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KTM · Shim-adjusted overhead-cam four-stroke, wet sump, gearbox shares engine oil, chain drive

Duke 125

Library entry covers 2011-2024

42 factory 33 guideline

Published source

KTM 125 Duke owner's manual 2019 (art. no. 3213936en), ch.10 Service schedule; Wayback copy of ktmshop.se PDF

Factory owner's handbook. Covers 2019 125 Duke owner's manual, art. no. 3213936en.

75 items for a 2020 model, grouped by interval the way a factory chart is laid out.

How this bike is built (what the schedule is based on)

Engine cycle: Four-stroke
Engine lubrication: Wet sump (oil in crankcase)
Oil filtration: Replaceable cartridge or spin-on filter
Valve gear: Overhead cam, shim adjusted (incl. desmo)
Ignition: Electronic (CDI / transistor / ECU)
Charging: Alternator / stator with rectifier
Battery: Wet cell (flooded lead-acid, needs topping up)
Fuel system: Fuel injection
Cooling: Liquid cooled
Primary drive: Gear or chain inside engine, shares engine oil
Gearbox oil: Shares engine oil
Clutch control: Hand lever, cable
Final drive: Chain
Front suspension: Telescopic fork
Rear suspension: Swingarm, single shock / cantilever
Front brake: Disc, hydraulic
Rear brake: Disc, hydraulic
Wheels: Cast / alloy, tubeless
Sidecar: No sidecar

Maintenance schedule

2020 KTM Duke 125

On the road: every 300 km

1 item

Check engine oil level

Pre-ride / on the road

Guideline

Each fuel stop on old machines. Dry sump: check the tank hot, engine idling or just stopped, per your manual.

On the road: every 500 km

3 items

Check lights, horn, brake light switches

Pre-ride / on the road

Guideline
Check tire pressures

Pre-ride / on the road

Guideline
Lubricate drive chain

Pre-ride / on the road

Guideline

Lube warm, ideally at the end of the riding day so it soaks in overnight. Sooner after rain.

On the road: every 800 km

1 item

Check coolant level

Pre-ride / on the road

Guideline

On the road: every 1,000 km

1 item

Check chain slack and rear wheel alignment

Pre-ride / on the road

Guideline

Every 5,000 km or 12 months

3 items

Clean drive chain thoroughly (remove and soak, re-lube)

Final drive

Guideline

Non O-ring chains on old machines: remove, clean, soak in hot chain grease or lube, refit with the master link clip closed end leading.
Check footrests, pegs, rear brake and gear lever pivots

Rear suspension and frame

Guideline
Grease and check center / side stand and springs

Rear suspension and frame

Guideline

Every 6,500 km or 12 months

2 items

Inspect, clean and gap spark plugs

Engine

Guideline
Adjust clutch free play, lubricate cable and lever pivot

Primary and gearbox

Guideline

Every 7,500 km or 12 months

30 items

Change engine oil

Engine

Factory

Manual: Change the engine oil and oil filter, clean the oil screen. Factory: One-time at 1,000 km (620 mi); Cols: after 1,000 km (620 mi); every 7,500 km (4,650 mi); every 15,000
Check that the electrical system is functioning properly.

Engine

Factory

Factory: As printed: ● Every two years; ● Every year; ● every 15,000 km (9,300 mi); ● every 7,500 km (4,650 mi); ○ after 1,000 km (620 mi)
Check that the radiator fan is functioning properly.

Engine

Factory

Factory: As printed: ● Every two years; ● Every year; ● every 15,000 km (9,300 mi); ● every 7,500 km (4,650 mi); ○ after 1,000 km (620 mi)
Check the antifreeze

Engine

Factory

Factory: After 1,000 km (620 mi) one-time, then every 7,500 km (4,650 mi) and every year; workshop item KTM 125 Duke owner's manual 2019 (3213936en, ktmshop.se copy), Service schedule p.109, read in the browser
Check the coolant level.

Engine

Factory

Factory: As printed: ● Every two years; ● Every year; ● every 15,000 km (9,300 mi); ● every 7,500 km (4,650 mi); ○ after 1,000 km (620 mi)
Check the screws and nuts for tightness.

Engine

Factory

Factory: As printed: ● Every four years; ● Every year; ● every 30,000 km (18,600 mi); ● every 7,500 km (4,650 mi); ○ after 1,000 km (620 mi)
Clean oil strainers / mesh screens

Engine

Factory

Manual: Change the engine oil and oil filter, clean the oil screen. Factory: One-time at 1,000 km (620 mi)
Empty the drainage hoses.

Engine

Factory

Factory: As printed: ● Every four years; ● Every year; ● every 30,000 km (18,600 mi); ● every 7,500 km (4,650 mi); ○ after 1,000 km (620 mi)
Final check: Check the vehicle is roadworthy and take a test ride.

Engine

Factory

Factory: As printed: ● Every two years; ● Every year; ● every 15,000 km (9,300 mi); ● every 7,500 km (4,650 mi); ○ after 1,000 km (620 mi)
Inspect coolant hoses and clamps

Engine

Factory

Manual: Check all hoses (e.g. fuel, coolant, bleeder, drainage, etc.) and sleeves for cracking, leaks, and.... Factory: One-time at 1,000 km (620 mi); Recommended work
Make the service entry in KTM Dealer.net and in the Service & Manufacturer Warranty booklet.

Engine

Factory

Factory: As printed: ● Every two years; ● Every year; ● every 15,000 km (9,300 mi); ● every 7,500 km (4,650 mi); ○ after 1,000 km (620 mi)
Read out the error memory after the test ride using the KTM diagnostics tool.

Engine

Factory

Factory: As printed: ● Every two years; ● Every year; ● every 15,000 km (9,300 mi); ● every 7,500 km (4,650 mi); ○ after 1,000 km (620 mi)
Read out the fault memory using the KTM diagnostics tool.

Engine

Factory

Factory: As printed: ● Every two years; ● Every year; ● every 15,000 km (9,300 mi); ● every 7,500 km (4,650 mi); ○ after 1,000 km (620 mi)
Replace oil filter

Engine

Factory

Manual: Change the engine oil and oil filter, clean the oil screen. Factory: One-time at 1,000 km (620 mi)
Set the service interval display.

Engine

Factory

Factory: As printed: ● Every two years; ● Every year; ● every 15,000 km (9,300 mi); ● every 7,500 km (4,650 mi); ○ after 1,000 km (620 mi)
Check throttle cable(s) free play and return

Fuel and air

Factory

Manual: Check that the throttle cables are undamaged, routed without sharp bends, and set cor- rectly. Factory: One-time at 1,000 km (620 mi)
Check the chain tension.

Final drive

Factory

Factory: As printed: ● Every two years; ● Every year; ● every 15,000 km (9,300 mi); ● every 7,500 km (4,650 mi); ○ after 1,000 km (620 mi)
Inspect chain and sprockets for wear (measure stretch)

Final drive

Factory

Manual: Check the chain, rear sprocket, and engine sprocket.
Check steering head bearing adjustment

Front end

Factory

Manual: Check the steering head bearing play. Factory: One-time at 1,000 km (620 mi)
Inspect fork seals, stanchions and fork boots

Front end

Factory

Manual: Check the shock absorber and fork for leaks. Factory: One-time at 1,000 km (620 mi)
Check brake pads and discs

Brakes

Factory

Manual: Check the brake discs. Factory: One-time at 1,000 km (620 mi)
Check the front brake fluid level

Brakes

Factory

Factory: After 1,000 km (one-time), then every 7,500 km (4,650 mi) and every year Re-read from KTM 125 Duke owner's manual 3213936 service schedule pp.106-108 (web.archive.org copy)
Check the front brake linings.

Brakes

Factory

Factory: As printed: ● Every two years; ● Every year; ● every 15,000 km (9,300 mi); ● every 7,500 km (4,650 mi); ○ after 1,000 km (620 mi)
Check the rear brake fluid level

Brakes

Factory

Factory: After 1,000 km (one-time), then every 7,500 km (4,650 mi) and every year Re-read from KTM 125 Duke owner's manual 3213936 service schedule pp.106-108 (web.archive.org copy)
Check the rear brake linings.

Brakes

Factory

Factory: As printed: ● Every two years; ● Every year; ● every 15,000 km (9,300 mi); ● every 7,500 km (4,650 mi); ○ after 1,000 km (620 mi)
Inspect brake hoses; replace old rubber

Brakes

Factory

Manual: Check the brake lines for damage and leakage. Factory: One-time at 1,000 km (620 mi)
Check tire pressure.

Wheels and tires

Factory

Factory: As printed: ● Every two years; ● Every year; ● every 15,000 km (9,300 mi); ● every 7,500 km (4,650 mi); ○ after 1,000 km (620 mi)
Inspect tire tread, sidewalls and date codes

Wheels and tires

Factory

Manual: Check the tire condition. Factory: One-time at 1,000 km (620 mi)
Check the cables for damage and routing without sharp bends.

Controls and cables

Factory

Factory: As printed: ● Every two years; ● Every year; ● every 15,000 km (9,300 mi); ● every 7,500 km (4,650 mi); ○ after 1,000 km (620 mi)
Lubricate control cables and lever pivots

Controls and cables

Factory

Manual: Grease all moving parts (e.g., side stand, hand lever, chain, ...) and check for smooth operation. Factory: One-time at 1,000 km (620 mi); Recommended work

Every 7,500 km

5 items

Check the headlight setting

Engine

Factory

Factory: After 1,000 km (one-time), then every 7,500 km (4,650 mi) Re-read from KTM 125 Duke owner's manual 3213936 service schedule pp.106-108 (web.archive.org copy)
Replace air filter element

Fuel and air

Factory

Manual: Change the air filter, clean the air filter box.
Clean the dust boots of the fork legs

Front end

Factory

Factory: Every 7,500 km (4,650 mi) and every 15,000 km columns Re-read from KTM 125 Duke owner's manual 3213936 service schedule pp.106-108 (web.archive.org copy)
Check swingarm bushes for play

Rear suspension and frame

Factory

Manual: Check the link fork bearing for play. Factory: Recommended work
Check wheel bearings for play

Wheels and tires

Factory

Manual: Check the wheel bearing for play. Factory: Recommended work

Every 9,500 km or 12 months

4 items

Clean / inspect air filter

Fuel and air

Guideline

Mesh or oiled foam: clean and re-oil. Paper: blow out or replace. Some very early machines have no filter at all.
Check charging voltage and regulator / cut-out

Ignition and electrics

Guideline
Inspect rear shocks for leaks and damping

Rear suspension and frame

Guideline
Lubricate speedometer / tachometer cables, check drive

Controls and cables

Guideline

A dry speedo cable whips the needle and eventually kills the instrument.

Every 15,000 km

2 items

Check and adjust valve clearances

Engine

Factory

Manual: Check the valve clearance, change the spark plug.
Replace spark plugs

Engine

Factory

Manual: Check the valve clearance, change the spark plug.

Every 16,000 km or 2 years

1 item

Compression test (or leak-down)

Engine

Guideline

Every 19,500 km or 2 years

3 items

Synchronize throttle bodies

Fuel and air

Guideline
Clean and grease rear suspension linkage

Rear suspension and frame

Guideline
Grease swingarm pivot

Rear suspension and frame

Guideline

Every 24,000 km or 3 years

1 item

Change fork oil

Front end

Guideline

Some early telescopic forks are grease filled or use very small oil quantities. Check your manual.

Every 24,000 km or 4 years

1 item

Check valve clearances (shim adjusted)

Engine

Guideline

Every 29,000 km

1 item

Replace chain and sprockets (wear based)

Final drive

Guideline

Every 30,000 km

2 items

Check the link fork

Front end

Factory

Factory: Every 30,000 km (18,600 mi); workshop item KTM 125 Duke owner's manual 2019 (3213936en, ktmshop.se copy), Service schedule p.109, read in the browser
Check the frame (recommended work)

Rear suspension and frame

Factory

Factory: Recommended work: every 30,000 km (18,600 mi) Re-read from KTM 125 Duke owner's manual 3213936 service schedule pp.106-108 (web.archive.org copy)

Every 32,000 km or 4 years

2 items

Repack / replace steering head bearings

Front end

Guideline

Many old machines use loose balls in cups and cones. Taper roller conversions are common.
Repack / replace wheel bearings

Wheels and tires

Guideline

Cup-and-cone and taper roller hubs need periodic repacking and adjustment.

Every 38,500 km or 4 years

1 item

Replace fuel filter

Fuel and air

Guideline

Every 40,000 km or 6 years

1 item

Replace swingarm bushes / bearings

Rear suspension and frame

Guideline

Every 48,500 km or 6 years

1 item

Rebuild forks: seals, bushes, springs

Front end

Guideline

Every 6 months

1 item

Clean battery terminals, check charge and strap

Ignition and electrics

Guideline

Every 2 years

4 items

Inspect wiring, bullet connectors and ground points

Ignition and electrics

Guideline
Inspect frame, welds and lugs for cracks

Rear suspension and frame

Guideline
Change the rear brake fluid

Brakes

Factory

Factory: Every two years Re-read from KTM 125 Duke owner's manual 3213936 service schedule pp.106-108 (web.archive.org copy)
Replace brake fluid

Brakes

Factory

Manual: Change the front brake fluid.

Every 4 years

3 items

Replace coolant

Engine

Factory

Manual: Change the coolant. Factory: Recommended work
Replace fuel lines

Fuel and air

Guideline

Old rubber and modern ethanol fuel do not mix well.
Rebuild calipers and master cylinders (seals)

Brakes

Guideline

Every 6 years

1 item

Replace tires on age (regardless of tread)

Wheels and tires

Guideline

Guideline lines: Intervals here are general guidelines for the machine's era and layout, compiled for this app. They are not factory manual figures. Check your workshop manual, and edit any interval in the bike's Schedule tab.