D I Y

Know your Duke Better….. Digital fuel injection System :

Sensors Actuators
1. Temperature /Manifold pressure
sensor. 1. Fuel pump.
2. Oxygen ( lambda) Sensor. 2. Injector.
3. Ignition Pulse Sensor. 3. HT coil.
4. Coolant Temperature Sensor. 4. Idle speed
5. Front wheel Speed Sensor. Actuator.
6. Vehicle Down ( Roll Over) sensor. 5. Malfunction light.
7. Throttle position Sensor. 6. Diagnostic
coupler.
7. Fan.
8. Water Temp
ECU The gauge.
9. Starter Relay.
brain
(Controls 10. Speedometer.
Ignition
advance & Fuel
Metering)

• “Intelligent engine management” by ECU based on inputs from different sensors.

• Better Power/fuel efficiency/less emissions.
• Razor sharp throttle response at all speed/load/environmental conditions.
• Superb cold starting ability.
• Do device, which would fiddle with DFi system.
• Do not allow any external ECU mis-management.
• Protect sensors/actuators during pressure washing.
Know your Duke Better….. Lubrication system :
Oil Pressure
Oil jet for cam Sensor switch
• Oil pump maintain pressure in the system.
journal • Oil Qty : 1.4 liters /Oil Grade : SAE 20 W 50.
• JASO MA/MA1 – SG/SL grade.
• Replacement interval : 1000 kms – every
5000 kms.
• Replace oil filter with each oil change.
• Recommended oil :
1. Bajaj DTSi 10000.
2. Motul 7100
Oil jet for
Piston Oil jet for
crank journal
• In case of Low oil pressure alarm is seen
report to nearest KTM service centre.
Oil filter Oil Pressure
• Workshops would insist for oil change at
regulator valve
specified intervals.
Oil Pump Oil drain plug/
oil screen
Know your Duke Better….. Water cooling system :
• Engine starts.
• Water pump impeller forces coolant.
Reservoir Tank • Coolant runs through jackets.
• Enters in to thermostat.
• Closed thermostat by passes radiator.
• Coolant flows to pump.
• Engine warms up quickly.
• At 72 degrees thermostat opens.
• Coolant flows through radiator – cools down.
Radiator cap • Engine load increases – temp goes up further.
Radiator &Fan • Fan switches ON at 96 degrees.
• Brings down temp to 88 degrees.
Bleeding • Fan switches off at 88 degrees.
screw. • When pressure is above 1.4 Kg.cm2.
Thermostat • Radiator cap valve opens.
• Coolant enters in res tank – releasing
pressure.
• After cooling down, pressure reduces.
Water jackets • Vacuum valve inside cap opens.
• Coolant flows back in system.
• When coolant alarm message is ON – Do not drive as it is.
Hose pipes • Do not open radiator cap in hot condition.
• No mixing of different brands of coolant/ ordinary water.
• In case of coolant leak on run – Pour ordinary water
Water Pump before continuing drive.
Know your Duke Better….. The Cockpit :
MI Light Indicator Shift rpm indicator
Side Indicator Neutral Gear
Display Indicator

Tachometer
Hi beam Indicator
Mode button
Gear Indicator Dummy

Set button Immobilizer

Speedometer Alarm Generic
signal

Coolant
Temperature Trip meter 1 & 2
Indicator Trip F

Odometer

Info Display Digital Clock Fuel Level Indicator

• Shift RPM 1 & 2 at 5000 & 7500 during running in. Rev limiter -10500 to 11000 rpm.
• Distance to empty would be shown after min of 0.8 kms drive, in ignition switch ON mode.
• Calculation of fuel consumption would vary based on speed/load/road conditions.
• Report to nearest KTM workshop in case of Alarm signal/MIL light remain ON.
Know your Duke Better….. Read before you ride :
1 Please read Owner's Manual before riding.
2 Use unleaded fuel with octane rating equal to or more than 91. Do not use any additives.
3 "Break in" period : Do not allow engine rpm to raise beyond 7500 rpm for first 1000 kms.
"Periodic Maintenance Schedule" - Follow as recommended in Owner's manual.
4 First service - 1000 kms and next services at every 5000 kms.
Kilometers remaining before next service would be indicated on speedometer.
Get the vehicle inspected from an authorized KTM workshop in case any one
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of the alarm message is being flashed at Speedometer.
6 Daily safety checks - Observe the daily safety checks as specified in owner's manual.
Maintaining Battery charge level is very essential, for starting of vehicle. Addition of distilled water is
7 not required. In case of low usage bench charge the battery at periodic interval. Ensure that the
Ignition switch is in OFF position when engine is not running, otherwise it would drain the battery.
Do not add any additional electrical / electronic gadgets on the vehicle, as they would disturb
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functioning of engine management system.
Use both the brakes at a time. Use of front brake for dead stop would give better control.
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Do not apply front brake while cornering.
Tyres fitted on this vehicle are tubeless. Do not allow anybody to open them by using wrong tools.
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Go to authorized MRF tyre dealers.
Chain with built in O ring is fitted on this vehicle. The lubrication is at every 600 kms with SAE 90 oil
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and adjustment at every 1000 kms. Pl see to it that the chain never runs in dry condition.
During washing of the vehicle, do not direct the jet of water towards electrical parts/sensors and
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radiator. Radiator fins will have to be protected from damage during washing.
Follow the instructions given in storage section of owner's manual in
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case of vehicle is not to be used for longer period.
Do it yourself – Periodic Maintenance Chart.
Do it yourself – Periodic Maintenance Chart.
 Do it yourself – Air Filter element cleaning.
1 2 3 4

Remove Pillion seat by Remove Rider seat bolts (2 Remove Rider seat by Remove Air filter cap bolts
unlocking. nos.) using spanner. pulling from front. (A) 2 nos. by spanner.

5 6 7

Lift cap of Air filter Pull out Air filter element Dust the Air filter element
gently ouside in by tapping

• Do not direct compressed air at filter as it may damage the paper element.
• Replace Air Filter element at every 5000 kms. or if observed torn / punctured during cleaning.
• In dusty areas, the element should be cleaned more frequently than the recommended interval.
• Fit the lugs of filter cover snugly in to the body of filter cover while installation.
 Do it yourself – Oil Level inspection.
Brake Oil level inspection Front & Rear :
•Check that the brake fluid level in •Check that the brake
the front brake reservoir [A] is fluid level in the rear
above the lower level line [B]. brake reservoir [A] is
•If the fluid level is lower than the above the lower level
lower lever line, top up the line [B]
reservoir to the upper level line [C] •If the fluid level is lower
in the reservoir. than the lower level line,
* Note: Hold the reservoir top -up the reservoir to
horizontal by turning the the upper line [C].
handlebar when checking brake
fluid level.

WARNING
Mixing of different brand/ types of brake fluid can reduce the effectiveness of braking system and cause an accident. Do
not mix two brands of brake fluid. In case the type and brand of the brake fluid that is already in the reservoir are not
known, replace the brake fluid in the brake line completely instead of topping up. Always use DOT4 Grade brake fluid.
Ensure that Engine oil level is in between upper [A] and lower [B] levels of the
Engine oil level inspection : gauge.
NOTE: -
• Park the motorcycle perpendicular to the ground level.
• If the motorcycle is just been used, wait few minutes to drain down the
A Max engine oil inside the engine.
B Min • If the oil has just been changed, start the engine and run it for several
minutes at idle speed. This will allow the engine to fill the oil in filter. Again
stop the engine then wait several minutes until the oil settles.
Do it yourself – Engine oil replacement.
Clean drain plug &
1
1. Take bike off side stand . 2
2. Put Vehicle on Wheel Stand & Lock screen thoroughly
front brake Position oil screen(B)
3. Remove Lower belly Pan. inside the drain passage
4. Start & off the engine after 10-15
B & then mount & tighten
seconds. oil drain plug(A) with
A 5. Drain oil by opening drain Plug(A) & the "o'" ring.
Pull out the screen with help of a pliers. TORQUE: 0.8 kgm

Pull out filter (A).

3 4 Completely remove oil
& clean the parts &
sealing areas.
A Remove two screws(A) of filter cover(B) &
Insert Oil filter (A).
remove cover with "o" ring
Oil the "o" ring of the oil
filter cover. Mount oil
B A filter cover & tighten
screws.

Fill the 1.4 Liter recommended Engine oil

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Recommended Oil : -
SAE 20W50 of API, “SL” or above with JASO
‘MA’, ‘MA1 or ‘MA2’

For Better performance use “Bajaj DTS-i

10,000” Genuine Engine Oil.
Do it yourself – Coolant level inspection/ Disc pad wear Inspection
With bike on upright position on a horizontal surface and engine in
cold condition:
• Coolant Level must be between MIN & MAX.
A • If less then top up with Coolant ( mixed ready to use) through
plug (A)
•Always use Recommended Premix permanent type Anti freeze
coolant for top up. Eg. Castrol Radicool series

Warning : Danger of poisoning Coolant is poisonous and a health hazard. Avoid contact between coolant and
skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and contact a doctor. Wash affected
skin areas immediately with soap and water.
• Tighten reservoir tank cap completely to ensure sealing of cap/tank joint.
• Do not drive the vehicle at high speeds in case of coolant loss, contact nearest workshop.
• A drop of @ 50 ml post filling would be natural. If drop is more than that get the vehicle inspected.
• Check Coolant level only after the bike has cooled down. For coolant top up do not add tap water.

•Remove the brake pads and check the lining

thickness [A] of the pads in each caliper.
•If the lining thickness of either pad is less
A than the service limit, replace both pads in the
caliper as a set.
•Pad lining thickness Service limit: 1mm
 Do it yourself – Drive chain slack inspection/adjustment & lubrication.
1. First loosen nut (A) and then loosen nuts (B)
D on either side.
2. Turn the adjustment screw (C) on the left &
right so that the markings on left & Right
chain adjuster (D) are in the same position
A in relation to reference marks (E).
B
3. Upper chain must be tight.
4. Chain wear is always not even, so please
C check the settings at different locations..
E 5. Tighten the nuts (B).
Chain slackness 5~ 7mm
6. Ensure that chain adjusters(D) are fitted
Position of Chain slackness inspection (B)
correctly on adjusting screws(C).

E . Check that the markings on left & Right chain

adjuster (D) are in the same position in relation
to reference marks (E) on swing arm.
. If they do not, adjust the chain slack and align
the wheel alignment,

Misalignment of wheel will result in abnormal

D wear and may result in an unsafe riding
condition. Be sure the wheel is properly aligned 36DH4029 - OKS Chain Spray

• Sports vehicles use open chains.

• `O’ rings are used aside roller case on open chains to prevent dust entry inside chain.
•`O’ rings must always be in wet condition to ensure better performance /longer life of chain.
• Lubricate chain every 500km & get slack adjusted every 1000kms.
• For better retention of lubricant ``chain lubrication spray“ can be used.
Do it yourself – Rear Shock absorber setting adjustment.
The standard adjuster
setting is 3rd position (A).

A Shock Road
Adjuster Damping Driving
Absorber Load Condition
Position force Speed
Hardness s
1st Weak Soft Light Good Low

10th Strong Hard Heavy Bad Highwa

y

Rear Shocker
Spring pre load can If the compression of the spring is not suited to the
be adjusted by operating conditions, adjust it to an appropriate
using special position by referring to the table above.
wrench.
Do it yourself – Battery : 12 V 8 AH VRLA
•Remove Pillion seat. B A •Slide out the (-)
• Remove Rider seat. C terminal cap [A] &
•Remove Battery Band disconnect the
A [A] negative (-) cable first.
•Slide out the(+)
terminal cap [B] &
disconnect the
positive (+)cable.
•Remove the battery
[C]
•Battery charging condition can be
checked by measuring battery terminal
voltage with a digital voltmeter (A).
Portable Booster
•If the reading is 12.4V or more, no Charger
refresh charge is required, However, if
the reading is below the specified,
refresh charge is required
• A Constant Voltage battery charger
having the capacity to charge 8 Amp
hours battery should be used for
charging the battery

• This battery is sealed type. Never remove sealing cap even at charging. Never add electrolyte / water.
• Use VRLA Battery charger for battery charging.
• Use Battery load tester to correctly gauge Battery charge capacity.
Do it yourself – Head light beam alignment.
•The light-dark boundary must
lie exactly on the lower mark
A when the motorcycle is ready
to operate with the rider
• Remove screws mounted along with luggage &
(A) a passenger if applicable.
• Remove A • Adjust focus if it does not
expanding rivets meet specifications by
(B) on both sides swinging the Headlight mask
• Fold the head forward.
light mask r • Adjust the beam distance of
forward headlight by turning screw (A).
• TURN CLOCKWISE TO
B INCREASE THE HEADLIGHT
HEIGHT, ANTICLOCKWISE TO
REDUCE HEIGHT.

•Position the vehicle straight on a horizontal surface in

front of a light color wall & make a mark at the height of
the centre of low beam headlight.- 890mm
•Make another mark at a distance (B) under first mark.
Dist (B) - 9 cm. ( 800 mm)
•Position the vehicle at a distance (A) in front of the
wall & switch on the low beam. Dist (A) - 5 mts
•Make rider sit on Motorcycle. Check the settings.
Do it yourself – Non use maintenance.
Wishing all the Kings riding the Duke 200 a very happy ride.