2012 Duke 125-200 Repair Manual

TABLE OF CONTENTS 14.11 Adding rear brake fluid .................................... .................................... 74 14.12 Changing the rear brake fluid ........................... ........................... 74 15 LIGHTING LIGHTING SYSTEM SYSTEM,, INSTRUME INSTRUMENTS NTS .......... ............... .......... .......... ....... .. 76 15.1 Setting Setting kilome kilometers ters or or miles... miles........ .......... .......... .......... .......... ........ ... 76 15.2 Adjusting Adjusting the shift shift speed speed RPM 1 .......... ............... .......... ....... .. 76 15.3 Adjusting Adjusting the shift shift speed speed RPM 2 .......... ............... .......... ....... .. 76 15.4 Setting Setting the the time...... time........... .......... .......... .......... .......... .......... .......... .......... ..... 77 15.5 Resetting Resetting the servic servicee interval interval displa displayy ....... ............ ......... .... 77 15.6 Checking Checking the headlight headlight setting setting .......... ............... .......... .......... ..... 77 15.7 Adjusting Adjusting the headl headlight ight range...... range........... .......... .......... .......... ....... 78 15.8 Changing Changing the parking parking light light bulb......... bulb.............. .......... .......... ..... 79 15.9 Changing Changing the the headligh headlightt bulb .......... .............. ......... .......... ......... .... 80 16 ENGINE ............................................ ................................................................... ......................... 82 16.1 Removin Removingg the engine....... engine............ .......... .......... .......... .......... .......... ....... .. 82 16.2 Installing the engine............................... engine........................................ ......... 85 85 16.3 Disasse Disassembli mbling ng the engine engine .......... ............... .......... .......... .......... ....... .. 90 16.3.1 16.3 .1 Preparat Preparations ions (125 Duke) Duke) .......... ............... .......... .......... ......... .... 90 16.3.2 16.3 .2 Draining Draining the engine engine oil (125 Duke)....... Duke)............ ........ ... 90 16.3.3 16.3 .3 Removin Removingg the chain chain securing securing guide guide (125 Duke) ........................................ ........................................................ ................ 91 16.3.4 16.3 .4 Removin Removingg the valve valve cover cover (125 Duke) Duke) .......... ............ 91 16.3.5 16.3 .5 Removin Removingg the spark spark plug (125 Duke)......... Duke)............ ... 91 16.3.6 16.3 .6 Removin Removingg the the clutch clutch cover cover (125 Duke) Duke) ......... ......... 91 16.3.7 16.3 .7 Setting Setting the engine engine to ignition ignition top dead center (125 Duke) ...................................... 92 16.3.8 16.3 .8 Removin Removingg the the starter starter motor motor (125 Duke) Duke) ........ ........ 92 16.3.9 16.3 .9 Removin Removingg the timing timing chain chain tensione tensionerr (125 Duke) ........................................ ........................................................ ................ 93 16.3.10 16.3 .10 Removin Removingg the camshaf camshaftt (125 Duke)... Duke)........ .......... ....... 93 16.3.11 16.3 .11 Removin Removingg the cylinde cylinderr head (125 (125 Duke) Duke) ....... ....... 94 16.3.12 16.3 .12 Removin Removingg the pisto piston n (125 Duke)...... Duke)........... .......... ....... .. 94 16.3.13 16.3 .13 Removin Removingg the water water pump wheel wheel (125 (125 Duke) ........................................ ........................................................ ................ 95 16.3.14 16.3 .14 Removin Removingg the altern alternato atorr cover cover (125 Duke). Duke)..... .... 96 16.3.15 16.3 .15 Removin Removingg the rotor rotor (125 Duke)......... Duke).............. ......... ...... .. 96 16.3.16 16.3 .16 Removin Removingg the starte starterr drive (125 Duke).. Duke)....... ........ ... 97 16.3.17 Removing the balancer shaft drive wheel (125 Duke) ........................................... ................................................ ..... 97 16.3.18 16.3 .18 Removin Removingg the gear gear positio position n sensor sensor (125 (125 Duke) ........................................ ........................................................ ................ 98 16.3.19 16.3 .19 Removin Removingg the spacer spacer (125 (125 Duke) Duke) ......... .............. ........ ... 99 16.3.20 16.3 .20 Removin Removingg the clutch clutch bask basket et (125 Duke) Duke) ....... ....... 99 16.3.21 16.3 .21 Removin Removingg the prima primary ry gear gear (125 (125 Duke) Duke) ....... ....... 100 16.3.22 16.3 .22 Removin Removingg the oil pump pump (125 (125 Duke)........ Duke)............ .... 100 16.3.23 16.3 .23 Removin Removingg the shift shift shaft shaft (125 (125 Duke) Duke) .......... .......... 101 16.3.24 16.3 .24 Removin Removingg the shift shift drum drum locatin locatingg (125 Duke) ........................................ ...................................................... .............. 101 16.3.25 16.3 .25 Removin Removingg the lockin lockingg lever lever (125 Duke)... Duke)....... .... 101 16.3.26 16.3 .26 Removin Removingg the oil oil filter filter (125 Duke) Duke) ...... ........... ....... .. 101 16.3.27 16.3 .27 Removin Removingg the left left engin enginee case case (125 (125 Duke) ........................................ ...................................................... .............. 102 16.3.28 16.3 .28 Removin Removingg the shift shift rails (125 (125 Duke) Duke) ....... ........... .... 103 16.3.29 16.3 .29 Removin Removingg the shift shift drum drum (125 (125 Duke)....... Duke).......... ... 103 16.3.30 16.3 .30 Removin Removingg the shift shift forks forks (125 (125 Duke) Duke) ...... .......... .... 103 16.3.31 Removing the transmission transmission shafts (125 Duke) ........................................ ...................................................... .............. 103 16.3.32 16.3 .32 Removin Removingg the balanc balancer er shaft shaft (125 Duke) Duke) .... 104 16.3.33 16.3 .33 Removin Removingg the cranks crankshaft haft (125 (125 Duke)...... Duke).......... .... 104 16.3.34 Preparations Preparations (200 Duke) ........................... ........................... 104 16.3.35 16.3 .35 Draining Draining the the engine engine oil oil (200 Duke).... Duke)......... ......... .... 104 16.3.36 16.3 .36 Removin Removingg the chain chain securi securing ng guide guide (200 Duke) ........................................ ...................................................... .............. 105 16.3.37 16.3 .37 Removin Removingg the valve valve cover cover (200 (200 Duke) Duke) ......... ......... 105

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16.3.38 Removin 16.3.38 Removingg the spark spark plug (200 (200 Duke)..... Duke).......... ..... 105 16.3.39 16.3 .39 Removin Removingg the clutch clutch cove coverr (200 Duke) Duke) ....... ....... 105 16.3.40 16.3 .40 Setting Setting the engin enginee to ignitio ignition n top dead dead center (200 Duke) .................................... 106 16.3.41 16.3 .41 Removin Removingg the starte starterr motor motor (200 Duke) Duke) ...... ...... 106 16.3.42 16.3 .42 Removin Removingg the timing timing chain chain tensione tensionerr (200 Duke) ......................................... ...................................................... ............. 107 16.3.43 16.3 .43 Removin Removingg the camsha camshaft ft (200 (200 Duke).... Duke)......... ........ ... 107 16.3.44 16.3 .44 Removin Removingg the cylinde cylinderr head (200 (200 Duke) Duke) ..... ..... 108 16.3.45 16.3 .45 Removin Removingg the pisto piston n (200 Duke) Duke) .......... ............... ....... 108 16.3.46 16.3 .46 Removin Removingg the water water pump whee wheell (200 Duke) ......................................... ...................................................... ............. 109 16.3.47 16.3 .47 Removin Removingg the altern alternator ator cove coverr (200 Duke) ......................................... ...................................................... ............. 110 16.3.48 16.3 .48 Removin Removingg the roto rotorr (200 Duke) Duke).... ......... .......... ......... .... 110 16.3.49 16.3 .49 Removin Removingg the starte starterr drive (200 (200 Duke).... Duke)........ .... 111 16.3.50 16.3 .50 Removin Removingg the balance balancerr shaft drive drive wheel wheel (200 Duke) ............................................ .............................................. .. 111 16.3.51 16.3 .51 Removin Removingg the gear gear position position senso sensorr (200 Duke) ......................................... ...................................................... ............. 112 16.3.52 16.3 .52 Removin Removingg the spacer spacer (200 (200 Duke) Duke) ......... .............. ....... 113 16.3.53 16.3 .53 Removin Removingg the clutch clutch baske baskett (200 Duke) Duke) ..... ..... 113 16.3.54 16.3 .54 Removin Removingg the prima primary ry gear gear (200 (200 Duke)....... Duke)....... 114 16.3.55 16.3 .55 Removin Removingg the oil pump pump (200 (200 Duke Duke)) .......... ............ .. 114 16.3.56 16.3 .56 Removin Removingg the shift shaft shaft (200 (200 Duke) Duke) .......... .......... 115 16.3.57 16.3 .57 Removin Removingg the shift shift drum drum locating locating (200 Duke) ......................................... ...................................................... ............. 115 16.3.58 16.3 .58 Removin Removingg the lockin lockingg lever lever (200 (200 Duke)....... Duke)....... 115 16.3.59 16.3 .59 Removin Removingg the oil oil filter filter (200 Duke) Duke) .......... ............. ... 115 16.3.60 16.3 .60 Removin Removingg the left left engin enginee case case (200 Duke) ......................................... ...................................................... ............. 116 16.3.61 16.3 .61 Removin Removingg the shift shift rails (200 (200 Duke) Duke) ....... ........... .... 117 16.3.62 16.3 .62 Removin Removingg the shift shift drum drum (200 (200 Duke)........ Duke).......... .. 117 16.3.63 16.3 .63 Removin Removingg the shift shift forks forks (200 (200 Duke) Duke) ........ .......... .. 117 16.3.64 Removing the transmission transmission shafts (200 Duke) ......................................... ...................................................... ............. 117 16.3.65 16.3 .65 Removin Removingg the balanc balancer er shaft shaft (200 Duke) Duke) .... 118 16.3.66 16.3 .66 Removin Removingg the crank crankshaf shaftt (200 Duke).... Duke)......... ....... 118 16.4 Work on indiv individual idual parts parts .......... ............... .......... .......... .......... ....... .. 118 16.4.1 16.4 .1 Work on the left section section of the engine engine case case (125 Duke) ............................................ .............................................. .. 118 16.4.2 16.4 .2 Work on the right right secti section on of the engine engine case (125 Duke)....................................... 119 16.4.3 16.4 .3 Changing Changing the shaft shaft seal seal ring of the water water pump (125 Duke) ..................................... ..................................... 119 16.4.4 16.4 .4 Removin Removingg the main bearing bearing (125 Duke) Duke) ...... ...... 120 16.4.5 16.4 .5 Checking Checking the radial radial play of the lower lower conrod bearing bearing (125 Duke) Duke) ........................ ........................ 121 16.4.6 16.4 .6 Changing Changing the conrod conrod bearing bearing (125 Duke) Duke) .... 122 16.4.7 16.4 .7 Changing Changing the balance balancerr shaft shaft bearing bearing (125 Duke) ......................................... ...................................................... ............. 123 16.4.8 16.4 .8 Changing Changing the camshaf camshaftt bearing bearing (125 Duke) ......................................... ...................................................... ............. 123 16.4.9 16.4 .9 Work on the cylinder cylinder head (125 Duke) Duke) ........ ........ 124 16.4.10 16.4 .10 Checking Checking the the cylinde cylinderr head (125 (125 Duke) Duke) ...... ...... 125 16.4.11 Checking/measuring Checking/measuring the cylinder (125 Duke) ......................................... ...................................................... ............. 125 16.4.12 16.4 .12 Checking Checking the piston piston ring end end gap (125 Duke) ......................................... ...................................................... ............. 126 16.4.13 16.4 .13 Checking Checking/mea /measuri suring ng the pisto piston n (125 Duke) ......................................... ...................................................... ............. 126 16.4.14 16.4 .14 Checking Checking the the piston/ piston/cyli cylinder nder mount mounting ing clearance (125 Duke)................................ 127 16.4.15 16.4 .15 Checking Checking the oil oil pump pump (125 Duke)...... Duke)........... ....... .. 127