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

Duke 200

Library entry covers 2012-2016

28 factory 50 guideline

Published source

KTM 200 Duke 2015 Owner's Manual, Service schedule (ManualsLib 1069181 pages 72-73)

Factory source. Covers KTM 200 Duke 2015 owner's manual, Art. no. 3213118en (cover prints 200 Duke 2015); other model years not checked.

78 items for a 2016 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

2016 KTM Duke 200

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 1,600 km or 6 months

1 item

Inspect tire tread, sidewalls and date codes

Wheels and tires

Guideline

Every 5,000 km or 12 months

9 items

Check throttle cable(s) free play and return

Fuel and air

Guideline
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.
Inspect chain and sprockets for wear (measure stretch)

Final drive

Guideline
Check steering head bearing adjustment

Front end

Guideline
Inspect fork seals, stanchions and fork boots

Front end

Guideline
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
Check brake pads and discs

Brakes

Guideline
Check wheel bearings for play

Wheels and tires

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

25 items

Antifreeze and coolant level (check)

Engine

Factory

Factory: Service schedule 9.1 (2015 owner's manual printed pp.70-71; columns: once after 1,000 km (621 mi), every 7,500 km (4,660 mi) or annually, every 15,000 km (9,321 mi) or every 2 years). every 7,500 km (4,660 mi) or annually. Also once after 1,000 km.
Electrical equipment (check function)

Engine

Factory

Factory: Service schedule 9.1 (2015 owner's manual printed pp.70-71; columns: once after 1,000 km (621 mi), every 7,500 km (4,660 mi) or annually, every 15,000 km (9,321 mi) or every 2 years). every 7,500 km (4,660 mi) or annually. Also once after 1,000 km.
Engine oil and oil filter (change), oil screen (clean)

Engine

Factory

Factory: Service schedule 9.1 (2015 owner's manual printed pp.70-71; columns: once after 1,000 km (621 mi), every 7,500 km (4,660 mi) or annually, every 15,000 km (9,321 mi) or every 2 years). every 7,500 km (4,660 mi) or annually. Also once after 1,000 km.
Fault memory (read out with KTM diagnostics tool)

Engine

Factory

Factory: Service schedule 9.1 (2015 owner's manual printed pp.70-71; columns: once after 1,000 km (621 mi), every 7,500 km (4,660 mi) or annually, every 15,000 km (9,321 mi) or every 2 years). every 7,500 km (4,660 mi) or annually. Also once after 1,000 km. Read out again after the test ride.
Final check and test ride

Engine

Factory

Factory: Service schedule 9.1 (2015 owner's manual printed pp.70-71; columns: once after 1,000 km (621 mi), every 7,500 km (4,660 mi) or annually, every 15,000 km (9,321 mi) or every 2 years). every 7,500 km (4,660 mi) or annually. Also once after 1,000 km.
Headlight setting (check)

Engine

Factory

Factory: Service schedule 9.1 (2015 owner's manual printed pp.70-71; columns: once after 1,000 km (621 mi), every 7,500 km (4,660 mi) or annually, every 15,000 km (9,321 mi) or every 2 years). every 7,500 km (4,660 mi) or annually. Also once after 1,000 km.
Hoses and bellows (check for cracking, leaks and routing)

Engine

Factory

Factory: Service schedule 9.1 (2015 owner's manual printed pp.70-71; columns: once after 1,000 km (621 mi), every 7,500 km (4,660 mi) or annually, every 15,000 km (9,321 mi) or every 2 years). every 7,500 km (4,660 mi) or annually. Also once after 1,000 km.
Moving parts (grease and check for smooth operation)

Engine

Factory

Factory: Service schedule 9.1 (2015 owner's manual printed pp.70-71; columns: once after 1,000 km (621 mi), every 7,500 km (4,660 mi) or annually, every 15,000 km (9,321 mi) or every 2 years). every 7,500 km (4,660 mi) or annually. Also once after 1,000 km.
Radiator fan (check function)

Engine

Factory

Factory: Service schedule 9.1 (2015 owner's manual printed pp.70-71; columns: once after 1,000 km (621 mi), every 7,500 km (4,660 mi) or annually, every 15,000 km (9,321 mi) or every 2 years). every 7,500 km (4,660 mi) or annually. Also once after 1,000 km.
Screws and nuts (check for tightness)

Engine

Factory

Factory: Service schedule 9.1 (2015 owner's manual printed pp.70-71; columns: once after 1,000 km (621 mi), every 7,500 km (4,660 mi) or annually, every 15,000 km (9,321 mi) or every 2 years). every 7,500 km (4,660 mi) or annually. Also once after 1,000 km.
Air filter (change), air filter box (clean)

Fuel and air

Factory

Factory: Service schedule 9.1 (2015 owner's manual printed pp.70-71; columns: once after 1,000 km (621 mi), every 7,500 km (4,660 mi) or annually, every 15,000 km (9,321 mi) or every 2 years). every 7,500 km (4,660 mi) or annually.
Chain tension (check)

Final drive

Factory

Factory: Service schedule 9.1 (2015 owner's manual printed pp.70-71; columns: once after 1,000 km (621 mi), every 7,500 km (4,660 mi) or annually, every 15,000 km (9,321 mi) or every 2 years). every 7,500 km (4,660 mi) or annually. Also once after 1,000 km.
Chain, rear sprocket and engine sprocket (check)

Final drive

Factory

Factory: Service schedule 9.1 (2015 owner's manual printed pp.70-71; columns: once after 1,000 km (621 mi), every 7,500 km (4,660 mi) or annually, every 15,000 km (9,321 mi) or every 2 years). every 7,500 km (4,660 mi) or annually.
Fork leg dust boots (clean)

Front end

Factory

Factory: Service schedule 9.1 (2015 owner's manual printed pp.70-71; columns: once after 1,000 km (621 mi), every 7,500 km (4,660 mi) or annually, every 15,000 km (9,321 mi) or every 2 years). every 7,500 km (4,660 mi) or annually.
Shock absorber and fork (check for leaks)

Front end

Factory

Factory: Service schedule 9.1 (2015 owner's manual printed pp.70-71; columns: once after 1,000 km (621 mi), every 7,500 km (4,660 mi) or annually, every 15,000 km (9,321 mi) or every 2 years). every 7,500 km (4,660 mi) or annually. Also once after 1,000 km.
Steering head bearing play (check)

Front end

Factory

Factory: Service schedule 9.1 (2015 owner's manual printed pp.70-71; columns: once after 1,000 km (621 mi), every 7,500 km (4,660 mi) or annually, every 15,000 km (9,321 mi) or every 2 years). every 7,500 km (4,660 mi) or annually. Also once after 1,000 km.
Swingarm bearing (check)

Rear suspension and frame

Factory

Factory: Service schedule 9.1 (2015 owner's manual printed pp.70-71; columns: once after 1,000 km (621 mi), every 7,500 km (4,660 mi) or annually, every 15,000 km (9,321 mi) or every 2 years). every 7,500 km (4,660 mi) or annually.
Brake discs (check)

Brakes

Factory

Factory: Service schedule 9.1 (2015 owner's manual printed pp.70-71; columns: once after 1,000 km (621 mi), every 7,500 km (4,660 mi) or annually, every 15,000 km (9,321 mi) or every 2 years). every 7,500 km (4,660 mi) or annually. Also once after 1,000 km.
Brake lines (check for damage and leakage)

Brakes

Factory

Factory: Service schedule 9.1 (2015 owner's manual printed pp.70-71; columns: once after 1,000 km (621 mi), every 7,500 km (4,660 mi) or annually, every 15,000 km (9,321 mi) or every 2 years). every 7,500 km (4,660 mi) or annually. Also once after 1,000 km.
Front and rear brake fluid level (check)

Brakes

Factory

Factory: Service schedule 9.1 (2015 owner's manual printed pp.70-71; columns: once after 1,000 km (621 mi), every 7,500 km (4,660 mi) or annually, every 15,000 km (9,321 mi) or every 2 years). every 7,500 km (4,660 mi) or annually. Also once after 1,000 km.
Front and rear brake linings (check)

Brakes

Factory

Factory: Service schedule 9.1 (2015 owner's manual printed pp.70-71; columns: once after 1,000 km (621 mi), every 7,500 km (4,660 mi) or annually, every 15,000 km (9,321 mi) or every 2 years). every 7,500 km (4,660 mi) or annually. Also once after 1,000 km.
Tire condition and air pressure (check)

Wheels and tires

Factory

Factory: Service schedule 9.1 (2015 owner's manual printed pp.70-71; columns: once after 1,000 km (621 mi), every 7,500 km (4,660 mi) or annually, every 15,000 km (9,321 mi) or every 2 years). every 7,500 km (4,660 mi) or annually. Also once after 1,000 km.
Wheel bearing play (check)

Wheels and tires

Factory

Factory: Service schedule 9.1 (2015 owner's manual printed pp.70-71; columns: once after 1,000 km (621 mi), every 7,500 km (4,660 mi) or annually, every 15,000 km (9,321 mi) or every 2 years). every 7,500 km (4,660 mi) or annually.
Cables (check for damage and routing)

Controls and cables

Factory

Factory: Service schedule 9.1 (2015 owner's manual printed pp.70-71; columns: once after 1,000 km (621 mi), every 7,500 km (4,660 mi) or annually, every 15,000 km (9,321 mi) or every 2 years). every 7,500 km (4,660 mi) or annually.
Throttle cables (check damage, routing and adjustment)

Controls and cables

Factory

Factory: Service schedule 9.1 (2015 owner's manual printed pp.70-71; columns: once after 1,000 km (621 mi), every 7,500 km (4,660 mi) or annually, every 15,000 km (9,321 mi) or every 2 years). every 7,500 km (4,660 mi) or annually. Also once after 1,000 km.

Every 8,000 km or 12 months

2 items

Change engine oil

Engine

Guideline

Pre-1970 machines: many owners run non-detergent or classic-spec oil with no filter, so short intervals matter. Dry sump: drain the tank and the crankcase/sump, flush the tank and clean the feed and return screens.
Replace oil filter

Engine

Guideline

Every 9,500 km or 12 months

7 items

Inspect coolant hoses and clamps

Engine

Guideline
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
Check swingarm bushes for play

Rear suspension and frame

Guideline
Inspect rear shocks for leaks and damping

Rear suspension and frame

Guideline
Lubricate control cables and lever pivots

Controls and cables

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 or 2 years

3 items

Spark plugs (change)

Engine

Factory

Factory: Service schedule 9.1 (2015 owner's manual printed pp.70-71; columns: once after 1,000 km (621 mi), every 7,500 km (4,660 mi) or annually, every 15,000 km (9,321 mi) or every 2 years). every 15,000 km (9,321 mi) or every 2 years.
Valve clearance (check)

Engine

Factory

Factory: Service schedule 9.1 (2015 owner's manual printed pp.70-71; columns: once after 1,000 km (621 mi), every 7,500 km (4,660 mi) or annually, every 15,000 km (9,321 mi) or every 2 years). every 15,000 km (9,321 mi) or every 2 years. Also once after 1,000 km.
Front and rear brake fluid (change)

Brakes

Factory

Factory: Service schedule 9.1 (2015 owner's manual printed pp.70-71; columns: once after 1,000 km (621 mi), every 7,500 km (4,660 mi) or annually, every 15,000 km (9,321 mi) or every 2 years). every 15,000 km (9,321 mi) or every 2 years.

Every 16,000 km or 2 years

1 item

Compression test (or leak-down)

Engine

Guideline

Every 19,500 km or 2 years

4 items

Replace air filter element

Fuel and air

Guideline
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 25,500 km or 4 years

1 item

Replace spark plugs

Engine

Guideline

Every 29,000 km

1 item

Replace chain and sprockets (wear based)

Final drive

Guideline

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

Replace coolant

Engine

Guideline
Inspect wiring, bullet connectors and ground points

Ignition and electrics

Guideline
Inspect frame, welds and lugs for cracks

Rear suspension and frame

Guideline
Replace brake fluid

Brakes

Guideline

Every 4 years

3 items

Replace fuel lines

Fuel and air

Guideline

Old rubber and modern ethanol fuel do not mix well.
Inspect brake hoses; replace old rubber

Brakes

Guideline
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.