indicates a page reference more information is provided on the specified page Indicates information with more details or tips Indicates the result of a test...

Page 8: ...her instructions included carefully The safety instructions are highlighted in the text and are referred to at the relevant passages Info Various information and warning labels are attached in promine...

Page 9: ...nger Danger of accidents A rider who is not fit to ride poses a danger to him or herself and others Do not operate the vehicle if you are not fit to ride due to alcohol drugs or medication Do not oper...

Page 10: ...g Precote has already been applied to a new part do not apply any additional thread locker After disassembly clean the parts that are to be reused and check them for damage and wear Change damaged or...

Page 11: ...again by the new owner 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 authori...

Page 12: ...ce A prerequisite for perfect operation and prevention of premature wear is that the service care and tuning work on the engine and chassis is properly carried out as described in the Owner s Manual A...

Page 13: ...e front left example S04210 10 1 Hand brake lever p 14 2 Combination instrument 3 Clutch lever p 14 4 Front rider s seat 5 Passenger seat 6 Seat lock p 18 7 Grab handles p 18 8 Passenger foot pegs p 1...

Page 14: ...right example S04211 10 1 Tool set p 18 2 Fuel tank filler cap 3 Light switch p 15 3 High beam flasher button p 15 3 Turn signal switch p 15 3 Horn button p 14 4 Start button p 16 4 Emergency OFF swit...

Page 15: ...ad 5 3 Engine number 402486 10 The engine number 1 is stamped on the left side of the engine under the engine sprocket 5 4 Key number 402245 10 The key number 1 can be found on the KEYCODECARD Info Th...

Page 16: ...ht side of the handle bar The front brake is engaged using the hand brake lever 6 3 Throttle grip S00664 10 The throttle grip 1 is fitted on the right side of the handlebar 6 4 Horn button S00660 10 H...

Page 17: ...Turn signal switch S00658 10 Turn signal switch 1 is fitted on the left side of the handlebar Possible states Turn signal off Turn signal switch pushed toward the switch housing Left turn signal on Tu...

Page 18: ...ne stops and a non running engine will not start The ignition key can be removed Ignition on ON In this position the ignition circuit is closed and the engine can be started Steering locked In this po...

Page 19: ...d clothing contact with fuel Immediately consult a doctor if you swallow fuel Do not inhale fuel vapors In case of skin contact rinse the affected area with plenty of water Rinse the eyes thoroughly w...

Page 20: ...in the event of contact with the skin Close the fuel tank filler cap Push down the fuel tank filler cap until the lock engages 6 15 Seat lock H01991 10 The seat lock 1 is located to the left of the se...

Page 21: ...olded down For operation with a pas senger 6 19 Shift lever 401950 10 Shift lever 1 is mounted on the left side of the engine 401950 11 The gear positions can be seen in the photograph The neutral or...

Page 22: ...must be folded up during motorcycle use The side stand is coupled with the safety starting system follow the riding instructions Possible states Side stand folded out The vehicle can be supported on t...

Page 23: ...r the turn signal indicator lamp and immobilizer indicator lamp The segments in the rpm gauge and the gear indicator light up and switch off in sequence The speedometer counts from 0 to 199 and back T...

Page 24: ...operating safety have been detected the general warning lamp also flashes A00979 10 If a malfunction has occurred in the CAN bus various warnings appear on the display CAN ABS FAILURE CAN FAILURE and...

Page 25: ...ed the general warning lamp also lights up Info 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...

Page 26: ...he Trip 1 display and Trip 2 display by keeping the MODE button pressed The shift warning light is always active during the running in phase up to 1 000 km 621 mi The shift warning light can only be d...

Page 27: ...fo The time must be reset if the 12 V battery was discon nected from the vehicle or the fuse was removed The brightness of the displays is controlled by an ambient light sensor in the combination inst...

Page 28: ...cessary correct the coolant level on the cool ing system while it is in a cooled state Info When all the bars light up the warning High Coolant Tem perature appears on the display If the cooling syste...

Page 29: ...y mode in the display 7 12 Warnings display A00974 10 Press the MODE button briefly and repeatedly until Warnings appears on the display The Warnings menu is available as soon as one or more operating...

Page 30: ...splay mode in the display 7 14 Service F01441 01 Press the MODE button briefly and repeatedly until ODO appears on the display Press the SET button briefly and repeatedly until the desired menu appear...

Page 31: ...ess the SET button briefly Next menu on the display Press the SET button for 3 seconds Display of TRIP 1 is reset Press the MODE button briefly Next display mode in the display 7 17 Time Trip 1 F01444...

Page 32: ...he display Press the SET button briefly and repeatedly until the desired menu appears Average fuel consumption 1 based on TRIP 1 is shown in this menu Press the SET button briefly Next menu on the dis...

Page 33: ...e display Press the SET button briefly and repeatedly until the desired menu appears Average speed 2 based on TRIP 2 is shown in this menu Press the SET button briefly Next menu on the display Press t...

Page 34: ...on pressed 7 25 Setting the clock Info The time is displayed in 24 hour format The time must be reset if the 12 V battery was disconnected from the vehicle or the fuse was removed Condition The motorc...

Page 35: ...ases the value The SET button decreases the value Press the MODE button and SET button simultaneously The RPM1 display disappears and the set shift speed RPM1 is adopted and saved 7 27 Adjusting the s...

Page 36: ...ntil Release Button is dis played The now active ABS mode is shown in the display Info Do not open the throttle during the selection If switching ABS mode was unsuccessful the previ ously set ABS mode...

Page 37: ...e tread pattern are fitted to the front and rear wheel Warning Danger of accidents Non approved or non recommended tires and wheels impact the handling character istic Only use tires wheels approved b...

Page 38: ...on Mount and secure all luggage according to the manufacturer s instructions Check that your luggage is fixed properly at regular intervals Warning Danger of accidents The luggage system will be damag...

Page 39: ...e and check the rear mirror setting Check the fuel level 9 2 Starting Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death Always make sure ther...

Page 40: ...on until the combination instrument function check has finished Do not open the throttle to start Start continuously for a maximum of 5 seconds Wait for at least five seconds before trying again This...

Page 41: ...ents A risky riding style constitutes a major risk Comply with traffic regulations and ride defensively and with foresight to detect sources of danger as early as possible Warning Danger of accidents...

Page 42: ...mperature indicator light up Only open the throttle as much as the engine can handle abrupt throttle grip opening increases fuel consumption Accelerate only up to a speed suitable for the road surface...

Page 43: ...the brakes blocks the wheels The ABS effectiveness is only ensured if it is switched on Leave the ABS switched on in order to benefit from the protective effect When braking release the throttle and...

Page 44: ...stand Note Fire hazard Hot vehicle components pose a fire hazard and explosion risk Do not park the vehicle near to materials which are highly flammable or explosive Allow the vehicle to cool down bef...

Page 45: ...hazard Avoid skin eye and clothing contact with fuel Immediately consult a doctor if you swallow fuel Do not inhale fuel vapors In case of skin contact rinse the affected area with plenty of water Ri...

Page 46: ...17 Fill the fuel tank with fuel up to the lower edge 1 of the fuel filler 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 cap...

Page 47: ...k the front brake linings p 61 Check the rear brake linings p 64 Check the brake lines for damage and leakage Check the front brake fluid level p 59 Check the rear brake fluid level p 62 Check the tir...

Page 48: ...er 1 000 km 620 mi Check the frame Check the link fork Check the fork bearing for play Check the wheel bearing for play Check the antifreeze Change the coolant p 85 Empty the drainage hoses Check all...

Page 49: ...promise between handling and stability S04220 10 Adjust the spring preload by turning adjusting ring 1 using the hook wrench from the tool set Guideline Spring preload Standard 3 clicks Hook wrench sh...

Page 50: ...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...

Page 51: ...adapters and raise the motorcycle 12 2 Removing the rear of the motorcycle from the lifting gear Note Danger of damage The parked vehicle can roll away or fall over Park the vehicle on a firm and leve...

Page 52: ...front lifting gear Note Danger of damage The parked vehicle can roll away or fall over Park the vehicle on a firm and level surface 402777 01 Main work Secure the motorcycle against falling over Remo...

Page 53: ...iscs free of oil and grease Clean the brake discs with brake cleaner when nec essary Clean and oil the dust boots and inner fork tubes of both fork legs Universal oil spray p 109 Press dust boots 2 of...

Page 54: ...After assembly check whether the seat is correctly locked and cannot be pulled up Finally check that the passenger seat is correctly mounted 12 8 Removing the front rider s seat Preparatory work Remov...

Page 55: ...an the brake discs with brake cleaner when necessary Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc corre...

Page 56: ...rk and measure chain tension A Info Top chain section B must be taut Chain wear is not always even so you should repeat this measurement at different chain positions Chain tension 5 7 mm 0 2 0 28 in I...

Page 57: ...even so you should check the setting at different chain positions Tighten nuts 2 Make sure that chain adjusters 4 are fitted correctly on adjusting screws 3 Tighten nut 1 Guideline Nut rear wheel spi...

Page 58: ...0 chain rollers at the longest chain section 301 6 mm 11 874 in If distance B is greater than the specified measurement Change the drivetrain kit Info When a new chain is mounted the rear sprocket and...

Page 59: ...S04212 10 Position the front spoiler Mount and tighten screws 1 Guideline Screw front spoiler rear M6x9 9 Nm 6 6 lbf ft 12 17 Removing the front fender G04960 10 Remove screws 1 Remove the front fend...

Page 60: ...t is not always possible to compensate for extreme riding situations for example with luggage loaded with a high center of gravity varying road surfaces steep descents or full braking without disengag...

Page 61: ...help 400480 10 Check the front and rear brake disc thickness at multiple points for the dimension A Info Wear will reduce the thickness of the brake disc at con tact surface 1 of the brake linings Bra...

Page 62: ...uitable protective clothing and safety glasses Do not allow brake fluid to come into contact with the skin the eyes or clothing Consult a doctor immediately if brake fluid has been swallowed Rinse the...

Page 63: ...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 re...

Page 64: ...uid level will cause the brake system to fail If the brake fluid level drops below the MIN marking the brake system is leaking or the brake linings are worn down Check the brake system and do not cont...

Page 65: ...Only use clean brake fluid from a sealed container Preparatory work Check the rear brake linings p 64 H01142 10 Condition The screw cap is locked Remove screw 1 and take off the screw cap lock S04214...

Page 66: ...inimum thickness is less than specified Change the rear brake linings Check the brake linings for damage and cracking If there is wear or tearing Change the rear brake linings 13 9 Checking the free t...

Page 67: ...brake lever pressure builds up in the brake system on the rear brake Set the free travel on the foot brake lever in accordance with the specification A00634 11 Detach spring 1 Release nut 2 and use s...

Page 68: ...lways lay the wheel down in such a way that the brake disc is not damaged Hold the front wheel and remove the wheel spindle Take the front wheel out of the fork Info Do not actuate the hand brake leve...

Page 69: ...holder M6 8 Nm 5 9 lbf ft Mount and tighten screws 5 Operate the hand brake lever repeatedly until the brake lin ings are in contact with the brake disc and there is a pressure point Take the motorcy...

Page 70: ...Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect Always keep the brake discs free of oil and grease Clean the brake discs with brake cleaner when necessary Warn...

Page 71: ...e rear wheel to be correctly aligned the mark ings on the left and right chain adjusters must be in the same position relative to reference markings B Nut rear wheel spin dle M14x1 5 98 Nm 72 3 lbf ft...

Page 72: ...bber pieces of the rear hub Finishing work Install the rear wheel p 68 Remove the rear of the motorcycle from the lifting gear p 49 Check the chain tension p 54 14 6 Checking the tire condition Warnin...

Page 73: ...contained in the tire label and is indicated by the last four digits of the DOT number The first two digits indicate the week of manufacture and the last two digits the year of manu facture KTM recom...

Page 74: ...14 WHEELS TIRES 72 Mount the protection cap...

Page 75: ...Remove the passenger seat p 51 Remove the front rider s seat p 52 V01273 10 Main work Disconnect negative cable 1 from the 12 V battery V01274 10 Pull back positive terminal cover 2 Disconnect positiv...

Page 76: ...terials Do not dispose of 12 V batteries as household waste Dispose of 12 V batteries at a collection point for used batteries Info Even when there is no load on the 12 V battery it discharges steadil...

Page 77: ...current charging voltage and charging time must not be exceeded Recharge the 12 V battery regularly when the motorcy cle is not being used 3 months Position the negative cable and mount and tighten th...

Page 78: ...011088010 p 102 Tip Insert spare fuse 2 in the fuse box so that it is available if needed Mount the protection cap S04216 11 To change the fuse of the ABS return pump Take off the protection cap and r...

Page 79: ...uel pump relay starter relay horn Fuse 5 10 A radiator fan Fuse 6 15 A brake light turn signal high beam low beam position light tail light license plate lamp Fuse 7 10 A ABS control unit CAN bus comb...

Page 80: ...deposited on the reflector Clean and degrease the bulbs before mounting Do not touch the bulbs with your bare hands G04938 10 Main work Remove screw 1 Lift the headlight mask slightly and swing forwa...

Page 81: ...the height of the center of the low beam headlight Make another mark at a distance B under the first marking Guideline Distance B 5 cm 2 in Position the vehicle perpendicular to the wall at a distance...

Page 82: ...u have a payload you may have to correct the headlight range Screw 1 also secures the headlight Ensure the screw is always screwed in far enough Finishing work Check the headlight setting p 79 15 9 Di...

Page 83: ...ited 16 2 Checking the coolant level Warning Danger of scalding During motorcycle operation the coolant gets very hot and is under pressure Do not open the radiator the radiator hoses or other cooling...

Page 84: ...ng During motorcycle operation the coolant gets very hot and is under pressure Do not open the radiator the radiator hoses or other cooling system components if the engine or the cooling system are at...

Page 85: ...e coolant antifreeze Check the coolant level in the radiator The radiator must be completely filled If the coolant level does not match the specified value Correct the coolant level and find out the c...

Page 86: ...upright Position an appropriate container under the engine Remove screw 1 with the seal ring Remove the radiator cap Completely drain the coolant Mount and tighten screw 1 with a new seal ring Guidel...

Page 87: ...gine and allow it to warm up G05016 10 Stop the engine and allow it to cool down When the engine is cool check the coolant level in the radiator and if necessary add coolant Remove the cap of compensa...

Page 88: ...is cold Preparatory work Remove the front spoiler p 57 S04240 10 Main work Position the motorcycle upright Position an appropriate container under the engine Remove screw 1 with the seal ring Remove...

Page 89: ...extraction when starting or running the engine in an enclosed space Start the engine and allow it to warm up G05016 12 Stop the engine and allow it to cool down When the engine is cool check the cool...

Page 90: ...unning the engine in an enclosed space Start the engine and let it run at idle speed Move the handle bar to and fro over the entire steering range The idle speed must not change If the idle speed chan...

Page 91: ...ecified value Adjust play in the clutch lever p 89 Move the handlebar to and fro over the entire steering range The clutch lever play must not change If the clutch lever play changes Check the routing...

Page 92: ...protective clothing and safety gloves In the event of scalding rinse the area affected immediately with lukewarm water Note Environmental hazard Hazardous substances cause environmental damage Dispose...

Page 93: ...ear of the engine L02203 10 Remove filler plug 6 with the O ring and fill up with engine oil Engine oil Ambient tempera ture 0 50 C 32 122 F 1 5 l 1 6 qt Engine oil SAE 15W 50 p 107 Engine oil Ambient...

Page 94: ...il performance it is 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 pois...

Page 95: ...ect sunshine when cleaning the motorcycle 401061 01 Close off exhaust system to keep water from entering Remove loose dirt first with a soft jet of water Spray the heavily soiled parts with a normal c...

Page 96: ...surfaces p 109 Lubricate the ignition and steering lock Universal oil spray p 109 19 2 Checks and maintenance steps for winter operation Info If you use the motorcycle in winter you must expect salt o...

Page 97: ...reen p 90 Check the antifreeze and coolant level p 82 Check tire pressure p 71 Remove the 12 V battery p 73 Charge the 12 V battery p 74 Guideline Storage temperature of the 12 V battery without direc...

Page 98: ...059 01 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 Set the clock p 32 Perform checks and maintenance...

Page 99: ...ormation in cooling sys tem Drain the coolant p 83 Fill bleed the cooling system p 84 Thermostat defective Check the thermostat Fuse 5 blown Change the fuses of individual electri cal power consumers...

Page 100: ...arge the 12 V battery p 74 The 12 V battery is not being charged by the alternator Check the charging voltage Check the open circuit current Combination instrument shows nothing on the display Fuse 8...

Page 101: ...gs One compression ring one tapered compression pis ton ring one oil scraper ring Engine lubrication Pressure circulation lubrication with one trochoidal pump Primary transmission 22 72 Clutch Clutch...

Page 102: ...et M6 6 Nm 4 4 lbf ft Loctite 243 Screw clutch cover M6 12 Nm 8 9 lbf ft Screw engine case M6x40 12 Nm 8 9 lbf ft Screw engine case M6x60 12 Nm 8 9 lbf ft Loctite 243 Screw engine sprocket M6 12 Nm 8...

Page 103: ...x1 10 Nm 7 4 lbf ft Spark plug M12 15 Nm 11 1 lbf ft Nut inner clutch hub M14LH 60 Nm 44 3 lbf ft Loctite 243 Nut primary gear wheel timing chain sprocket M14 55 Nm 40 6 lbf ft Loctite 243 Oil drain p...

Page 104: ...ar 2 2 bar 32 psi Secondary ratio 14 42 Chain 5 8 x 1 4 520 X ring Steering head angle 65 Wheelbase 1 367 15 mm 53 82 0 59 in Seat height unloaded 800 mm 31 5 in Dry weight 140 kg 309 lb Maximum permi...

Page 105: ...d EJOT PT K60x30 7 Nm 5 2 lbf ft Remaining screws chassis M4 4 Nm 3 lbf ft Remaining nuts chassis M5 5 Nm 3 7 lbf ft Remaining screws chassis M5 5 Nm 3 7 lbf ft Screw chain guard M5 7 Nm 5 2 lbf ft Lo...

Page 106: ...ew ignition coil M6 8 Nm 5 9 lbf ft Screw ignition lock tamper proof screw M6 13 Nm 9 6 lbf ft Screw license plate holder M6 12 Nm 8 9 lbf ft Loctite 243 Screw lower rear panel M6 7 Nm 5 2 lbf ft Scre...

Page 107: ...11 1 lbf ft Screw front brake caliper M8x1 30 Nm 22 1 lbf ft Loctite 243 Banjo bolt brake line M10 24 Nm 17 7 lbf ft Fitting side stand M10 35 Nm 25 8 lbf ft Loctite 243 Remaining nuts chassis M10 45...

Page 108: ...6 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 2nd sta...

Page 109: ...Only use coolant that complies with the requirements stated see specifications on the container and that has the relevant properties Antifreeze protection to at least 25 C 13 F The mixture ratio must...

Page 110: ...leaded fuel that matches or is equivalent to the specifications Super unleaded fuel with an ethanol content of 19 to 20 is permissible Info Do not use fuel made of methanol e g M15 M85 M100 Do not use...

Page 111: ...Clean Perfect finish and high gloss polish for paints Recommended supplier MOTOREX Moto Shine Preserving materials for paints metal and rubber Recommended supplier MOTOREX Moto Protect Special cleane...

Page 112: ...ce intervals are demanded for automobile engines the focus for motorcycle engines is on high performance at high engine speeds In most motorcycle engines the transmission and clutch are lubricated wit...

Page 113: ...ck braking system Safety system that prevents locking of the wheels when driving straight ahead without the influence of lateral forces OBD On board diagnosis Vehicle system which monitors the specifi...

Page 114: ...27 LIST OF ABBREVIATIONS 112 Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly...

Page 115: ...hop 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 Status...

Page 116: ...ting 54 checking 54 Clutch lever 14 Clutch lever play checking 88 Combination instrument 21 34 ABS display 27 activation and test 21 Actual F C 28 Average Speed Trip1 30 Average Speed Trip2 31 Avg F C...

Page 117: ...lamps 23 Intended use 6 K Key number 13 Kilometers or miles adjusting 32 L Light switch 15 Load the vehicle 36 Luggage 36 M Manufacturer warranty 10 Misuse 6 Motorcycle cleaning 93 lifting with front...

Page 118: ...rage 95 T Technical accessories 10 Technical data capacities 101 chassis 102 chassis tightening torques 103 electrical system 102 engine 99 engine tightening torques 100 fork 103 shock absorber 103 ti...

Page 119: ...3214318en 3214318en 01 2022 KTM Sportmotorcycle GmbH 5230 Mattighofen Austria KTM COM Photo Mitterbauer KISKA KTM...

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