Ktm exc 125 мануал

125 / 200
Repair manual KTM 125 / 200
Art No 320588 -E
REPAIR MANUAL
ENGINE
KTM SPORTMOTORCYCLE AG
5230 Mattighofen
Austria
www.ktm.at
125/200
REPAIR
MANUAL
ENGINE
1 SERVICE-INFORMATIONS
2 GENERAL INFORMATION
3 REMOVING AND REFITTING ENGINE
4 DISASSEMBLING THE ENGINE
5 SERVICING INDIVIDUAL COMPONENTS
6 ASSEMBLING THE ENGINE
7 ELECTRICAL
8 TROUBLE SHOOTING
9 TECHNICAL SPECIFICATIONS
10 PERIODIC MAINTENANCE SCHEDULE
11 WIRING DIAGRAMS
12
13
14
15
16
I M P O RTA N T I N F O R M AT I O N /U P D AT I N G
INSTRUCTIONS
To be able to continue using the existing loose-leaf repair instructions, simply print the
following pages and insert them in the existing repair instructions:
15,17,18,21,23,27,39,43,44,69,70,73-85,91,107-129,135-139,155-158
Remove page (s)
Replace by page (s)
2-1
2-1C
2-2
2-2C bis 2-3C
3-1
3-1C
3-4 bis 3-5
3-4C
5-1
5-1C
5-4 bis 5-5
5-4C bis 5-5C
6-10 bis 6-11
6-10C bis 6-11C
7-1 bis 7-3
7-1C bis 7-13C
9-1
9-1C
9-16 bis 9-28
9-16C bis 9-36C
10-1
10-1C
10-6
10-6C bis 10-9C
11-1
11-1C
11-15
11-15C bis 11-18C
Insert page (s)
after page
2-6
2-5
KTM REPAIR MANUAL IN LOOSE-LEAF FORM
STORING THE REPAIR MANUAL IN THE BINDER
– Put the index into the binder.
– Put the front page of the repair manual (210x297 mm) into the transparent pocket provided for
this purpose on the outside of the binder.
– Put the spine label (170x45 mm) into the transparent pocket provided for this purpose on the
spine of the binder.
– Put the summary list of contents (150x297 mm) into the transparent pocket provided for this
purpose on the inside of the binder or insert this page on the beginning of the manual.
– Then insert the individual chapters of the manual between the sheets of the index according to
the page number printed in the right bottom corner of each page.
Example: page no. 3-5
3 = chapter 3
5 = page 5
All pages with a page number that begins with the digit 3, for example, must be put under the
index heading „Chapter 3“.
– Index sheets that have not been marked with a certain chapter are for your personal convenience.
The respective headings can be entered in the list of contents.
E X P L A N AT I O N - U P D AT I N G
3.205.74-E
Repair Manual 125/200 SX, MXC, EXC
Basicversion Modelyear 1999
(Engine number with first digit “9“)
3/1999
3.205.88-E
Updating of Rep.Manual 3.205.74-E
Modelyear 2000/2001
(2000: Engine number with first digit “0“)
(2001: Engine number with first digit “1“)
8/2000
3.210.27-E
Updating of Rep.Manual 3.205.74-E
Modelyear 2002
(Engine number with first digit “2“)
7/2001
3.206.005-E Updating of Rep.Manual 3.205.74-E
Modelyear 2003
(Engine number with first digit “3“)
11/2002
Modification / Updating:
Technical Details, Technical Specifications,
Periodic Maintenance Schedule, Wiring Diagrams
Edition 11/2002
INTRODUCTION
This repair manual offers extensiv repair-instructions and is an up-to-date version that describes the
latest models of the series. However, the right to modifications in the interest of technical
improvement is reserved without updating the current issue of this manual.
A description of general working modes common in work shops has not been included. Safety rules
common in the work shop have also not been listed. We take it for granted that the repairs are
made by qualified profesionally trained mechanics.
Read through the repair manual before beginning with the repair work.
WARNING
STRICT COMPLIANCE WITH THESE INSTRUCTIONS
ESSENTIAL TO AVOID DANGER TO LIFE AND LIMB.
!
CAUTION
IS
!
NON-COMPLIANCE WITH THESE INSTRUCTIONS CAN LEAD
TO DAMAGE OF MOTORCYCLE COMPONENTS OR RENDER
MOTORCYCLES UNFIT FOR TRAFFIC !
„NOTE” POINTS OUT USEFUL TIPS.
Use only ORIGINAL KTM SPARE PARTS when replacing parts.
The KTM high performance engine is only able to meet user expectations if the maintenance work is
performed regularly and professionally.
KTM Austria’s certificate of achievement for its quality system ISO 9001 is the beginning of an
ongoing total reengineered quality plan for a brighter tomorrow.
KTM Sportmotorcycle AG
5230 Mattighofen, Austria
All design and assembly modification rights reserved.
C by KTM SPORTMOTORCYCLE AG, AUSTRIA
All rights reserved
REPLY FAX FOR REPAIR MANUALS
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a mistake or two to creep in.
To keep improving the quality of our repair manuals, we request mechanics and shop foremen to assist us
as follows:
If you find any errors or inaccuracies in one of our repair manual – whether these are technical errors,
incorrect or unclear repair procedures, tool problems, missing technical data or torques, inaccurate or
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NOTE to table:
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–
–
Enter the corresponding page number in the repair manual (e.g.: 5-7c) in column 2.
–
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–
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Correct text
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2-1C
GENERAL INFORMATION
INDEX
Repair manual 125 / 200
Art No 3.206.005-E
OPERATING RANGES OF THE CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . .2-2
CARBURETOR ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
BLEEDING OF THE HYDRAULIC CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
OIL PUMP ADJUSTING MODELS WITH SEPARATE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
CHECK OF EXHAUST CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
2
2-2C
main jet
jet needle
jet needle
idle jet
throttle valve
air control screw
idle adjusting screw
mixture too lean:
not enough fuel in proportion to air
2
mixture too rich:
Art No 3.206.005 -E
too much fuel in proportion to air
1
Idling range
A
Operation with closed throttle valve. This range is influenced by the position of the air control screw 1 and the idle adjusting screw
2. Only make adjustments when the engine is hot.
To this end, slightly decrease the idling speed of the engine by means of the idle adjusting screw. Turning it clockwise produces a
higher idling speed and turning the screw counterclockwise produces a lower idling speed. Create a round and stable engine speed
using the air control screw (basic position of the air control screw = open by 1.5 turns and 1,25 on EXE and Supermoto). Then
adjust to the normal idling speed by means of the idle adjusting screw.
Opening up
B
Repair manual KTM 125 / 200
Engine behavior when the throttle opens. The idle jet and the shape of the throttle valve influences this range. If, despite good
idling-speed and part-throttle setting, the engine sputters and smokes when the throttle is fully opened and develops its full power
not smoothly but suddenly at high engine speeds, the mixture to the carburetor will be too rich, the fuel level too high or the float
needle is leaking.
Part-throttle range
C
Operation with partly open throttle valve. This range is only influenced by the jet needle (shape and position). The optimum
part-throttle setting is controlled by the idling setting in the lower range and by the main jet in the upper range. If the engine runs
on a four-stroke cycle or with reduced power when it is accelerated with the throttle partly open, the jet needle must be lowered by
one notch. If then the engine pings, especially when accelerating under full power at maximum engine revs, the jet needle should
be raised.
If these faults should occur at the lower end of the part throttle range at a four-stroke running, make the idling range leaner; if the
engine pings, adjust the idling range richer.
Full throttle range
D
Operation with the throttle fully open (flat out). This range is influenced by the main jet and the jet needle. If the porcelain of the
new spark plug is found to have a very bright or white coating or if the engine rings, after a short distance of riding flat out, a
larger main jet is required. If the porcelain is dark brown or black with soot the main jet must be replaced by a smaller one.
2-3C
Carburetor adjustment
Basic information on the original carburetor setting
The original carburetor setting was adapted for an altitude of approx. 500 meters (1600 ft.) above sea level, and the ambient
temperature of approx. 20° C (68° F), mainly for off-road use and central European premium-grade fuel (125: ROZ 98 / 200: ROZ 95).
Mixing ratio 2-stroke motor oil : super fuel 1:40.
Basic information on a change of the carburetor setting
Always start out from the original carburetor setting. Essential requirements are a clean air filter system, air-tight exhaust system
and an intact carburetor. Experience has shown that adjusting the main jet, the idling jet and the jet needle is sufficient and that
changes of other parts of the carburetor will not greatly affect engine performance.
RULE OF THUMB:
high altitude or high temperatures
low altitude or low temperatures
➞
➞
choose leaner carburetor adjustment
choose richer carburetor adjustment
WARNING
– ONLY
–
–
–
USE PREMIUM-GRADE GASOLINE (125: ROZ 98 / 200: ROZ 95) MIXED WITH HIGH-GRADE TWO-STROKE ENGINE OIL. OTHER TYPES OF
GASOLINE CAN CAUSE ENGINE FAILURE, AND USE OF SAME WILL VOID YOUR WARRANTY.
ONLY USE HIGH-GRADE 2-STROKE ENGINE OIL OF KNOWN BRANDS.
NOT ENOUGH OIL OR LOW-GRADE OIL CAN CAUSE EROSION OF THE PISTON. USING TOO MUCH OIL, THE ENGINE CAN START SMOKING AND FOUL
THE SPARK PLUG.
IN THE CASE OF A LEANER ADJUSTMENT OF THE CARBURETOR PROCEED CAUTIOUSLY. ALWAYS REDUCE THE JET SIZE IN STEPS OF ONE NUMBER TO
AVOID OVERHEATING AND PISTON SEIZURE.
NOTE: If despite a changed adjustment the engine does not run properly, look for mechanical faults and check the ignition system.
Basic information on carburetor wear
As a result of engine vibrations, throttle valve, jet needle, and needle jet are subjected to increased wear. This wear may cause
carburetor malfunction (e.g., overly rich mixture). Therefore, these parts should be replaced after 10 000 kilometers (6 000 miles).
jet needle
throttle valve open
NOZ C
NOZ D
NOZ E
NOZ F
NOZ G
NOZ H
NOZ I
0 – /4
jet needle
R 1466D
R 1467D
R 1468D
R 1469D
R 1470D
R 1471D
effect
1
0 – 1/4
–
0 – 1/4
–
–
0 – 1/4
–
–
–
1
0 – /4
Explanation - Example
Compared to the needle NOZ D, the jet needle NOZ F is two steps
leaner in the range from the closed position of the throttle to 1/4
throttle. Otherwise, there are not differences.
NOZ F
0 – 1/4
–
–
–
–
–
–
0 – 1/4
–
–
–
–
–
0 – 1/4
–
–
–
–
–
–
throttle valve open
effect
0 – /4
Explanation - Example
1
0 – 1/4
–
0 – 1/4
–
–
0 – /4
–
–
–
0 – 1/4
–
–
–
–
1
1
0 – /4
–
–
–
–
–
Compared to the needle R 1467D, the jet needle R 1469D is two steps
leaner in the range from the closed position of the throttle to 1/4
throttle. Otherwise, there are not differences.
R 1469D
0 – 1/4
–
–
2-4C
Bleeding of the hydraulic clutch
2
– Remove screws and take off cover together with rubber bellows.
– At the slave cylinder of the clutch, remove the bleeder nipple 1.
Instead of mount the bleeder syringe 2 which is filled with SAE 10
biodegradable hydraulic oil (ex. Shell Naturelle HF-E15).
1
– Refill oil, until oil is discharged from the bore 3 of the master cylinder
in a bubble-free state. Make sure that the oil does not overflow.
3
!
HAVING
CAUTION
!
COMPLETED THE BLEEDING PROCEDURE, YOU HAVE TO VERIFY THAT THE OIL
LEVEL IN THE MASTER CYLINDER IS CORRECT. FOR FILLING OF THE MASTER CYLINDER,
SAE 10 BIODEGRADABLE HYDRAULIC OIL ONLY (EX. SHELL NATURELLE
HF-E15); NEVER USE BRAKE FLUID NOR MIX BIODEGRADABLE HYDRAULIC OILS WITH
MINERAL OILS.
Repair manual KTM 125 / 200
Art No 3.206.005 -E
USE
2-5C
Adjusting oil pump (only with separate lubrication)
NOTE: Prior to adjusting the oil pump, you have to check and, if
necessary, adjust the clearance of the throttle cable.
– Loosen the 3 bolts 1 of the oil pump housing and remove the oil
pump cover 2. To make adjustment and control easier, loosen the
bolts of the intake flange 3, remove 4 of them and move the flange
sidewards.
1
3
2
A
C
– If the oil pump has been adjusted correctly, the mark A must coincide
with the notch B on the cable pulley (except 125 EXE and 125
Supermoto).
– On 125 EXE- and 125 Supermoto-models the notch B must coincide
with the edge C.
!
CAUTION
!
THE ADJUSTMENT OF THE OIL PUMP IS NOT CORRECT, THE ENGINE IS NOT SUPLIED
WITH THE CORRECT AMOUNT OF OIL AND THIS CAN RESULT IN ENGINE DAMAGE.
IF
B
B
– If necessary, loosen the lock nut 4, and correct the adjustment by
turning the adjusting screw 5 as required.
– Following the adjustment procedure, the lock nut has to be tightened
again.
5
– Mount cover 2 and flange 3, tighten the 2 bolts.
4
2-6C
Check of the exhaust control (engine running)
– Remove the left side cover from the cylinder.
– Start engine.
– Mark 1 of the control segment is near by mark 2 of the guide plate.
!
CAUTION
!
BASE POSITION MUST BE ADJUSTED WITH A DEPTH GAUGE - SHOWN IN CHAPTER
6-10 - DIMENSION „Z“.
1
2
1
– Mount cover and tighten the bolts.
4
Art No 3.206.005 -E
3
Repair manual KTM 125 / 200
– Open throttle flap, with increasing the revolutions mark 1 moves
downwards to the bore in the housing 3.
!
CAUTION
!
– MARK 4 IS NOT USED.
– IF MARK 1 DOES NOT REACH BORE 3 OR DOES NOT MOVE, THE EXHAUST
CONTROL MECHANISM IS TO BE OVERHAULED.
3-1C
REMOVING AND REFITTING ENGINE
INDEX
Repair manual 125 / 200
Art No 3.206.005-E
REMOVING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
REFITTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
3
3-2C
Removing the engine
NOTE: The cylinder head and the cylinder can be removed without
previously removing the engine. It is also possible to work on the clutch,
the primary drive and the shift drum locating device without previously
removing the engine. The water pump can be removed and installed
without previously removing the clutch cover.
– Thoroughly clean the motorcycle.
– Use a suitable supporting device to jack up the motorcycle.
– Remove the seat and the tank with the spoilers.
–
–
–
–
Drain the cooling liquid.
Remove the exhaust system and the engine brace.
Disconnect the radiator hoses at the engine.
Remove the carburetor.
Art No 3.206.005 -E
– Dismount the brake cylinder cover.
– Remove the engine sprocket cover and the chain.
– Disconnect the electrical wires.
Repair manual KTM 125 / 200
– Unscrew the clutch master cylinder and reposition the clutch line such
that it will not get entangled when the engine is lifted out.
– Unhook the return spring of the foot brake pedal from the clutch
cover.
– Undo the engine mounting bolts.
– Remove the swingarm pivot and pull the swingarm backwards.
– Lift the engine out of the frame on the left side.
3-3C
Installing the engine
– Lift the engine into the frame from the left side, slightly grease and
mount the swingarm pivot. Tighten collar nut with 100 Nm (74 ft.lb.).
– Twist in the engine mounting bolts.
– Mount the engine brace.
– Connect the electrical wires.
– Position clutch line correctly, and mount clutch master cylinder at
handlebar.
– Mount the chain and the engine sprocket cover.
– Mount brake cylinder cover.
– Mount the carburetor.
3-4C
– Connect the radiator hoses to the engine and fill the cooling system
with a mixture of 40 % antifreeze and 60 % water. For this purpose
twist out the bleeder screws at the cylinder head and at the right
radiator. Retighten the screws as soon as the cooling liquid that
emerges is free of air bubbles.
– Mount the exhaust system.
– Mount the tank with the spoilers and the seat.
– Fix the breather tube to the frame.
Art No 3.206.005 -E
– Check the electrical system for faultless operation.
– Adjust the carburetor.
– Test ride.
– After the test ride, check the engine, the cooling system and the
exhaust system for leaks.
Fixing the cables to the frame - Models with separate
lubrication
!
TO
CAUTION
!
Repair manual KTM 125 / 200
PREVENT DISENGAGEMENT OF THE THROTTLE CABLE AND THE OIL PUMP CABLE IT
IS NECESSARY TO FIX 1 THE CABLES ABOVE THE CARBURATOR TO THE FRAME.
1
4-1C
DISMANTLING THE ENGINE
Repair manual 125 / 200
Art No 3.206.005-E
INDEX
SPECIAL TOOLS – ENGINE 125/200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
DRAINING THE GEAR OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
DISMOUNTING THE CLUTCH SLAVE CYLINDER . . . . . . . . . . . . . . . . . . . . .4-3
CYLINDER HEAD, CYLINDER, PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
IGNITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
ENGINE SPROCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
REED VALVE HOUSING, INTAKE FLANGE AND CLUTCH COVER . . . . . . . . .4-5
REED VALVE HOUSING, INTAKE FLANGE AND OIL PUMP
MODELS WITH SEPARATE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
REMOVING CLUTCH AND PRIMARY DRIVE . . . . . . . . . . . . . . . . . . . . . . . .4-6
SHIFT DRUM LOCATING, KICKSTARTER . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
DIVIDING THE ENGINE HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
REMOVING SHIFT MECHANISM AND TRANSMISSION . . . . . . . . . . . . . . . .4-9
REMOVING CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9
4
4-2C
SPECIAL TOOLS – ENGINE
125 / 200
13
7
16
14
1
5
38
22
Repair manual KTM 125 / 200
Art No 3.206.005 -E
4
20
FIG
1
3
4
5
7
8
13
14
16
20
22
38
PART. NO.
560.12.001.000
503.29.003.000
503.29.004.000
546.29.009.044
510.12.011.000
546.29.012.100
501.12.013.000
501.12.030.000
6 899 785
584.29.037.037
503.29.022.000
503.29.038.000
8
HOLZGABEL
SELBSTGEFERTIGT
WOODEN FORK PLATE
HOME MADE
3
DESCRIPTIOIN
Universal engine work stand
Clutch holder 125 / 200
Holding spanner for primary gear wheel
Magneto extractor M27x1 Kokusan
Circlip plier
Holding spanner for flywheel Kokusan 2K-1/2/3/4
Dial gauge 1-10 mm
Dial gauge support
Loctite 243 blue 6 ccm
Mounting tool inner ring NJ206
Adjusting plate for control flap
Holding plate for locating drum
4-3C
–
–
–
–
2
Thoroughly clean the engine.
Clamp the engine into the mounting rack.
Remove the kickstarter and the shift lever.
Remove bolt 1 and take off wire hanger 2.
1
Draining the gear oil
– Twist out the drain plug 3 and drain the gear oil.
3
Dismounting the clutch slave cylinder
– Remove the 2 bolts 4 and withdraw the clutch slave cylinder
together with the gasket.
– Pull push rod out of drive shaft.
4
Cylinder head, cylinder, piston
5
– Undo the 6 bolts 5 and remove the cylinder head together with the
gasket.
NOTE: on 125 SX/EXC-engines from model 2002 onwards an O-ring is
used instead of the gasket.
– Take the O-ring(s) out of the groove in the cylinder.
– Remove the 4 collar nuts 6 at the cylinder base and remove the
cylinder.
6
4-4C
– Cover the crankcase.
– Place the piston onto an appropriate wooden support and remove
both piston pin retainers.
– Press the piston pin out of the piston without applying excessive
force. An appropriate mandrel can be used if necessary.
– Remove the piston and take the piston pin bearing out of the conrod
eye.
– Remove the cylinder base gaskets.
Ignition
– Remove 4 bolts and take off the ignition cover together with the
gasket.
– Hold the rotor with the special tool and undo the hexagon nut.
– Take the hexagon nut and the detent edged ring off the crankshaft.
Art No 3.206.005 -E
– Twist the rotor extractor into the thread of the rotor (LH thread) and
remove the rotor.
Repair manual KTM 125 / 200
– Remove the 3 collar bolts 1 and take the stator out of the housing.
– Take the woodruff key out of the crankshaft.
1
Engine sprocket
– Use a pair of circlip pliers to take the circlip 2 off the countershaft.
– Take the engine sprocket, the distance bushing and the O-ring off the
countershaft.
2
4-5C
Reed valve housing, intake flange and clutch cover
1
– Remove 5 bolts 1 together with the corrugated washers, remove the
intake flange and the reed valve housing.
NOTE: The following step need not be performed unless you intend to
take the centrifugal timer out of the clutch cover.
– Remove the cover 3 of the centrifugal timer together with the seal
ring and undo screw 2.
2
7
3
4
– Remove all bolts of clutch cover and the 2 front-end bolts 4 of the
water-pump cover, and dismount clutch cover.
– Remove the clutch cover gasket and pull the dowels out of the
housing.
– Take O-ring 8 out of water bore.
NOTE: The water pump cover 5, the exterior cap 6 and the hexagon
cap nut 3 need not be removed. The water pump and the centrifugal
timer are left in the clutch cover.
5
!
4
6
8
CAUTION
!
REMOVING THE CLUTCH COVER MAKE SURE THAT THE ROCKER ARM 7 OF
THE EXHAUST CONTROL DOES NOT JAM IN THE HOUSING AND IS NOT DAMAGED.
WHEN
4-6C
Reed valve housing, intake flange and oil pump (separate
lubrication)
1
– When dismounting the clutch cover 2 additionally remove the bolt
1
2
A
C
A
E
C
B
D
B
– Pull the oil pump wheel A off the oil pump
Art No 3.206.005 -E
– Remove the cover D from the oil pump housing.
– Remove the 4 bolts of the intake flange and then, move the intake
flange sideways as shown.
– Pull the 2 dowel bushings B out of the housing.
NOTE: The bolt 3 at the intake flange can be unscrewed completely
only as soon as the oil pump housing E has been dismantled.
B
– Pull the oil pump housing off the engine case and swing it
sideways (see picture).
– Remove the 2 bolts C, and withdraw oil pump together with gasket
from the engine case.
– Remove the bolt 3 at the intake flange, and dismount intake flange
together with reed valve housing.
Repair manual KTM 125 / 200
3
C
Removing clutch and primary drive
4
– Undo the 5 bolts 4 in diagonal order so as to prevent jamming of the
clutch discs when the springs relax.
– Remove bolts, spring retainers and springs.
– Take the pressure cap and the disc package out of the outer clutch
hub.
– Pull the thrust bearings out of the main shaft.
4-7C
– Open the lock washer of the inner clutch hub.
– Mount the clutch holder on the inner clutch hub and undo the
hexagon nut.
– Remove the clutch holder.
– Take the hexagon nut, the detent edged ring and the inner clutch
hub off the main shaft.
– Take the supporting disc 1 and the outer clutch hub together with
the bearing off the main shaft.
1
– Remove the intermediate starter gear and the stop disc 2 below.
2
– Mount the primary gear holder and undo the hexagon nut (LH
thread).
– Remove the primary gear holder.
– Take the hexagon nut, the detent edged ring and the primary gear off
the crankshaft.
– Take the woodruff key out of the crankshaft.
Shift drum locating, kickstarter
– Simply pull the shift shaft out of the housing. Keep in mind the stop
disc 3 (It can be left in the housing).
3
4-8C
– Carefully unhook the kickstarter spring from bore 1 (pretensioned
spring) and release it.
– Rotate the kickstarter shaft approximately 1/4 turn counterclockwise
and pull it out of the housing. Keep in mind the stop disc behind !
1
– Undo 3 bolts and remove the gear shifting gate 2 together with the
ratchet carrier 3. Procede with care by watching out for the collar
bushing 4 on the ratchet carrier.
4
3
2
Art No 3.206.005 -E
6
7
– The locking lever 5 need not be removed unless the engine housing
is exchanged.
– For this purpose, undo bolt 6, then remove the locking lever
together with the spring.
– Take the washer 7 out of the locking drum.
5
– Hold the locking drum 9 with the special tool, undo bolt 8 and
remove the bolt together with the washer.
– Pull the locking drum off the shift roller.
Repair manual KTM 125 / 200
!
CAUTION
!
THE LOCKING DRUM MUST BE HELD WITH THE SPECIAL TOOL TO PREVENT DAMAGING
OF THE BUSHINGS ON THE DRIVING PINS OF THE SHIFT FORKS.
8
9
Dividing the engine housing
– Swing the ignition side upwards and remove all 12 housing bolts.
– Undo the engine mounting device at the mounting rack.
– Lift the left housing half by the lifting points of the housing, using
appropriate tools, or separate it from the right housing half by lightly
tapping the countershaft with a plastic hammer.
!
CAUTION
!
TO
PREVENT DAMAGING OF THE SEALING SURFACES, DO NOT USE A SCREWDRIVER
OR SIMILAR TOOL TO LEVER THE HOUSING HALVES APART!
– Remove the housing half and the gasket.
– Keep in mind the stop disc of the main shaft (can stick to the inside of
the housing).
4-9C
4
1
1
Removing shift mechanism and transmission
– Pull out the shift rails 1 and swing the shift forks 2 including rollers
3 sideways.
– Pull the shift roller 4 out of the grooved ball bearing.
– Take the shift forks 2 out of the housing.
NOTE: When dismounting the shift forks, make sure that you do not
lose the rollers 3 on the shift forks.
2
3
2
2
– Pull the complete main shaft and the countershaft together out of the
bearing seats.
Removing crankshaft
– Pull the crankshaft out of the bearing seat (if necessary lightly tap it
with a plastic hammer).
– Take the distance bushing 5 and the O-ring 6 out of the right
crankshaft seal ring.
6
– Clean all parts. Check for wear and exchange worn components.
NOTE: All gaskets, shaft seal rings, O-rings and bearings should be
exchanged on the occasion of each complete engine overhaul.
5
5-1C
SERVICING INDIVIDUAL COMPONENTS
5
Repair manual 125 / 200
Art No 3.206.005-E
INDEX
RIGHT HOUSING HALF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
LEFT HOUSING HALF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
CRANKSHAFT WEBS – MEASURE OUTER DIMENSION . . . . . . . . . . . . . . . .5-4
PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
PISTON RING END GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
CHECKING CYLINDER FOR WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5
NIKASIL COATING OF CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5
DISMOUNTING AND CHECKING THE EXHAUST CONTROL
SYSTEM IN THE CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
PREASSEMBLING THE CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7
CLUTCH COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10
PREASSEMBLING THE CLUTCH COVER . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11
PREASSEMBLING THE WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11
CHECKING CLUTCH FOR WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12
REED VALVE HOUSING, INTAKE FLANGE . . . . . . . . . . . . . . . . . . . . . . . . . .5-13
KICKSTARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14
PREASSEMBLING THE KICKSTARTER SHAFT . . . . . . . . . . . . . . . . . . . . . . .5-14
SHIFT MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16
PREASSEMBLING THE SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-17
ASSEMBLING THE MAIN SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-17
ASSEMBLING THE COUNTERSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18
IGNITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-19
CHECK STATOR AND PULSE GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . .5-19
Engine housing
NOTE: Read through the following section before commencing work. Then determine the assembly sequence so that
the engine housing halves only need to be heated up once before replacing the bearings.
Having first removed the dowels, in order to expel the bearings or remove them with light mallet blows, the housing
halves must be placed on a suitably large plane surface, supporting the whole of the sealing surface without damaging
it. A wooden panel is best used as a base.
Bearings or shaft seal rings should not be hammered into their seats. If no suitable press is available, use a suitable
mandrel and hammer them in with great care. Cold bearings will practically drop into their seats at an engine housing
temperature of approx. 150° C.
After cooling, should the bearings fail to lock in the bore, they are bound to rotate after warming. In that event the
housing must be replaced.
5-2C
Right housing half
2
Remove the shaft seal rings and use a hot plate to heat the housing half
to a temperature of approximately 150° C.
3
NOTE: At a temperature of 150° C it is usually sufficient to tap the
housing half onto a plane wooden surface and the bearings will simply
drop out of the bearing seats. However, in some cases it is necessary to
press the bearings out of their seats. To prevent damaging of the
bearings, the device used to press in the new bearings must be designed
in such a way that it touches only the outer ring of the bearing.
Grooved ball bearing of the crankshaft 1
Press the old grooved ball bearing inwards from the outside. Insert a
new grooved ball bearing with the open side of the ball cage facing
downwards (i.e. towards the exterior) and press it all the way into the
seat.
4
1
8
6
9
Grooved ball bearing of the main shaft 2
Apply a suitable mandrel on the outside to press the grooved ball
bearing inwards.
Before pressing the new grooved ball bearing inwards, mount the gear
shifting gate bk. Then, the grooved ball bearing can be pressed in from
the inside and up to the stop.
!
CAUTION
APPLY ONLY A LIGHT PRESSURE WHEN PRESSING
OTHERWISE, YOU WILL DAMAGE THE SHIFTING GATE.
10
7
Grooved ball bearing of the countershaft 3
Apply a suitable mandrel on the outside to press the old grooved ball
bearing inwards. Insert a new grooved ball bearing from the inside and
press it all the way into the seat.
Art No 3.206.005 -E
Grooved ball bearing of the shift roller 4
Apply a suitable mandrel on the outside to press the old grooved ball
bearing inwards. Insert a new grooved ball bearing from the inside and
press it all the way into the seat.
5
11
S
Repair manual KTM 125 / 200
!
IN THE GEAR SHIFTING GATE.
!
CAUTION
!
– MODEL 2000 UPWARDS THE GROOVED BALL BEARING IS SECURED WITH A
SCREW bl, THIS IS TO BE REMOVED BEFORE PRESSING OUTWARDS THE BEARING
AND TO BE MOUNTED AFTER PRESSING INWARDS THE BEARING.
DUE TO THIS SCREW THE SHIFT ROLLER HAS CHANGED, AN „OLD“ SHIFT ROLLER
IS NOT ABLE TO MOUNT WITH A SCREW SECURING THE BEARING.
– DO NOT APPLY EXCESSIVE FORCE WHEN PRESSING THE GROOVED BALL BEARINGS
FLUSH WITH THE COLLAR IN THE HOUSING. THE COLLAR WALL IS VERY THIN AND
CAN EASILY BE DAMAGED!
Needle bearing of the shifting shaft 5 (from model 2002 on)
Use a suitable mandrel to press out the needle bearing. Insert the new
needle bearing and press it all the way in.
Grooved ball bearing of the centrifugal timer 6
Use an interior extractor and a Ø 5-7 mm insert to pull the grooved ball
bearing out of the housing. Press a new grooved ball bearing all the way
into the seat.
Grooved ball bearing of the water pump shaft 7
Use an interior extractor and a Ø 5-7 mm insert to pull the grooved ball
bearing out of the housing. Press a new grooved ball bearing all the way
into the seat.
Kickstarter release plate 8
When exchanging the release plate keep in mind to apply Loctite 243 to
both bolts.
Shaft seal ring of the crankshaft 9
Insert a new shaft seal ring from the outside and press it in flush, the
open side facing inwards.
Then check the lubrication bore for the grooved ball bearing S of the
crankshaft for obstructions.
5-3C
Left housing half
Remove the shaft seal rings and use a hot plate to heat the housing half
to a temperature of approximately 150° C.
3
NOTE: At a temperature of 150° C it is usually sufficient to tap the
housing half onto a plane wooden surface and the bearings will simply
drop out of the bearing seats. However, in some cases it is necessary to
press the bearings out of their seats. To prevent damaging of the
bearings, the device used to press in the new bearings must be designed
in such a way that it touches only the outer ring of the bearing.
5
Roller bearing or the crankshaft 1
Apply a suitable mandrel on the outside to press the roller bearing
inwards. Insert a new roller bearing from the inside and press it all the
way into the seat.
1
2
4
6
Grooved ball bearing of the main shaft 2
Apply a suitable mandrel on the outside to press the grooved ball
bearing inwards. Insert a new grooved ball bearing from the inside and
press it all the way into the seat.
!
CAUTION
!
TO
PREVENT DAMAGING OF THE HOUSING, NEVER APPLY TOO MUCH FORCE WHEN
PRESSING IN GROOVED BALL BEARINGS.
Grooved ball bearing of the countershaft 3
Apply a suitable mandrel on the outside to press the grooved ball
bearing inwards. Insert a new grooved ball bearing from the inside and
press it all the way into the seat.
7
Shaft seal ring of the countershaft 4
Insert a new shaft seal ring from the outside and press it in flush. Do not
forget the stop disc (position it on the grooved ball bearing of the
countershaft before mounting).
Needle bearing of the shifting shaft 5 (from model 2002 on)
Use a suitable mandrel to press out the needle bearing. Insert the new
needle bearing and press it all the way in.
S
Shaft seal ring of the shifting shaft 6
Insert a new shaft seal ring from the outside and press it in flush.
Shaft seal ring of the crankshaft 7
Insert a new shaft seal ring from the outside and press it in flush.
8
Lubrication bore of the crankshaft roller bearing S
Check for obstructions and clean the bore with compressed air, if
necessary.
Check if the oil guiding rubber 8 of the left housing half is correctly
mounted (i.e. with the narrower end of the guide slots facing inwards)
and apply a small quantity of grease to fix it in the housing. Brittle or
hard oil guiding tubes must be replaced.
5-4C
Crankshaft
– When replacing the roller bearing, the inner crankshaft ring must also
be renewed.
– Heat special tool 584.29.037.037 on a heating pad up to approx.
150°C and slip it on the inner ring immediately. Press the special tool
together tightly so as to obtain a good heat transfer and pull the
inner ring off the crankshaft.
– To mount the new inner ring, heat the special tool again to approx.
150°C, engage the inner ring and slip it on the crankshaft journal
immediately.
!
CAUTION
!
NEVER CLAMP THE CRANKSHAFT WITH A STUD OR WEB IN THE VICE, AND NEVER TRY
TO KNOCK THE BEARING INNER RING FREE. THE CRANKSHAFT WEBS MAY BE
COM-PRESSED AND THE CON-ROD PLUG AND BEARING MAY BE DAMAGES, THEREBY
MAKING THE CRANKSHAFT UNUSABLE.
NOTE: Distance adjustment of the main bearings is not requested.
– Place the crankshaft on a roller block or the like, and impact-test the
crankshaft journals at their outer ends, using a test gage.
run out of crankshaft journals: max. 0.02 mm (0.0008 in.)
Crankshaft webs – measure outer dimension
– Crankshaft webs – measure outer dimension with a sliding gauge as
illustrated.
Crankshaft webs – outer dimension = 55 mm ± 0.05 mm
Piston
Art No 3.206.005 -E
If a used piston is to remain in service then the following should be
checked:
1. Piston running surface: Check for pressure marks (seizing marks)
minor friction marks can be removed with a fine abrasive stick.
2. Piston ring grooves: The piston rings must not get jammed in the
grooves. For cleaning the grooves, use an old piston ring or abrasive
paper (grain size 400).
3. The piston ring locating pins must be firmly seated in the piston and
must not be worn out.
4. Check piston rings for wear and check end gap.
– The piston is measured at the piston skirt, transverse to the piston pin
10 mm from the lower edge, as shown in the illustration.
– The smallest cylinder diameter minus the largest piston diameter
determines the piston fitting clearance.
Repair manual KTM 125 / 200
Piston fitting clearance: 0,06 mm (125) / 0,055 mm (200)
Piston ring end gap
– Insert pisto ring into the cylinder and adjust. Piston ring must be
approx. 10 mm (0.5 in) from top of cylinder.
– The end gap B can now be checked which a feeler gauge.
End gap max. 0.40 mm (0.015 in)
NOTE: If the end gap is greater check piston and cylinder for wear. If
piston and cylinder wear are within the permitted tolerance limits,
replace the piston ring.
5-5C
Checking cylinder for wear
10mm
Measure diameter of cylinder approx. 10 mm (0.5 in) below top of
cylinder edge. Check diameter in several corresponding places to see if
cylinder in worn oval.
x
y
Cylinder diameter 125
Piston size
up to Model 2000
54.250 - 54.262 mm . . . . . . . . . . . . . . . . . 1
54.263 - 54.275 mm . . . . . . . . . . . . . . . . . 2
Cylinder diameter 125
Piston size
Model 2001 onwards
54.000 - 54.012 mm . . . . . . . . . . . . . . . . . 1
54.013 - 54.025 mm . . . . . . . . . . . . . . . . . 2
Cylinder diameter 200
Piston size
64.000 - 64.012 mm . . . . . . . . . . . . . . . .1
64.013 - 64.025 mm . . . . . . . . . . . . . . . . .2
If the cylinder diameter is larger than 54.275 mm (125 up to 2000),
54,025 (125 2001 onwards) or 64.025 mm (200), the Nikasil cylinder
must be reconditioned or replaced.
NOTE: For reconditioning of the old cylinder all exhaust control
components must be removed.
Reconditioned cylinders are available on order from your KTM dealer.
The piston size is stamped into the bottom of the piston.
Nikasil coating of cylinder
Nikasil is the brand name for a cylinder coating process, developed by
the piston manufacturer Mahle. The name is derived from the two
materials used in this process - a nickel layer into which the particularly
hard silicon carbide is inbedded.
The main advantages of the Nikasil coating are:
● excellent heat dissipation and thus better power output
● low wear
● low weight of the cylinder.
NOTE: The worn coating can be regenerated at low cost provided that
the cylinders running surface is flawless.
5-6C
11
7
13
8
9
4
13
12
3
9
10
8
6
5
7
15
2
Art No 3.206.005 -E
5
1
14
Repair manual KTM 125 / 200
Dismounting and checking the exhaust control system in the cylinder
– Remove the 6 bolts bo and take off the exhaust flange 1 together with the gasket.
– Undo 2 bolts 2 and take the guide plate 3 out of the cylinder.
– Remove 3 collar bushings 4 and the control segment bm. To prevent subsequent jamming of the exhaust control, do not
damage the bearing surfaces of the collar bushings and the control segment bm.
– Take the three roller guides 4 behind out of the cylinder.
– Pull the two control rollers 5 and the eccentric shaft 6 out of the bores in the cylinder.
– Undo the bolts 7 to the left and to the right and remove them together with the locking plates 8.
– Twist out the left and the right control flap axles 9.
– Slightly push the control flap bk upwards through the exhaust port. Turn the lifting bolt bl of the control flap a quarter of a full
rotation (for this purpose, it is recommended to twist a M5x40 bolt into the thread of the lifting bolt) and pull it upwards out of
the cylinder. Now the control flap can be taken out of the cylinder.
– Clean all parts of the exhaust control and check for wear and damage.
Roller guides 4
Check the contact surface between the roller guides and the control roller segment for grooves and exchange them, if necessary.
Control rollers 5
Check bearing for play.
Check the teeth of the control rollers for wear.
Control flap axles 9
Check the control flap axles for wear, especially at the pins.
NOTE: to prevent sticking of the control flap on 125 EXE- and 125 Supermoto models, there are nitrogenized control flap axles
(bright surface) available which subseed the original fitted axles (dark surface).
Control segment bm
Check the contact surface between the control segment and the roller guides for grooves and exchange them, if necessary.
O-rings bn
Check the O-rings of the control flap axles for wear and brittleness and exchange them, if necessary.
NOTE: from model 2002 the left side cover bp is drilled for the crank case ventilation.
5-7C
Control flap bk
Clean the control flap and check the pins in the control flap for tight fit.
Measure the distance A between the two pins (see illustration).
When mounted, the control flap must not scrape against the exhaust
port.
A
Distance A: min. 5.5 mm (0.22 in)/max. 5.8 mm (0.23 in)
Preassembling the cylinder
ca. 0,20 mm
– Grease O-rings bn and control flap axles 9, especially at the pins.
– Slide control flap bk through the exhaust duct into the cylinder, and
position it such that the control flap axles may engage the 2 recesses
of the control flap.
– Mount the left and the right control flap axles 9 without tightening
them yet.
– Insert two feeler gauges of identical thickness (approx. 0.20 mm /
0.008 in) between the control flap and the cylinder wall at points B.
This distance must be equal on both sides.
– Twist the control flap axles 9 all the way in and then 1/8 of a full
turn out again.
– Apply Loctite 243 to two bolts 7 and use them to fix the two locking
plates 8, thereby taking care to turn the control flap axles 9 as little
as possible.
– Remove the two feeler gauges and check control flap for easy
operation.
– When installed, the control flap must not touch the exhaust duct.
ca. 0,20 mm
B
B
– Thoroughly oil the lifting bolt bl and insert it from above into the
bore in the cylinder. Insert the lifting bolt until it engages in the
control flap bk. Then rotate it a quarter of a full turn so that the flat
section is perpendicular to the direction of travel and faces forward
(in the direction of the exhaust port).
11
6
5
5
– Thoroughly oil the control rollers 5 and insert them into the bores in
the cylinder. Insert the control roller with one mark on the left and the
control roller with 2 marks on the right side.
– Thoroughly oil the eccentric shaft 6 of the control flap and mount it
in the cylinder. Move the control flap up and down. The eccentric
shaft should move with the control flap.
5-8C
Art No 3.206.005 -E
4
12
NOTE: When all marks are aligned, the control flap must be in the
bottom position and the bores of the control rollers must be completely
closed.
4
4
2
3
Repair manual KTM 125 / 200
– Grease the pins in the cylinder and mount the 3 roller guides 4 with
the large collar facing the cylinder.
– Turn the control rollers and the adjusting roller of the control flap so
that the marks are on the outside (facing the control segment).
– Mount the control segment bm in such a way that the marks on the
control rollers coincide with those of the control segment (see
illustration).
– Mount three roller guides 4 with the small collar facing the cylinder.
– Mount the guide plate 3, apply Loctite 243 to two bolts 2 and use
them to fix the guide plate in the cylinder.
– Turn the control segment clockwise. The control flap must open and
the bores of the control rollers must be opened.
– Mount a new gasket.
– Fix the cover with the six bolts. Don’t forget the 2 brackets for the
exhaust springs.
– Finally, check the exhaust control system for easy operability
5-9C
7
8
11
9
4
3
2
1
1
10
6
5
5-10C
Dismounting the exhaust control system in the clutch
cover, and checking parts for wear.
– Undo 2 bolts 1 and remove the closure cap 2 together with the
gasket and the copper seal rings.
– Press the grooved ball bearing 3 below out of the clutch cover. For
this purpose, push the rocker arm 4 of the centrifugal timer forward
(in the direction of the grooved ball bearing).
– Turn the adjusting lever 5 so that it rests against the clutch cover
(see illustration).
– Undo the bolt 6 and pull the rocker arm 4 off the adjusting lever 5.
– Undo the collar bolt 7 of the centrifugal timer bk and pull the
centrifugal timer inwards out of the clutch cover.
– Pull the adjusting lever 5 out of the clutch cover.
– Clean all parts and check for wear.
5
Adjusting lever 5
Check the pins of the adjusting lever for wear. Check the bearing surface
between the adjusting lever and the needle bushing for wear.
Grooved ball bearing 3
Check for wear.
Repair manual KTM 125 / 200
Art No 3.206.005 -E
Needle bushing of the adjusting lever 9
The bearing bushing of the adjusting lever normally shows no signs of
wear. If this is nevertheless the case, it is recommended to replace the
entire clutch cover.
Shaft seal ring of the kickstarter shaft 8
Lever the used shaft seal ring out of the clutch cover with a screwdriver.
Grease the new shaft seal ring and insert it with the open side facing
inwards. Press it in flush.
7
Centrifugal timer bk
The centrifugal advance device is factory-preset and must not be
disassembled.
Preassembling the clutch cover
– Grease the bearing 9 of the adjusting lever, insert the adjusting lever
5 into the clutch cover and let it rest against the clutch cover (see
illustration).
– Fix the centrifugal timer with the bolt in the clutch cover. Secure the
bolt with Loctite 243.
NOTE: The bolt 7 is tightened after mounting the clutch cover.
A
– Hook the pins of the adjusting lever 5 into the track of the
centrifugal timer.
– Mount the rocker arm 4 on the adjusting lever 6 and fix it with a
bolt.
– Insert the grooved ball bearing with the open side of the cage facing
inwards into the clutch cover.
– Mount the cover 2 with a new gasket and new copper gaskets.
!
CAUTION
!
MOUNTING THE COVER 2, MAKE SURE THAT THE FLAT SECTION
CORRECTLY ALIGNED SO AS TO PREVENT DAMAGING OF THE CLUTCH COVER.
WHEN
A
IS
5-11C
Disassembling and checking the water pump
– Remove the 2 bolts of the water pump cover and take off the water
pump cover.
– Pull the water pump and the O-ring out of the clutch cover.
– Clamp the water pump with the water pump wheel facing upwards
into the vise (use protective jaws).
!
CAUTION
!
TO
PREVENT DAMAGING OF THE WATER PUMP DRIVING WHEEL, NEVER CLAMP THE
WATER PUMP DRIVING WHEEL ITSELF INTO THE VISE.
– Remove collar bolt 1 together with the washer.
– Pull the water pump wheel 2 upwards off the water pump shaft 3.
– Take the water pump shaft out of the vise and pull the water pump
shaft out of the water pump housing 4.
Shaft seal ring of the water pump shaft 5
Use a screwdriver to lever the shaft seal ring out of the water pump
housing.
Apply Loctite 648 to the outside of the new shaft seal ring and press it
into the housing with the label facing inwards.
Grooved ball bearing of the water pump shaft 6
The shaft seal ring 5 must be removed to exchange the grooved ball
bearing. Use an appropriate mandrel to press the grooved ball bearing
out of the water pump housing 4.
Press a new grooved ball bearing all the way into the seat. Apply Loctite
648 to the outside of a new water pump shaft seal ring and insert it with
the label facing inwards.
Water pump driving wheel 7
The water pump driving wheel should not turn on the water pump
shaft.
Check the teeth of the water pump driving wheel for wear.
2
1
5
4
6
3
7
Preassembling the water pump
– Grease the shaft seal ring 5 and the grooved ball bearing 6 of the
water pump shaft and insert the water pump shaft into the water
pump housing 4.
– Clamp the water pump shaft into the vise (use protective jaws).
!
CAUTION
!
TO
PREVENT DAMAGING OF THE WATER PUMP DRIVING WHEEL, NEVER CLAMP THE
WATER PUMP DRIVING WHEEL ITSELF INTO THE VISE.
– Put the water pump wheel 2 on the shaft, apply Loctite 243 to the
bolt 1 and mount bolt and washer.
– Place preassembled water pump and new O-ring into clutch cover.
– Fix water pump cover with 2 short bolts.
5-12C
5
6
3
4
A
C
8
9
B
Art No 3.206.005 -E
7
11
1
10
2
Checking clutch for wear
Thrust bearing 1- check it for score marks and easy operability.
Repair manual KTM 125 / 200
Push rod 2- place it on a flat surfacecheck for bents.
Clutch springs 3- minimum length 38 mm (1.496 in) (new 39 mm / 1.535 in); if necessary exchange all 5 springs.
7 Lining discs 4- minimum thickness: 2.9 mm (0.114 in) (new 3,0 mm / 0.118 in). Discs must be plane.
4 Clutch discs - aluminium 5- discs must be plane; check for mechanical damage.
2 Clutch discs - steel 6- discs must be plane; check for mechanical damage.
Inner clutch hub 7- check the bearing surface of the lining disc for damage.
Check the bearing surfaces A of the steel discs at the inner clutch hub. If the grooves are deeper than 0.5 mm (0.02 in) replace the
inner clutch hub.
Pressure cap 8- check the bearing surface B of the lining disc for damage.
Outer clutch hub 9- check the stop faces C of the lining discs for wear. The outer clutch hub must be replaced if the grooves are
more than 0.5 mm (0.02 in) deep (see below).
Mount the inner ring bk and the needle cage bl and check for play.
5-13C
Reed valve housing, intake flange
NOTE: The reed paddles 1 slowly lose their tension during operation,
thus reducing the overall performance. Damaged or worn reed paddles
must therefore be replaced.
The entire reed valve housing must be exchanged if the sealing surfaces
of the reed valve housing 2 are also damaged.
!
CAUTION
WHEN
MOUNTING THE REED VALVE HOUSING BE SURE TO APPLY
ALL BOLTS.
!
LOCTITE 243
TO
Velocity insert 3
Check for tight fit and damage.
Intake flange 4
Check for cracks and other damage.
LOCTITE 243
4
3
1
5
2
1
LOCTITE 243
M
NOTE: Model 2000 onwards velocity insert 3 and wing 5 is only
available as one part.
– Measure distance M between the stop plates with a sliding gauge.
Distance M = 28 mm (1.1 in)
5-14C
9
8
7
6
1
5
4
3
11
Art No 3.206.005 -E
2
12
10
Kickstarter
Take all components off the kickstarter shaft and clean them.
Kickstarter gear 1
Check the bearing for play and grooves.
Intermediate kickstarter gear 2
Check the bearing for play and grooves.
Locking pawl 3
Check for wear and damage.
Kickstarter shaft 4
Check for wear and damage, paying particular attention to pivot points
and teeth. Check the lubrication bores for free passage.
Preassembling the kickstarter shaft
Repair manual KTM 125 / 200
B
A
– Mount the locking pawl on the kickstarter shaft. Ensure that the mark
A on the locking pawl coincides with the bore B in the kickstarter
shaft.
– Clamp the kickstarter shaft 4 into the vise (use protective jaws) with
the teethed end facing upwards.
– Mount the stop disc 5 (17x24x1 mm) and the kickstarter gear 1
with the ratchet teeth facing downwards.
– Put the stop disc 6 (17x24x1 mm) on the shaft.
– Mount the circlip 7 with the sharp edge facing upwards.
– Mount the kickstarter spring 8; insert the inner end of the kickstarter
spring into the bore of the kickstarter shaft.
– Mount the driving hub 9; the slot must be positioned above the
inner end of the kickstarter spring.
– Take the kickstarter shaft out of the vise.
– Mount the ratchet gear spring bk and the stop disc bl on the
kickstarter shaft.
5-15C
C
Shifting mechanism from model 2001 on
7
6
9
8
9
Needle bearing from model 2002
10
4
14
A
1
B
3
1
5
15
5
13
5
2
1
11
13
12
5-16C
Shifting mechanism
Shift forks 1
Check the blade A for wear.
Shift roller 2
Check the shift grooves B for wear.
Ensure that the shift roller rests properly in the grooved ball bearing 3.
Check the grooved ball bearing bl in the shift roller for wear. To replace
it, remove the Seeger circlip ring bm and pull the grooved ball bearing
out of the shift roller (slide seat). Mount the Seeger circlip ring with the
sharp edge pointing to the outside.
C
Shift ratchet 4
Check the contact surface toward the gear shifting gate for wear. The
shift ratchets must not jam when mounted.
Grooved ball bearing 3
Check for smooth operation.
Sleeves 5
on the driving pin for the shift shaft must be free of pressure marks.
Shift rails bn
Impact-test the shift rails on a planar surface. Check shift rails for score
and seizing marks. The easy operability of the shift forks on the shift rails
must be ensured.
Art No 3.206.005 -E
Preassembling the shifting shaft (up to model 2000)
– Grease the 2 stop discs 6 (14.3x20x1 mm), and slide them onto the
shift shaft.
– Mount the return spring 7 on the shift shaft; the two legs of the
spring must rest against bracket C of the shift shaft.
– Put the disc 9 (14,3x20x1 mm) on the shaft, then mount the circlip
8 with the sharp edge facing upwards in the groove of the shift
shaft.
– Put on the disc 9 (14,3x20x1 mm).
up to 2000
6
7
9
8
9
Repair manual KTM 125 / 200
Preassembling the shifting shaft (model 2001 onwards)
– Mount the return spring 7 on the shift shaft; the two legs of the
spring must rest against bracket C of the shift shaft.
– Put discs 6 (14,2x22x1,5 mm) and 9 (14,3x20x1 mm) on the shaft,
then mount the circlip 8 with the sharp edge facing upwards in the
groove of the shift shaft.
– Put on the disc 9 (14,3x20x1 mm).
2001 onwards
7
6
9
8
9
5-17C
! ATTENTION !
When replacing
gears, watch
X
out for this mark !
X
1
2
3
4
5
6
7
8
9
10
11
Transmission
Clamp the main shaft or counter shaft, respectively, into the vise (use protective jaws). Remove the gears and check the following
parts for wear and grooves:
● Bearing sleeves
● Pivot points of the main shaft and countershaft and pivot points of the idler gears
● Shift dogs of the gears
● Tooth faces of all gears
● Tooth profiles of the main shaft and countershaft as well as of the corresponding gears
● Check the profiles of all control gears for smooth operation
Thoroughly clean all parts, exchange damaged components. New axial securing elements
should be mounted whenever repair work is performed.
Assembling the main shaft
– Clamp the main shaft into a vise (use protective jaws) with the toothed end facing
downwards.
– Carefully grease all parts before mounting them.
– Mount the bearing sleeve 1 (22x25x11.1 mm) on the main shaft. Then put the 5th idler
gear 2 on the shaft with the shifting claws facing upwards.
– Put the stop disc 3 (22.2x27.8x1 mm) onto the shaft and mount the axial securing
element 4.
– Mount the 3rd/4th sliding gear 5 with the small gear facing downwards and mount the
axial securing element 6.
– Put the stop disc 7 (22.2x27.8x1 mm) onto the shaft.
– Mount the bearing sleeve 8 (22x25x11.1 mm) and the 6th idler gear 9 with the recess
for the shifting claws facing downwards.
– Mount the 2nd fixed gear bk and the stop disc bl (17.2x26x1 mm).
– Then check all gears for smooth operation.
5-18C
5
! ATTENTION !
When replacing gears, watch
out for this mark !
4
3
2
X
1
18
17
16
15
14
13
12
11
10
9
Art No 3.206.000 -E
8
7
6
Transmission
Repair manual KTM 125 / 200
Clamp the main shaft or counter shaft, respectively, into the vise (use protective jaws). Remove the gears and check the following
parts for wear and grooves:
● Bearing sleeves
● Pivot points of the main shaft and countershaft and pivot points of the idler gears
● Shift dogs of the gears
● Tooth faces of all gears
● Tooth profiles of the main shaft and countershaft as well as of the corresponding gears
● Check the profiles of all control gears for smooth operation
Thoroughly clean all parts, exchange damaged components. New axial securing elements
should be mounted whenever repair work is performed.
Assembling the countershaft
– Clamp the countershaft into the vise (use protective jaws!) with the toothed end facing
downwards.
– All parts must be carefully greased before mounting.
– Mount the bearing sleeve 1 (25x28x9.7 mm) and the 2nd idler gear 2 with the recess for
the shifting claws facing upwards.
– Mount the stop disc 3 (25.2x32x1 mm) and the axial securing element 4 on the
countershaft.
– Mount the 6th idler gear 5 with the shift groove facing upwards, then mount the stop
disc 6 (22.2x28x1 mm).
– Mount the bearing sleeve 7 (22x25x8.1 mm), the 4th idler gear 8 and the stop disc 9
(22.2x30x2.5 mm).
– Mount the bearing sleeve bk (22x25x8.1 mm), the 3rd idler gear bl, the stop disc bm
(22.2x27.8x1 mm) with internal teeth and the axial securing element bn.
– Mount the 5th sliding gear bo with the shift groove facing downwards and the stop disc bp
(17.2x26x1 mm).
– Mount the bearing sleeve bq (17x20x9.7 mm), the 1st idler gear br with the collar facing
upwards and the stop disc bs (17.2x26x1 mm).
5-19C
Ignition
General information
The measurements described below will only reveal severe problems.
Coil short circuits leading to weak ignition sparks or low generator
output, respectively, can only be detected with the help of an ignition
test bench. In the case of malfunction always check the cables and the
plug and socket connections of the ignition system first.
Make sure to select the correct measuring range when performing
measurements.
The CDI unit can be checked only on the ignition test bench.
LOCTITE 243
2K-1
Spark plug
Electrode distance: 0.60 mm (0.024 in)
LOCTITE 243
Insulator
Check for cracks and fissures.
2K-2
!
ALWAYS USE A
THE CDI UNIT.
CAUTION
OTHERWISE
SPARK PLUG WITH RESISTOR.
!
PROBLEMS CAN OCCUR IN
LOCTITE 243
2K-3
Kokusan 2K-1
0,60 mm
Check stator and pulse generator
Use an ohmmeter to perform the following measurements:
Kokusan 2K-2
Ignition
Measure
cable colours
Resistance
2K-1
Pulser coil
Exciter
red – green
black/red – red/white
100 Ω 20%
24,8 Ω 20%
2K-2
Pulser coil
Exciter
Charge coil
red – green
black/red– red/white
ground – yellow
100 Ω 20%
24,8 Ω 20%
0,74 Ω 20%
Pulser coil
Exciter
Charge coil
red – green
black/red – red/white
ground – yellow
white – yellow
100 Ω 20%
12,7 Ω 20%
0,65 Ω 20%
0,16 Ω 20%
2K-3
Kokusan 2K-3
NOTE: The measuring must be performed at a temperature of 20° C.
Otherwise significant deviations must be expected.
Replace the stator and/or the pulse generator if the measured values
deviate significantly from the setpoint values.
6-1C
ASSEMBLING THE ENGINE
Repair manual 125 / 200
Art No 3.206.005-E
INDEX
MOUNTING THE CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
TRANSMISSION SHAFT, SHIFT MECHANISM . . . . . . . . . . . . . . . . . . . . . . . .6-2
ASSEMBLING THE ENGINE HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3
ENGINE SPROCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3
IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3
SHIFT DRUM LOCATING DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4
KICKSTARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5
PRIMARY DRIVE, CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5
CLUTCH DISCS, PRESSURE CAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6
OIL PUMP, REED VALVE HOUSING, INTAKE FLANGE
(SEPARATE LUBRICATION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7
REED VALVE HOUSING, INTAKE FLANGE . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8
CLUTCH COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8
PISTON, CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9
ADJUSTING DIMENSION „X“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9
ADJUSTING THE CONTROL FLAP (DIMENSION „Z“) . . . . . . . . . . . . . . . .6-10
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10
IGNITION COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11
MEASURING DIMENSION „Y“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11
MOUNTING THE CLUTCH SLAVE CYLINDER . . . . . . . . . . . . . . . . . . . . . . .6-12
FILLING IN THE GEAR OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12
6
6-2C
– Clamp the right housing half onto the mounting rack.
Mounting the crankshaft
– Oil the grooved ball bearing of the crankshaft.
– Insert the crankshaft into the grooved ball bearing from above and
carefully push it as far as it will go.
!
CAUTION
!
THE
CONROD MUST BE DIRECTED TOWARDS THE CYLINDER WHEN THE CRANKSHAFT
IS INSERTED!
Transmission, shift mechanism
– Mount the stop disc at the bottom of the countershaft and fix it with
grease to prevent it from slipping off the shaft.
– Align the teeth of the main shaft and the countershaft and insert both
shafts together into the bearing seats.
– Grease the driving pins 2 of the shift forks and mount the rollers 1.
Art No 3.206.005 -E
1
2
Repair manual KTM 125 / 200
– Oil the blades of the shift forks and hook them into the sliding gears.
– Insert the shift roller into the bearing seat and hook the shift forks
into the shift roller.
– Oil the shift rails and insert them into the shift forks (short rail facing
the main shaft).
1
6-3C
50
M6x... mm
55
55
55
50
50
50
50
50
55
55
Assembling the engine housing
–
–
–
–
–
–
–
–
–
–
Remove the engine holder at the mounting rack.
Make sure that both dowels are properly located in the right housing half.
Slightly grease the sealing surface of the housing and mount a new gasket.
Make sure that the rubber is properly inserted into the left housing half and that the sleeves have not slipped off the driving pins
of the shift forks.
Grease the shaft seal rings of the left housing half and put on the left housing half.
Check the housing gasket for proper fit.
Grease the threaded sections and the contact surfaces at the heads of the housing bolts. Insert the bolts and assemble the housing (bolt lengths are indicated in the illustration).
Before and after tightening the housing bolts with 8 Nm (6 ft.lb.) check all shafts for easy operation.
Fix the engine on the mounting rack.
Cut the protruding gasket off cleanly at the sealing surfaces at cylinder base and reed valve housing.
Engine sprocket
– Oil the O-ring (≠ 1.78 mm) and put it on the countershaft.
– Mount the distance bushing 1 in such a way that the O-ring is
located in the chamfer.
– Put the chain sprocket onto the countershaft with the collar facing
inwards and fix it with the circlip (sharp edge outwards).
– Tap the chain sprocket with a hollow mandrel or a similar tool to
slightly pretension the O-ring and to press the circlip into the groove.
1
Ignition system
B
A
– Insert the woodruff key into the crankshaft.
– Apply Loctite 243 to the thread of the bolt and fix the stator in the
housing with the 3 bolts without yet tightening the bolts.
– Turn the stator so that mark of the stator coincides with the middle
mark of the housing. Then tighten all three bolts of the stator.
NOTE: The left-hand mark A in the housing is intended for the 2K-1 and
2K-2 ignition systems. The right-hand mark B in the housing is meant for
the 2K-3 ignition system.
– Insert the cable guide into the housing.
6-4C
– Mount the rotor.
– Mount the detent edged ring and the nut.
– Hold the rotor with the holding spanner and tighten the hexagon nut
with 60 Nm / 44 ft.lb.).
Shift drum locating device
2
– Mount the locking drum 1 on the shift roller. Keep in mind that the
pin of the shift roller must engage in the corresponding recess of the
locking drum.
– Slide washer onto bolt 2, apply Loctite 243 on its thread and mount
the bolt. Block the locking drum with a special tool
(see picture), and tighten the bolt.
1
!
CAUTION
!
THE LOCKING DRUM MUST BE HELD WITH THE SPECIAL TOOL TO PREVENT DAMAGING
OF THE BUSHINGS ON THE DRIVING PINS OF THE SHIFT FORKS.
NOTE: If the locking lever hasn’t been removed, push it sideways
against the resistance of the spring when mounting the locking drum.
4
Art No 3.206.005 -E
3
A
B
5
– Mount washer 3.
– Line the washer, the locking lever, the collar bushing (the small collar
facing the head of the bolt) and the locking spring upon bolt 4.
Hook the end A of the locking spring into the locking lever.
– Apply Loctite 243 to bolt 4 and use it to fix the locking lever. Make
sure that the other end of the locking spring rests against the housing
bracket B.
6
Repair manual KTM 125 / 200
– Insert the ratchet carrier 5 into the gear shifting gate as shown in the
illustration.
– Use a small quantity of grease to fix the collar bushing 6 on the
ratchet carrier.
8
7
7
– Mount the ratchet carrier together with the gear shifting gate in the
housing. The ratchets 7 must be slightly squeezed to insert the
ratchet carrier into the locking drum.
– Fix the gear shifting gate with 3 bolts 8 on the housing.
6-5C
– Grease the shaft seal ring of the shift shaft.
– Oil the shift shaft and insert it into the housing. Do not forget the
stop disc! When mounting the shift shaft make sure that both legs of
the return spring rest against the prolongation of the shift rail 1.
1
Kickstarter
A
– Grease the bearing bore of the kickstarter shaft in the housing.
– Insert the preassembled kickstarter shaft into the housing so that the
locking pawl is located on the kickstarter shaft behind the release
plate in the housing.
– Pretension the kickstarter spring clockwise and hook it into the
corresponding bore in the housing A.
Primary drive, clutch
– Grease the shaft seal ring of the crankshaft.
– Put the oiled O-ring (25x2 mm) onto the crankshaft and mount
distance bushing with the chamfer facing the crank web so that
O-ring is located in the chamfer.
– Insert the woodruff key into the crankshaft.
– Put the primary gear onto the crankshaft with the collar facing
housing.
– Mount a new detent edged ring and a hexagon nut (LH thread).
– Mount the holding spanner for the primary gear and tighten
hexagon nut with 180 Nm (133 ft.lb.).
3
2
the
the
the
the
– Put the stop disc (17.2x26x1 mm) and the intermediate starter gear
2 onto the countershaft.
– Oil the bearing of the outer clutch hub 3 and put it onto the main
shaft.
6-6C
– Mount the outer clutch hub and the supporting disc (20x39.6x3 mm)
on the main shaft.
– Mount the inner clutch hub, a new lock washer and the hexagon nut
on the main shaft.
– Mount the clutch holder 1 and tighten the hexagon nut with 120
Nm (88 ft.lb.).
– Remove the clutch holder and secure the hexagon nut by bending
the two brackets of the lock washer upwards.
– The bracket of the lock washer that meshes with the inner clutch hub
must be carefully hammered down after tightening the hexagon nut
to make sure that it rests properly against the inner clutch hub.
1
Art No 3.206.005 -E
aluminium
steel
aluminium
Clutch discs, pressure cap
– Oil the thrust bearing and insert it into the main shaft.
– Properly oil the lining discs before mounting them.
NOTE: These engines have 4 clutch discs of aluminum and 2 clutch discs
of steel. These must be mounted in the following order:
1 lining disc
1 lining disc
1 lining disc
1 lining disc
1 lining disc
1 lining disc
Repair manual KTM 125 / 200
1 lining disc
1 clutch disc (aluminium)
1 clutch disc (aluminium)
1 clutch disc (steel)
1 clutch disc (steel)
1 clutch disc (aluminium)
1 clutch disc (aluminium)
– One of the lining discs must be on top.
– Mount the pressure cap, then the clutch springs, the spring retainers
and the collar bolts.
– Tighten the collar bolts crosswise. Apply a maximum of 6 Nm
(4.5 ft.lb.) to prevent damaging of the threads in the inner clutch
hub.
6-7C
Oil pump, reed valve housing and intake flange (separate
lubrication)
– Insert the reed valve housing into the engine case, and position the
intake flange such that the bolt 1 can be mounted. Mount the bolt,
but only tighten it such that it is still possible to rotate the intake
flange.
– Insert the oil pump with a new gasket into the engine case, and fix it
with the 2 bolts 2.
1
2
– Mount the oil pump housing. When mounting, be careful not to kink
the two hoses .
– Mount the 2 dowel bushings 3.
3
– Slide the oil-pump wheel 4 onto the oil pump.
4
– Mount the clutch cover 5 and tighten the bolts including 6. To
tighten the two bolts 7 it is necessary to hold the oil pump cover 8
in position.
6
7
5
– Mount the remaining 4 bolts of the intake flange, and tighten each of
the 5 bolts.
8
6-8C
Clutch cover
– Check if both dowels have been mounted in the engine housing.
– Grease the shaft seal ring of the kickstarter shaft and fix the clutch
cover gasket with a small quantity of grease.
– Fix the O-ring 1 in the housing with a small quantity of grease.
– Carefully mount the preassembled clutch cover and press it on.
Slightly rotate the crankshaft so that the centrifugal timer and the
water pump can mesh with the primary gear.
– Mount the collar bolts (bolt lengths indicated in the illustration on
next page) and tighten with 8 Nm (6 ft.lb.).
– Check all shafts for smooth operation.
1
35
35
40
35
35
M6x... mm
Art No 3.206.005 -E
55
40
40
35
55
35
35
Repair manual KTM 125 / 200
– Tighten the collar bolt 2 of the centrifugal timer.
2
Reed valve housing, intake flange
– Mount the reed valve housing and the intake flange and fix with 5
collar bolts and corrugated washers.
– Close the intake flange with a clean cloth or an appropriate plug.
6-9C
Piston, cylinder
– Carefully oil the sliding points of all components before mounting.
– Insert the needle bearing into the conrod eye, mount the piston (the
arrow on the piston head indicates the direction of the exhaust port).
– Mount the piston pin and the wire circlips with the open side facing
downwards (see illustration).
– Mount the cylinder base gaskets (recommended gasket thickness:
approx. 0.60 mm / 0.024 in).
– Place the piston on a self-made wooden mounting device and align
the piston rings.
– Mount the preassembled cylinder, remove the mounting device and
clamp the cylinder down with two collar nuts.
!
CAUTION
!
MOUNTING THE CYLINDER MAKE SURE THAT THE ROCKER ARM 1 OF THE
CENTRIFUGAL TIMER IS LOCATED IN THE CORRESPONDING RECESS 2 OF THE CONTROL SEGMENT IN THE CYLINDER. IF NECESSARY REMOVE THE SMALL CAP ON THE
RIGHT SIDE OF THE CYLINDER AND CHECK.
WHEN
1
2
Adjusting dimension „X“
NOTE: Dimension „X“ is the distance between the upper piston edge
and the offset upper cylinder edge with the cylinder clamped down and
the piston in position TDC.
Dimension „X“ must be adjusted particularly carefully by inserting
cylinder base gaskets of different thicknesses.
!
IF
CAUTION
!
DIMENSION „X“ IS TOO LARGE, THE COMPRESSION VALUE WILL DECREASE, THUS
REDUCING THE OVERALL ENGINE OUTPUT. IF DIMENSION „X“ IS TOO SMALL, THE
ENGINE WILL „PINK“ AND OVERHEAT.
6-10C
– Position the sliding gauge on the cylinder and turn the piston to TDC
by turning the flywheel. Read the value indicated by the sliding
gauge.
X
125 ccm up to model 2000: dimension „X“ = 0.60 mm (0.024 in)
125 ccm model 2001 onwards: dimension „X“ = 0.0 mm (0.0 in)
200 ccm up to model 2002: dimension „X“ = 0.55 mm (0.022 in)
200 ccm model 2003 onwards: dimension „X“ = 0.0 mm (0.0 in)
– Adjust dimension „X“ by adding or removing cylinder base gaskets.
NOTE: Adding of cylinder base gaskets increases and removing cylinder
base gaskets reduces dimension „X“.
– Mount the two remaining collar nuts at the cylinder base and tighten
all 4 collar nuts with 30 Nm (22 ft.lb.).
Adjusting the control flap (dimension „Z“)
NOTE: Dimension „Z“ is the distance between the lower edge of the
control flap and the upper edge of the cylinder, measured in the middle
of the exhaust port.
2
125 SX/EXC/EXE up to model 2000: Z = 42.0 mm + 0.2/- 0.6 mm
125 SX/EXC/EXE model 2001: Z = 42.5 mm + 0.2/- 0.6 mm
125 SX/EXC from model 2002: Z = 43 mm + 0.2/- 0.6 mm
200 MXC/EXC up to model 2001: Z = 46.0 mm + 0.2/- 0.6 mm
1
200 MXC/EXC model 2002: Z = 46,5 mm + 0.2/- 0.6 mm
200 MXC/EXC from model 2003: Z = 47 mm + 0.2/- 0.6 mm
Art No 3.206.005 -E
200 SX from model 2003: Z = 46 mm + 0.2/- 0.6 mm
– Loosen locking bolt 1 only 2 turns .
– Adjust the depth gauge to the indicated value and fix it in this
position.
– Insert the depth gauge into the cylinder.
– Turn the bearing carrier 2 at the clutch cover so that the control flap
rests against the depth gauge.
Z
– Tighten the locking bolt 1 to prevent the bearing carrier from
turning
– Mount the hexagon cap nut 3 of the centrifugal timer together with
a new seal ring.
3
!
CAUTION
!
WHEN
Repair manual KTM 125 / 200
MOUNTING THE HEXAGON CAP NUT MAKE SURE THAT THE BEARING CARRIER
OF THE CENTRIFUGAL TIMER IS NOT TURNED ANY MORE. OTHERWISE DIMENSION
„Z“ MUST BE ADJUSTED ONCE AGAIN.
1
Cylinder head
– Clean the sealing surfaces of the cylinder and the cylinder head.
– Insert a new O-ring into the corresponding groove of the cylinder
and mount a new cylinder head gasket.
NOTE: on 125 SX/EXC-engines from model 2002 onwards an O-ring is
used instead of the gasket.
– Mount the cylinder head with the water nozzle facing the exhaust
side and slightly turn it back and forth to prevent crushing of the
O-ring.
– Mount the collar bolts with new copper gaskets and tighten them
crosswise, taking 3 turns to achieve the total tightening torque of
18 Nm (13 ft.lb.).
– Initially, the bolts should only be tightened until the first slight
resistance is felt.
– Insert the spark plug and tighten with 20 Nm (15 ft.lb.).
6-11C
Ignition cover
– Apply silicone to several points of the gasket to fix it in the ignition
cover.
– Fix the ignition cover with 4 collar bolts.
– Use the collar bolt 2 to mount the wire bracket 1 for the
carburetor air hoses on the housing.
1
2
Measuring dimension „Y“
NOTE: The gasket of the driving cylinder of the clutch must be
appropriately thick to ensure smooth clutch release. For this purpose
measure dimension „Y“. Dimension "Y" is the distance from the sealing
surface of the clutch slave cylinder to the push rod.
– Swing the ignition side up.
– Oil the push rod and push it into the main shaft as far as it will go.
– Then use a sliding gauge to measure the distance between the
bearing surface of the driving cylinder of the clutch and the push rod.
– Write down dimension „Y“ and use an appropriate gasket (see table)
when mounting the driving cylinder of the clutch.
Dimension „Y“
2,5 - 2,8 mm
2,8 - 3,0 mm
3,0 - 3,3 mm
0.1 - 0.11 in
0.11 - 0.12 in
0.12 - 0.13 in
DIMENSION „Y“
Sealing surface of the clutch
slave cylinder
!
ALWAYS
USE A NEW GASKET.
OF THE HYDRAULIC CLUTCH.
push rod
counter
shaft
gasket thickness
0,75 mm
0,50 mm
0,30 mm
0,30 in
0,20 in
0,012 in
CAUTION
DAMAGED GASKETS MAY
!
IMPAIR THE EASY OPERABILITY
6-12C
Mounting the clutch slave cylinder
1
2
– Verify that the ball 2 has been correctly mounted in the piston of the
clutch slave cylinder.
– Put a new gasket in place, and mount the clutch slave cylinder. Apply
Loctite 243 onto the bolt's 1 thread.
NOTE: to make shure the clutch works well, the correct thickness of the
clutch slave cylinder gasket is to be measured - see dimension Y.
Filling in the gear oil
– Mount the oil drain plug with a new seal ring and tighten with 15 Nm
(11 ft.lb.).
3
Repair manual KTM 125 / 200
Art No 3.206.005 -E
– Remove the plug at the clutch cover and fill in 0.70 l oil (see
spezifications chapter 9).
– Mount the plug and check the engine for leaks.
– Mount kickstart and shift lever.
7-1C
ELECTRICAL
INDEX
CHECKING THE VOLTAGE REGULATOR-RECTIFIER (SHINDENGEN) . . . . . .7-2
CHECKING THE VOLTAGE REGULATOR (KOKUSAN) . . . . . . . . . . . . . . . . . .7-2
CHECKING THE CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2
IGNITION COIL (KOKUSAN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2
CDI UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3
MEASUREMENTS WITH PEAK VOLTAGE ADAPTER
STATIC IGNITION VALUES 125-200 SX, MXC, EXC . . . . . . . . . . . . . . . . . . . . .7-4
STATIC GENERATOR VALUES 125-200 EXC . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6
STATIC IGNITION VALUES/GENERATOR VALUES 125-200 MXC, EXC USA . . . .7-8
Repair manual 125 / 200
Art No 3.206.005-E
STATIC IGNITION VALUES 125 EXE, SUPERMOTO . . . . . . . . . . . . . . . . . . . .7-10
STATIC GENERATOR VALUES 125 EXE, SUPERMOTO . . . . . . . . . . . . . . . . . .7-12
7
7-2C
Checking the voltage regulator-rectifier (Shindengen)
– Start the engine and switch on the low beam.
– Connect a voltmeter to the two terminals of the capacitor (red/white
cable = positive, brown cable = negative).
– Accelerate the engine to a speed of 5000 r.p.m. and read off the
voltage.
Nominal value: 14.0 - 15.0 V
In the case of a significant deviation from the nominal value:
– Check the capacitor
– Check the connector between the stator and the voltage regulatorrectifier and between the voltage regulator and the cable tree.
– Check the stator.
– Replace the voltage regulator-rectifier.
Checking the voltage regulator (Kokusan)
A defect voltage regulator can cause different kinds of trouble:
● No voltage in the circuit
In this case, the voltage regulator must be disconnected at idle speed.
The voltage regulator is defect if the power consumers now work
properly.
If the power consumers are still not supplied with power, the switch,
the wiring harness or the ignition system must be checked for defects.
● Excessive voltage in the circuit
The bulbs burn out. In this case the voltage regulator must be
replaced.
Checking the capacitor
– Discharge the capacitor by bridging the two terminals with a
screwdriver and remove.
– Connect the negative pole of a 12V battery with the negative
terminal of the capacitor. The connection between the positive pole
of the battery and the positive terminal of the capacitor (marked +) is
made with a test lamp 3.
– When the power circuit is closed, the test lamp must begin to light
up. As capacitor charging increases, the brightness of the test lamp
must decrease.
– The test lamp must go out after 0,5-2 seconds (depending on the
lamp capacity).
– If the test lamp does not go out or does not light up at all, the
capacitor is faulty.
3
!
CAUTION
!
DISCHARGE THE CAPACITOR BEFORE AND AFTER EACH TEST.
WHEN INSTALLING THE CAPACITOR, MAKE SURE THAT THE TERMINALS ARE
CONNECTED IN ACCORDANCE WITH THEIR MARKINGS (CONNECT RED/WHITE CABLE
TO + TERMINAL).
Ignition coil
– Disconnect all cables and remove the spark plug connector.
– Use an ohmmeter to measure the following values.
NOTE: The indicated setpoint values correspond to a temperature
of 20° C.
Replace the ignition coil if the measured values deviate significantly from
the setpoint values.
Measure
Cable colours
Resistance
primary coil
blue/white – ground
0,425 - 0,575 Ω
secondary coil
blue/white – ignition wire
10,80 - 16,20 kΩ
7-3C
CDI unit
Check the cables and plug and socket connections of the CDI unit.
The CDI unit function can only be checked on an ignition test bench.
Repair manual KTM 125 / 200
Art No 3.206.005 -E
!
CAUTION
!
NEVER USE A COMMERCIAL MEASURING DEVICE TO CHECK THE CDI UNIT. COMMERCIAL MEASURING DEVICES CAN DESTROY HIGHLY SENSITIVE ELECTRONIC COMPONENTS.
7-4C
SPORTMOTORCYCLES
5
1
4
3
2
7-5C
STATIC IGNITION VALUES 125-200 SX, MXC, EXC (KOKUSAN 2K-1, 2K-3)
Measuring conditions:
– cold engine
– seat and tank removed
– all connectors and the ground connection in a non-corroding condition, connectors tightly connected
– spark plug screwed out and spark plug connector attached to ground
– light switch turned off
– the gap between the rotor and pulse generator must be set to 0.75 mm
– kick the kick starter forcefully at least 5 times for each measurement
1
Check the pulse generator for an output signal – two-pin connector 1
with green and red cable colors (also see circuit diagram on opposite
page):
– Apply the red measuring lead of the peak voltage adapter to the
green cable and the black measuring lead to the red cable, disconnect
both connectors 1 to disconnect the CDI unit 2
1
Multimeter display: 6 volts +/- 1 volt
3
– Same measurement with CDI unit connected
Multimeter display: 3 volts +/- 1 volt
Check the generator charging coil for ignition capacitor charge for
output voltage – two-pin connector 3 with black/red and red/white
cable colors (also see circuit diagram on opposite page):
Art No 3.206.005 -E
– Apply the red measuring lead of the peak voltage adapter to the
black/red cable and the black measuring lead to the red/white cable,
disconnect connector 3 to disconnect the CDI unit 2
Multimeter display: 35 volts +/- 5 volts
– Same measurement with connectors CDI unit connected
Multimeter display: 200 volts +/- 10 volts
S
4
Check the primary voltage output 4 for ignition coil control (also see
circuit diagram on opposite page) for output voltage (blue/white cable
color):
– Apply the red measuring lead R of the peak voltage adapter to the
black/white cable (ground) and the black measuring lead S to the
blue/white cable, CDI unit 2 and ignition coil 5 connected
R
Multimeter display: 200 volts +/- 10 volts
Repair manual KTM 125 / 200
NOTE: the ignition coil does not need to be removed to measure.
5
7-6C
SPORTMOTORCYCLES
6
10
9
11
7-7C
STATIC GENERATOR VALUES 125-200 EXC (KOKUSAN 2K-3)
Measuring conditions:
– cold engine
– seat and tank removed
– all connectors and the ground connection in a non-corroding condition, connectors tightly connected
– light switch turned off
– kick the kick starter forcefully at least 5 times for each measurement
Check the generator output 6 (also see circuit diagram on opposite
page) for voltage between the following cable colors:
– between yellow and brown (ground), connector 7 disconnected
Multimeter display: 19 volts +/- 2 volts
– between white and brown (ground), connector 8 disconnected
7
Multimeter display: 24 volts +/- 2 volts
– Repeat both measurements with connector 7 and 8 connected. The
measured values should be the same.
8
NOTE: the black measuring lead of the peak voltage adapter must be
applied to the ground.
Repair manual KTM 125 / 200
Art No 3.206.005 -E
Check regulator rectifier output voltage 9 (also see circuit diagram on
opposite page) cable colors yellow/red, regulator rectifier bk connected,
capacitor bl disconnected:
– between yellow/red and brown (ground)
Multimeter display: 14 volts +/- 1 volt
10
S
NOTE: the black measuring lead S of the peak voltage adapter must be
applied to the ground.
7-8C
5
3
4
2
1
6
7-9C
STATIC IGNITION AND GENERATOR VALUES 125-200 MXC, EXC USA (KOKUSAN 2K-2)
Measuring conditions:
– cold engine
– seat and tank removed
– all connectors and the ground connection in a non-corroding condition, connectors tightly connected
– spark plug screwed out and spark plug connector attached to ground
– light switch turned off
– the gap between the rotor and pulse generator must be set to 0.75 mm
– kick the kick starter forcefully at least 5 times for each measurement
1
Check the pulse generator for an output signal – two one-pin connectors 1 with green and red cable colors (also see circuit diagram on
opposite page):
– Apply the red measuring lead of the peak voltage adapter to the
green cable and the black measuring lead to the red cable, disconnect
both connectors 1 to disconnect the CDI unit 2
1
Multimeter display: 3.5 volts +/- 1 volt
3
– Same measurement with CDI unit connected
Multimeter display: 2 volts +/- 0.5 volt
Check the generator charging coil for ignition capacitor charge for
output voltage – two-pin connector 3 with black/red and red/white
cable colors (also see circuit diagram on opposite page)
Art No 3.206.005 -E
– apply the red measuring lead of the peak voltage adapter to the
black/red cable and the black measuring lead to the red/white cable,
disconnect connector 3 to disconnect the CDI unit 2
Multimeter display: 45 volts +/- 5 volts
– Same measurement with connectors CDI unit connected
Multimeter display: 220 volts +/- 10 volts
S
4
Check the primary voltage output 4 for ignition coil control (also see
circuit diagram on opposite page) for output voltage (blue/white cable
color):
– apply the red measuring lead R of the peak voltage adapter to the
black/white cable (ground) and the black measuring lead S to the
blue/white cable, CDI unit 2 and ignition coil 5 connected
R
Multimeter display: 210 volts +/- 10 volts
Repair manual KTM 125 / 200
NOTE: the ignition coil does not need to be removed to measure.
5
Check the generator output 6 for the lighting system (also see circuit
diagram on opposite page) for voltage:
– between yellow and brown (ground), connector disconnected
Multimeter display: 10.5 volts +/- 1 volt
7-10C
Europa
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27
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4
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7
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6
br
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2
Datum, Name:
22.11.99 Hasl.
13
1
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9
Land:
Kabelstrangnummer:
vorne:512.11.075.000
hinten:503.14.040.100
125 EXE 2000/2001
125 Super Moto 2000/2001
Modell:
bl
SERVICE
SPORTMOTORCYCLES
o
ge-bl
14
23
g
bl
10 ger
br
w
s-ge
g
bl
ge
r
br
ge-bl
11
g-w
s-ge
16
17
ge-s
br
bl-w
s-w
1
4
5
28
KOKUSAN
3
s-w
bl-w
2K3
15
s-ge
s-r
r-w
o
r
g
w
ge
G
18
30
20
2
ge-r
g-w
w
12
ge-bl
br
22
br
21
br
54
58
25
26
br
31
24
29
s
br
g-w
w
v
br
g-w
ge-bl
8
s
ge-r
br
v
s
ge-r
br
v
s
ge
7-11C
STATIC IGNITION VALUES 125 EXE / 125 SUPERMOTO (KOKUSAN 2K-3)
Measuring conditions:
– cold engine
– seat and tank removed
– all connectors and the ground connection in a non-corroding condition, connectors tightly connected
– spark plug screwed out and spark plug connector attached to ground
– battery loaded, ignition switch to position 1 (light turned off)
– the gap between the rotor and pulse generator must be set to 0.75 mm
– kick the kick starter forcefully at least 5 times for each measurement
Check the pulse generator for an output signal – two one-pin connectors 1 with green and red cable colors (also see circuit diagram on
opposite page):
– Apply the red measuring lead of the peak voltage adapter to the
green cable and the black measuring lead to the red cable, disconnect
both connectors 1 to disconnect the CDI unit 2
1
Multimeter display: 6 volts +/- 1 volt
1
3
– Same measurement with CDI unit connected
Multimeter display: 3 volts +/- 1 volt
Check the generator charging coil for the ignition capacitor charge for
output voltage – two-pin connector 3 with black/red and red/white
cable colors (also see circuit diagram on opposite page):
Art No 3.206.005 -E
– Apply the red measuring lead of the peak voltage adapter to the
black/red cable and the black measuring lead to the red/white cable,
disconnect connector 3 to disconnect the CDI unit 2
Multimeter display: 35 volts +/- 5 volts
– Same measurement with connectors CDI unit connected
Multimeter display: 200 volts +/- 10 volts
Check the primary voltage output 4 for ignition coil control (also see
circuit diagram on opposite page) for output voltage (blue/white cable
color):
4
S
R
Multimeter display: 200 volts +/- 10 volts
5
Repair manual KTM 125 / 200
– Apply the red measuring lead R of the peak voltage adapter to
black/white cable (ground) and the black measuring lead S to the
blue/white cable, CDI unit 2 and ignition coil 5 connected
NOTE: the ignition coil does not need to be removed to measure.
7-12C
22.11.99 Hasl.
ge-bl
r
v
s
o
27
s
4
ge-bl
8
br
7
5
v
s
br
br
6
br
g
bl
ge-bl
br
2
Datum, Name:
Europa
13
1
ge-bl
br
g
bl
s-ge
ge-r
ge-bl
br
v
r-w
g
o
bl
3
ge-s
ge-bl
br
19
9
Land:
Kabelstrangnummer:
vorne:512.11.075.000
hinten:503.14.040.100
125 EXE 2000/2001
125 Super Moto 2000/2001
Modell:
bl
SERVICE
SPORTMOTORCYCLES
o
ge-bl
14
23
g
bl
10 ger
br
w
s-ge
g
bl
ge
r
br
ge-bl
11
g-w
s-ge
17
16
ge-s
br
bl-w
s-w
28
KOKUSAN
2K3
s-w
bl-w
15
s-ge
s-r
r-w
o
r
g
w
ge
G
30
6
20
18
9
ge-r
g-w
w
12
ge-bl
br
ge-r
br
v
s
ge
8
s
29
58
25
26
br
br
54
br
21
11
br
g-w
ge-bl
br
g-w
w
v
31
24
22
ge-r
br
v
s
10
s
7-13C
STATIC GENERATOR VALUES 125 EXE / 125 SUPERMOTO (KOKUSAN 2K-3)
Measuring conditions:
– cold engine
– seat and tank removed
– all connectors and the ground connection in a non-corroding condition, connectors tightly connected
– battery loaded, ignition switch to position 1 (light turned off)
– kick the kick starter forcefully at least 5 times for each measurement
7
Check the generator output 6 (also see circuit diagram on opposite
page) for voltage between the following cable colors:
– between yellow and brown (ground), connector 7 disconnected
Multimeter display: 19 volts +/- 2 volts
– between white and brown (ground), connector 8 disconnected
Multimeter display: 24 volts +/- 2 volts
8
– Repeat both measurements with connector 7 and 8 connected. The
measured values should be the same.
NOTE: the black measuring lead of the peak voltage adapter must be
applied to the ground.
Repair manual KTM 125 / 200
Art No 3.206.005 -E
Check regulator rectifier output voltage 9 (also see circuit diagram on
opposite page) cable colors yellow/red, regulator rectifier bk connected,
fuse bl disconnected, ignition switched off:
– between yellow/red and brown (ground)
Multimeter display: 14 volts +/- 1 volt
NOTE: the black measuring lead S of the peak voltage adapter must be
applied to the brown cable (ground).
10
S
8-1C
TROUBLE SHOOTING
INDEX
Repair manual 125 / 200
Art No 3.206.005-E
TROUBLE SHOOTING 125 / 200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-2
8
8-2C
TROUBLE SHOOTING
If you let the specified maintenance work on your motorcycle be carried out, disturbances can hardly be expected. Should an error
occur nevertheless, we advise you to use the trouble shooting chart in order to find the cause of error.
TROUBLE
CAUSE
Art No 3.206.005 -E
Engine fails to start
Engine without idle running
Repair manual KTM 125 / 200
Engine
power
has
not
enough
REMEDY
Operating error
Open fuel tap, switch o ignition, replenish fuel, do not use choke
Fuel supply interrupted
Close fuel tap, loosen fuel hose at carburettor, lead into a
basin and open fuel tap,
– if fuel leaks out, clean carburettor
– if no fuel leaks out, check tank ventilation, i.e. clean fuel tap
Electrode distance too great
Reduce electrode distance (0.60 mm)
Plug fouled by oil, wet or bridged
Clean spark plug or renew
Ignition wire or spark plug connector
damaged
Dismount spark plug, connect ignition cable, hold to ground
(blank place on engine) and actuate kickstarter, a strong
spark must be produced at the spark plug
– If no spark is produced, loosen spark plug cap from ignition
cable, hold about 5 mm from ground and actuate kickstarter
– If a spark now occurs, replace spark plug cap
– If no spark is produced, control ignition system
Kill button wire or
short-circuit switch faulty
Disconnect yellow-black coloured cable from CDI and check
ignition spark. If the spark is O.K. repair defective part of
cable, ignition lock or ignition switch
Loose ignition cable connectors
Inspect cable connectors
Spark too weak
Examine ignition system
Water in the carburetor and jets
blocked
Dismantle and clean carburetor
Idle adjusting screw out of adjustment
Readjust idle running or replace idle adjusting screw
Ignition system damaged
Examine ignition system
Wear
Overhaul engine
Charred glass fiber yarn in silencer
Renew filling
Air filter obstructed
Clean or renew airfilter
Control flap does not work
Check control flap, joint rod and centrifugal timer
Fuel supply partly interrupted or
blocked
Blow through fuel pipe and clean carburetor
Loss of compression through loose
spark plug
Tighten spark plug
Exhaust system damaged
Check exhaust system for damage
Engine has not enough preignition
Check and adjust ignition
8-3C
TROUBLE
Engine
power
has
not
CAUSE
enough
Engine revs not high and
running with four stroke
cycle
High rpm misfiring
REMEDY
Reed paddles tensionless or
damaged, surface of reed valve
housing damaged
Replace reed paddles or reed valve housing
Wear
Overhaul engine
Electronical ignition timing faulty
Have ignition system checked
Carburetor overflows if level adjust
too high, float needle seating is
dirty or enlarged
Clean carburetor, if necessary replace float needle and adjust
level
Loose carburetor jets
Tighten jets
Incorrect heat range spark plug or
low quality spark plug
Refer to technical data section
Incorrect or
connector
Test and/or replace spark plug connectors correct type
faulty
spark
plug
Loose, corroded or non conductive
ignition socket connector
Check and seal with silicon
Lack of fuel
Clean fuel pipes, examine tank aeration and clean
Spark plug with incorrect heat
value (Ignition by incandescence)
Fit correct spark plug
Engine takes air out of control
Check intake flange and carburetor if firmly setted
Insufficient liquid in cooling system
Top up coolant and bleed cooling system check cooling
system for leaks
Cooling system not or insufficiently
bleeded
Bleed cooling system (see operating instructions)
Radiator fins clogged
Clean radiator fins with water jet
Frothing in cooling system
Renew coolant using branded anti-freeze/anti-corrosive
Pinched or kinked water hoses
Replace with correct routed hoses
Incorrect ignition timing because of
loose stator bolts
Readjust to correct ignition timing specifications, secure bolts
properly with Loctite 243
Incorrect dimension ,,X“
Measure and adjust to correct specification
Emission of white smoke
(steam)
Cylinder head or cylinder head
gasket leaks
Check cylinder head, replace cyllinder head gasket
Excessive oil escapes from
transmission breather tube
Excessive oil quantity in transmission
Correct transmission oil level
Water pump shaft seal ring or
right-hand crankshaft seal ring
defect
Replace shaft seal ring and change gear oil, check coolant
Voltage regulator faulty
Control connections of voltage regulator. Check voltage
regulator
Engine spluters into the carburetor
Engine overheating
All switched on lamps blown
out
9-1C
TECHNICAL SPECIFICATIONS
INDEX
MODEL 1999
TECHNICAL SPECIFICATIONS – ENGINE 125/200 . . . . . . . . . . . . . . . . . . . .9-2
TECHNICAL SPECIFICATIONS – CHASSIS 125/200 . . . . . . . . . . . . . . . . . . .9-4
TECHNICAL SPECIFICATIONS – ENGINE 200 ONLY SINGAPORE . . . . . . . . .9-5
BASIC CARBURETOR SETTING – 200 ONLY SINGAPORE . . . . . . . . . . . . . .9-5
Art No 3.206.005-E
MODEL 2000
TECHNICAL SPECIFICATIONS – ENGINE 125 EXE, SUPERMOTO . . . . . . . . .9-6
TECHNICAL SPECIFICATIONS – CHASSIS 125 EXE, SUPERMOTO . . . . . . . .9-7
TECHNICAL SPECIFICATIONS – ENGINE 125/200 SX, MXC, EXC . . . . . . . .9-8
TECHNICAL SPECIFICATIONS – CHASSIS 125/200 SX, MXC, EXC . . . . . . .9-10
MODEL 2001
TECHNICAL SPECIFICATIONS – ENGINE 125 EXE, SUPERMOTO . . . . . . . . .9-6
TECHNICAL SPECIFICATIONS – CHASSIS 125 EXE, SUPERMOTO . . . . . . . .9-7
TECHNICAL SPECIFICATIONS – ENGINE 125/200 . . . . . . . . . . . . . . . . . . .9-11
TECHNICAL SPECIFICATIONS – CHASSIS 125/200 . . . . . . . . . . . . . . . . . .9-13
Repair manual 125 / 200
MODEL 2002
TECHNICAL SPECIFICATIONS – ENGINE 125/200 . . . . . . . . . . . . . . . . . . .9-14
TECHNICAL SPECIFICATIONS – CHASSIS 125/200 . . . . . . . . . . . . . . . . . .9-16
MODEL 2003
TECHNICAL SPECIFICATIONS – ENGINE 125/200 . . . . . . . . . . . . . . . . . . .9-17
TECHNICAL SPECIFICATIONS – CHASSIS 125/200 . . . . . . . . . . . . . . . . . .9-19
CARBURATOR SPECIFICATION
MODEL 1999 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-21
MODEL 2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-24
MODEL 2001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-27
MODEL 2002 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-30
MODEL 2003 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-33
9
125 EGS
54.25 / 54 mm (2.136 / 2.126 in)
124.8 ccm
no generator
Generator output
Air-filter
Carburetor
KOKUSAN 2K-1
13 : 32
15 : 30
17 : 28
19 : 26
21 : 25
22 : 24
Ignition system
Coolant
Available chain sprockets
Gear lubrication
Gear ratio
1st gear
2nd gear
3rd gear
4th gear
5th gear
6th gear
Transmission
Clutch
Primary drive
Dimension "Z"
Electrode gap
Spark plug
(height of the
control flap)
(upper edge piston upper edge cylinder)
Ignition timing
Dimension "X"
Piston ring
straight cut spur gears, primary ratio 23:73
6 speed, claw actuated
for chain 5/8 x 1/4"
12V 110 W
wet foam type air filter insert
flat-slide carburetor, carburetor setting see table
12V / 110 W
KOKUSAN 2K-3
0.55 mm (0.22 in)
12V 40 W
KOKUSAN 2K-2
46 mm (1.81 in)
NGK BR 8 EG
12V 110 W
KOKUSAN 2K-3
12 : 33
15 : 31
17 : 28
19 : 26
22 : 25 / 17 : 19
22 : 20
1.6 mm (0.063 in) (17°) BTDC
13 : 32
15 : 30
17 : 28
19 : 26
21 : 25
22 : 23
1.2 litres, 40% anti freeze, 60% water, at least -25 °C (-13 °F)
13t / 14t / 15t
0.7 l engine oil 20W-40 (Shell Advance VSX4)
12 : 33
15 : 31
17 : 28
19 : 26
21 : 25
20 : 20
USA: KOKUSAN 2K-2 EU: 2K-3
12V 40 W
0.60 mm (0,024 in)
multiple disc clutch in oil bath, hydraulic operated (Shell HF-E15)
42 mm (1.65 in)
NGK R 6918-B8
1.4 mm (0.055 in) (16.5°) BTDC
0.60 mm (0.024 in)
two plain compression rings
cast piston
needle bearing
Piston pin bearing
Piston
needle bearing
1 deep-groove ball bearing / 1 cylinder roller bearing
SUPER fuel, research octane no 95, mixed with high grade two stroke oil
1:40 when using high grade two stroke oil (Shell Advance Racing X). When in doupt, please contact your importer
Conrod bearing
200 EXC, EGS
64 / 60 mm (2.52 / 2.362 in)
193 ccm
Crankshaft bearing
one plain compression ring
200 MXC
Liquid-cooled single-cylinder two-stroke engine with intake and exhaust control
125 EXC
SUPER fuel, research octane no 98, mixed with high grade two stroke oil
125 SX
TECHNICAL DATA - ENGINE 125 / 200 ‘99
Art No 3.206.005 -E
Oil / gasoline ratio
Fuel
Bore / stroke
Piston displacement
Design
Engine
Repair manual KTM 125 / 200
9-2C
125 EGS
200 MXC, EXC USA
Carburetor
Keihin PWK 39
Keihin PWK 39
Keihin PWK 39
Keihin PWK 39
Carburetor setting number
120598
160598
140598
130598
Main jet
190 (188/192/195)
190 (188/192/195)
150 (188/190/192/195) 180 (175/178/182/185)
Idling jet
48 (45/50)
48 (45/50)
45 (48/50)
45 (42/48)
Starting jet
85
85
85
85
Jetneedle
NOZH (NOZF/NOZG/NOZI) NOZF (NOZG/NOZH/NOZI) R1471J (NOZF/NOZG/NOZH/NOZI) NOZH (NOZG/NOZI)
Needle position from top
III
IV
III
III
Throttle valve
6
6
6
6
Air adjustment screw top
1,5
1,5
1,5
1,5
Performance restrictor
–
–
–
–
125 SX, EXC
EUROPE
0,5 mm
0,5 mm
0.30 / 0.50 / 0.75 mm
as required
0,07 / 0.15 / 0.20 / 0.25 / 0.40 / 0.50 / 0.75 mm
1.10 mm + O-ring
125 SX, EXC USA
125 EGS AUSTRALIA
BASIC CARBURETOR SETTING
Crankcase
Clutch cover
Clutch driving cylinder
Cylinder bottom gasket
Available bottom gasket
Cylinder-head gasket
GASKET THICKNESSES
Keihin PWK 39
170598
180 (175/178/182/185)
45 (42/48)
85
NOZG (NOZH/NOZI)
II
6
1,5
–
200 EXC
EUROPE
200 EGS
18 Nm
30 Nm
60 Nm
180 Nm
120 Nm
8 Nm
20 Nm
100 Nm
10 Nm
25 Nm
45 Nm
200 EGS AUSTRALIA
M7
M8
M 12x1
M 16x1.5
M 18x1.5
M6
M 14x1.25
M 14x1.5
M6
M8
M 10
Keihin PWK 39
Keihin PWK 39
140598
150598
180 (175/178/182/185) 180 (175/178/182/185)
45 (42/48)
45 (42/48)
85
85
R1472J (NOZG/NOZH/NOZI) NOZH (NOZG/NOZI)
IV
III
6
6
1,5
1,5
slide stop 36mm
slide stop 36mm
Flange bolts - cylinder-head
Nuts-cylinder base
Flywheel collar nut
Nut for primary sprocket (LH thread)
Nut for inner clutch hub
Crankcase and clutch cover bolts
Spark plug
Nut swingarm pivot
Other bolts
Piston fitting clearance
Piston ring end cap
Connecting rod bearing - radial clearance
Transmission shafts end float
Clutch springs - length
125 = 0.06 mm 200 = 0.085 mm
max. 0.40 mm
0.025– 0.035 mm
0.20– 0.40 mm
new = 39 mm, minimum length = 38 mm
TIGHTENING TORQUES
TOLERANCES AND FITTING CLEARANCES
(14 ft.lb)
(22 ft.lb)
(44 ft.lb)
(133 ft.lb)
(88 ft.lb)
(6 ft.lb)
(14 ft.lb)
(74 ft.lb)
(7 ft.lb)
(19 ft.lb)
(33 ft.lb)
9-3C
9-4C
TECHNICAL SPECIFICATIONS CHASSIS
125 SX
125 SX / EXC / EGS, 200 MXC / EXC / EGS ‘99
125 EXC
125 EGS
Frame
Fork
Wheel travel front/rear
200 MXC
200 EXC
200 EGS
Central chrome-moly-steel frame
WP Extreme
Marzocchi Magnum 45 Code 91
280 / 320 mm
285 / 320 mm
(11.0 / 12.6 in)
(11.2 / 12.6 in)
Rear suspension
WP Progressive Damping System shock absorber, aluminium swingarm
Front brake
Disc brake with carbon-steel brake disc Ø 260 mm (10.2 in), brake caliper floated
Rear brake
Disc brake with carbon-steel brake disc Ø 220 mm (8.7 in), brake caliper floated
Front tires
80/100 - 21“ 51M
Air pressure offroad
1.0 bar (14psi)
Air press. road driver only
–
90/90 - 21“ 54R
1,0 bar (14psi)
1,5 bar (21psi)
90/90 - 21“ 54R
1.0 bar (14psi)
1,5 bar (21psi)
80/100 - 21“ 51M
1.0 bar (14psi)
-
90/90 - 21“ 54R
1.0 bar (14psi)
1.5 bar (21psi)
90/90 - 21“ 54R
1.0 bar (14psi)
1.5 bar (21psi)
Rear tires
100/90 - 19“ 57M 120/90 - 18“ 65R 120/90 - 18“ 65R 100/100 - 18“ 59M 120/90 - 18“ 65R 120/90 - 18“ 65R
Air pressure offroad
1.0 bar (14psi)
1.0 bar (14psi)
1.0 bar (14psi)
1.0 bar (14psi)
1.0 bar (14psi)
1.0 bar (14psi)
Air press. road driver only
–
2.0 bar (28psi)
2.0 bar (28psi)
2.0 bar (28psi)
2.0 bar (28psi)
Fuel tank capacity
Final drive ratio
7.5 liter
(2 US Gallons)
9.5 liter
(2.5 US gallons)
9.5 or 12 liter
(2.4 US gallons)
12 liter
(3.2 US gallons)
13:50
13:50
14:38
14:48
Chain
925 mm (36.4 in)
Ground clearance, unloaded
Art No 3.206.005 -E
385 mm (15,2 in)
92 kg
(203 lbs)
96 kg
(212 lbs)
STANDARD ADJUSTMENT - FORK
M 10
40 Nm (30 ft.lb)
Brake caliper front
M8
25 Nm (19 ft.lb)
4.0 N/mm
Clamping bolts upper fork bridge
M8
15 Nm (11 ft.lb)
5 mm (0.2in)
Clamping bolts lower fork bridge
M8
20 Nm (15 ft.lb)
Clamping bolts fork stubs
(Marzocchi)
M6
7 Nm
(5 ft.lb)
Clamping bolts fork stubs
(WP Extreme)
M8
10 Nm
(7 ft.lb)
Compression adjuster
15
12
Rebound adjuster
15
12
4.0 N/mm
10 mm (0.4in)
140 mm (5.5in)
150 mm (5.9in)
appropx. 600 ccm
appropx. 750 ccm
SAE 7.5
SAE 5
Repair manual KTM 125 / 200
NOTE: The damping units in the left and the right fork
leg are of different design. Make sure not to mix them
up in case of repair or service jobs.
STANDARD ADJUSTMENT - SHOCK ABSORBER
WP 1218T711
WP 1218T713
Compression adjuster
5
6
Rebound adjuster
14
14
Spring
Spring preload
96 kg
(212 lbs)
TIGHTENING TORQUES - CHASSIS
WP 918T767
Fork oil
100 kg
(221 lbs)
Collar bolt front wheel spindle
Marzocchi 91
Capacity per fork leg
101 kg
(223 Ibs)
1461 ± 10 mm (57.3 ± 0,4 in)
Seat height, unloaded
Air chamber length
97 kg
(214 Ibs)
63°
Wheel base
Spring preload
14:38
38, 40, 42, 45, 48, 50, 52
Steering head angle
Spring
14:48
5/8 x 1/4 "
Available final sprockets
Dead-weight without fuel
9.5 or 12 liter
9.5 or 12 liter
(2.5 or 3.2 US gallons) (2.5 or 3.2 US gallons)
PDS2–250
PDS1–250
5 mm (0.2 in)
6 mm (0.23 in)
+ Loctite 243
Collar nut rear wheel spindle
M 20x1.5
80 Nm (59 ft.lb)
Hexagon nut swingarm bolt
M 14x1.5
100 Nm (74 ft.lb)
Shock absorber top
M 12
60 Nm (44 ft.lb)
Shock absorber bottom
M 12
40 Nm (30 ft.lb)
Other bolts on chassis
M6
M8
M 10
10 Nm (7 ft.lb)
25 Nm (19 ft.lb)
45 Nm (33 ft.lb)
9-5C
TECHNICAL DATA - ENGINE 200 EGS ONLY SINGAPORE ‘99
Engine
Design
Piston displacement
Bore / stroke
Fuel
Lubrication
Engine oil
Crankshaft bearing
Connecting rod bearing
Piston pin bearing
Piston
Piston ring
edge piston Dimension "X"(upper
upper edge cylinder)
Ignition timing
Spark plug
Electrode gap
of the
Dimension "Z" (height
control flap)
Primary drive
Clutch
Transmission
1st gear
2nd gear
3rd gear
4th gear
5th gear
6th gear
Gear lubrication
Available chain sprockets
Coolant
Ignition system
Generator output
Carburetor
Air-filter
200 EGS Singapore
Liquid-cooled single-cylinder two-stroke engine with intake and exhaust control
193 ccm
64 / 60 mm (2.52 / 2.362 in)
SUPER fuel, research octane no 95
Separate lubrication
Shell Advance Racing X or high grade 2-stroke oil for a mixture ratio 1:50 and separate lubrication
1 deep-groove ball bearing / 1 cylinder roller bearing
needle bearing
needle bearing
cast piston
two plain compression rings
0.55 mm (0.22 in)
1.6 mm (0.063 in) (17°) BTDC
NGK BR 8 EG
0.60 mm (0,024 in)
46 mm (1.81 in)
straight cut spur gears, primary ratio 23:73
multiple disc clutch in oil bath, hydraulic operated (Shell HF-E15)
6 speed, claw actuated
12 : 33
15 : 31
17 : 28
19 : 26
22 : 25 / 17 : 19
22 : 20
0.70 l engine oil 20W-40 (Shell Advance VSX4)
13t / 14t / 15t for chain 5/8 x 1/4"
1.2 litres, 40% anti freeze, 60% water, at least -25 °C (-13 °F)
KOKUSAN 2K-3
12V 110 W
flat-slide carburetor, carburetor setting see table
wet foam type air filter insert
BASIC CARBURETOR SETTING
200 EGS (Sgp)
Carburetor
Carburetor setting number
Main jet
Idling jet
Starting jet
Jet needle
Needle position from top
Throttle valve
Air adjustment screw top
Performance restrictor
Keihin PWK 39
180698
178 (175/180/182/185)
42 (45/48)
85
NOZI (NOZG/NOZH)
II
6
1,5
slide stop 36 mm
9-6C
Art No 3.206.005 -E
TECHNICAL DATA - ENGINE 125 EXE / 125 SUPERMOTO 2000
Engine
Design
Piston displacement
Bore / stroke
Fuel
Lubrication
Oil / gasolin ratio
Crankshaft bearing
Connecting rod bearing
Piston pin bearing
Piston
Piston ring
Spark plug
Electrode gap
Primary drive
Clutch
Transmission
Gear ratio
1st gear
2nd gear
3rd gear
4th gear
5th gear
6th gear
125 EXE
Liquid-cooled single-cylinder two-stroke engine with intake and exhaust control
124.8 ccm
54,0 / 54,5 mm (2.125 / 2.145 in)
unleaded fuel with a least RON 91
separate lubrication
Shell Advance Ultra 2 or 2-stroke oil for a mix ratio1:50 and separate lubrication
2 grooved ball bearing
needle bearing
needle bearing
cast light alloy
2 rectangular ring
NGK BR8 HS
0.60 mm (0,024 in)
straight cut spur gears, primary ratio 23:73
multiple disc clutch in oil bath, hydraulic operated (Shell HF-E15)
6 speed, claw actuated
Gear lubrication
Available chain sprockets
Coolant
Ignition system
Generator output
Carburetor
Air-filter
Oil tank
0.7 l gear oil SAE-80W (Shell Advance Gear EP)
14t for chain 5/8 x 1/4"
0,8 litres, 40% anti freeze, 60% water, at least -25 °C (-13 °F)
Kokusan digital 2K-3
12V / 110 W
flat-slide carburetor, carburetor setting see table
wet foam type air filter insert
tank content: 1,3 liter (0,34 US gallons)
12 : 33
15 : 31
17 : 28
19 : 26
21 : 25
22 : 24
Repair manual KTM 125 / 200
BASIC CARBURETOR SETTING
Carburetor
Carburetor setting number
Main jet
Idling jet
Starting jet
Jetneedle
Needle position from top
Throttle valve
Air adjustment screw top
Performance restrictor
125 EXE
(80 km/h)
125 EXE
(100km/h)
125 Supermoto
(80 km/h)
125 Supermoto
(100 km/h)
Dell’Orto PHBH 28
051299
120
50
70
X83
III
40
1,25
–
Dell’Orto PHBH 28
021199
125
50
70
X83
III
40
1,25
–
Dell’Orto PHBH 28
051299
120
50
70
X83
III
40
1,25
–
Dell’Orto PHBH 28
021199
125
50
70
X83
III
40
1,25
–
9-7C
TECHNICAL SPECIFICATIONS CHASSIS
125 EXE / 125 SUPERMOTO
125 EXE
2000
125 Supermoto
Frame
Central chrome-moly-steel frame
Fork
White Power – Up Side Down 40 TA
Wheel travel front/rear
220/260 mm (8,7/10,2 in)
Rear suspension
WP Progressive Damping System shock absorber, aluminium swingarm
Front brake
Disc brake with carbon-steel brake disc, brake caliper floated
Front brake disc
Ø 260 mm (10,2 in)
Rear brake
Ø 320 mm (12,6 in)
Disc brake with carbon-steel brake disc Ø 220 mm (8.7 in), brake caliper floated
Brake discs
Wear limit max. 0,4 mm (0,016 in)
Front tires
3.00 - 21“
110/70 - 17“
Air pressure, driver only
1,8 bar (26 psi)
1,8 bar (26 psi)
Air pressure, driver plus passenger
2,0 bar (29 psi)
2,0 bar (29 psi)
Rear tires
4.60 - 18“
130/70 - 17“
Air pressure, driver only
2,0 bar (29 psi)
2,1 bar (30 psi)
Air pressure, driver plus passenger
2,2 bar (32 psi)
2,3 bar (33 psi)
Fuel tank capacity
11,0 liter (3 US Gallons), 2,5 liter (0,6 US gallons) reserve
Final drive ratio
14:40 t
14:38 t
Chain
O-ring 5/8 x 1/4 "
Battery
maintenance free 12V 3Ah
Lamps
head light
H4 12V 60/55W (socket P43t)
parking light
12V 5W (socket W2,1x9,5d)
cockpit light
12V 2W (socket W2x4,6d)
stop and tail light
12V 21/5W (socket BaY15d)
flasher
12V 10W (socket Ba15s)
Steering head angle
63°
Wheel base
1461 ± 10 mm (57,5 ± 0,4 in)
Seat height, unloaded
865 mm (34,0 in)
Ground clearance, unloaded
290 mm (11,4 in)
830 mm (32,7 in)
255 mm (10,0 in)
Dead-weight *
104 kg (230 lbs)
Max. permissible front axle load
145 kg (320 Ibs)
Max. permissible rear axle load
190 kg (419 Ibs)
Max. permissible laden weight
335 kg (740 Ibs)
* Dead-weight without fuel
STANDARD ADJUSTMENT - FORK
WP 0618T777A
TIGHTENING TORQUES - CHASSIS
M 16x1,5
40 Nm (30 ft.lb)
Brake caliper front
M8
25 Nm (19 ft.lb)
4,2 N/mm
Clamping bolts upper fork bridge
M8
20 Nm (15 ft.lb)
10 mm (0.4 in)
Clamping bolts lower fork bridge
M8
15 Nm (11 ft.lb)
Air chamber length
140 mm (5.5 in)
Clamping bolts fork stubs
Capacity per fork leg
approx. 500 ccm
Collar nut rear wheel spindle
M 20x1.5
80 Nm (59 ft.lb)
SAE 5
Hexagon nut swing arm bolt
M 14x1.5
100 Nm (74 ft.lb)
Collar bolt handlebar clamp
M8
20 Nm (15 ft.lb)
Allen head bolt handlebar support
M 10
40 Nm (30 ft.lb)
Shock absorber top
M 12
60 Nm (44 ft.lb)
Shock absorber bottom
M 12
60 Nm (44 ft.lb)
Screw adjusting ring spring preload
M6
Other bolts on chassis
M6
M8
M 10
Compression adjuster
10
Rebound adjuster
9
Spring
Spring preload
Fork oil
STANDARD ADJUSTMENT - SHOCK ABSORBER
WP 1218T715
Compression adjuster
3
Rebound adjuster
14
Spring
Spring preload
PDS1–250
5 mm (0.2 in)
Collar nut front wheel spindle
+Loctite 243
M8
10 Nm
(7 ft.lb)
+Loctite 243
8 Nm
(6 ft.lb)
10 Nm (7 ft.lb)
25 Nm (19 ft.lb)
45 Nm (33 ft.lb)
Gear lubrication
Available chain sprockets
Coolant
Ignition system
Generator output
Ignition system USA
Generator output
Carburetor
Air-filter
Engine
Design
Piston displacement
Bore / stroke
Fuel
Oil / gasolin ratio
Crankshaft bearing
Connecting rod bearing
Piston pin bearing
Piston
Piston ring
edge pistonDimension "X" (upper
upper edge cylinder
Ignition timing
Spark plug
Electrode gap
of the
Dimension "Z" height
control flap
Primary drive
Clutch
Transmission
Gear ratio
1st gear
2nd gear
3rd gear
4th gear
5th gear
6th gear
TECHNICAL DATA - ENGINE 125 / 200 2000
Art No 3.206.005 -E
KOKUSAN 2K-1
no generator
KOKUSAN 2K-1
no generator
13 : 32
15 : 30
17 : 28
19 : 26
21 : 25
22 : 24
13 : 32
15 : 30
17 : 28
19 : 26
21 : 25
22 : 23
0.7 l engine oil 20W-40 (Shell Advance VSX4)
13t / 14t / 15t for chain 5/8 x 1/4"
1.2 litres, 40% anti freeze, 60% water, at least -25 °C (-13 °F)
KOKUSAN 2K-3
–
12V / 110 W
–
KOKUSAN 2K-2
12V 40 W
flat-slide carburetor, carburetor setting see table
wet foam type air filter insert
12 : 33
15 : 31
17 : 28
19 : 26
21 : 25
20 : 20
KOKUSAN 2K-3
12V 110 W
12 : 33
15 : 31
17 : 28
19 : 26
17 : 19
22 : 20
125 EXC
200 MXC
200 EXC
Liquid-cooled single-cylinder two-stroke engine with intake and exhaust control
124.8 ccm
193 ccm
54.25 / 54 mm (2.136 / 2.126 in)
64 / 60 mm (2.52 / 2.362 in)
unleaded SUPER fuel, research octane no 95, mixed with high grade two stroke oil
1:40-1:60 when using high grade two stroke oil (Shell Advance Racing X). When in doupt, please contact your importer
1 deep-groove ball bearing / 1 cylinder roller bearing
needle bearing
needle bearing
forged piston
cast piston
one plain compression ring
two plain compression rings
0.60 mm (0.024 in)
0.55 mm (0.22 in)
1.4 mm (0.055 in) (16.5°) BTDC
1.6 mm (0.063 in) (17°) BTDC
NGK BR9 EVX
NGK BR 8 EG
0.60 mm (0,024 in)
42 mm (1.65 in)
46 mm (1.81 in)
straight cut spur gears, primary ratio 23:73
multiple disc clutch in oil bath, hydraulic operated (Shell HF-E15)
6 speed, claw actuated
125 SX
Repair manual KTM 125 / 200
9-8C
9-9C
TIGHTENING TORQUES - ENGINE
Flange bolts - cylinder-head
Nuts-cylinder base
Flywheel collar nut
Nut for primary sprocket (LH thread)
Nut for inner clutch hub
Crankcase and clutch cover bolts
Spark plug
Other bolts
M7
M8
M 12x1
M 16x1.5
M 18x1.5
M6
M 14x1.25
M6
M8
M 10
18 Nm
30 Nm
60 Nm
180 Nm
120 Nm
8 Nm
20 Nm
10 Nm
25 Nm
45 Nm
(13 ft.lb)
(22 ft.lb)
(44 ft.lb)
(133 ft.lb)
(88 ft.lb)
(6 ft.lb)
(14 ft.lb)
(7 ft.lb)
(19 ft.lb)
(33 ft.lb)
TOLERANCES AND FITTING CLEARANCES
Piston fitting clearance
Piston ring end cap
Connecting rod bearing - radial clearance
Transmission shafts end float
Clutch springs - length
125 = 0.06 mm 200 = 0.085 mm
max. 0.40 mm
0.025– 0.035 mm
0.20– 0.40 mm
new = 39 mm, minimum length = 38 mm
GASKET THICKNESSES
Crankcase
Clutch cover
Clutch driving cylinder
Cylinder bottom gasket
Available bottom gasket
Cylinder-head gasket
0,5 mm
0,5 mm
0.30 / 0.50 / 0.75 mm
as required
0.07 / 0.15 / 0.20 / 0.25 / 0.40 / 0.5 0 / 0.75 mm
1.10 mm + O-ring
BASIC CARBURETOR SETTING
Carburetor
Carburetor setting number
Main jet
Idling jet
Starting jet
Jetneedle
Needle position from top
Throttle valve
Air adjustment screw top
Performance restrictor
125 SX
125/200
MXC, EXC
125 EXC
throttled
200 EXC
throttled
Keihin PWK 39
100499
190 (188/192)
48 (45/50)
85
R 1467 D (R 1468 D)
III
55
1,5
–
Keihin PWK 38 AG
120499
180 (185)
45 (48)
85
NOZ H (NOZ I)
III
6
1,5
–
Keihin PWK 39
030799
142
35
85
R 1472 N
V
6
1,5
–
Keihin PWK 38 AG
040799
180
35
85
R 1475 J
IV
6
1,5
slide stop 36mm
9-10C
TECHNICAL SPECIFICATIONS CHASSIS
125 SX
125 SX / EXC, 200 MXC / EXC 2000
125 EXC
Frame
200 MXC
Fork
White Power – Up Side Down 43 MA
Wheel travel front/rear
295/320 mm (11,3/12,6 in)
Rear suspension
WP Progressive Damping System shock absorber, aluminium swingarm
Front brake
Disc brake with carbon-steel brake disc Ø 260 mm (10.2 in), brake caliper floated
Rear brake
Disc brake with carbon-steel brake disc Ø 220 mm (8.7 in), brake caliper floated
Brake discs
Wear limit max. 0,4 mm (0,016 in)
Front tires
80/100 - 21“51M
90/90 - 21“ 54R
–
90/90 - 21“ 54R
Front tires USA
80/100 - 21“51M
80/100 - 21“51M
80/100 - 21“51M
80/100 - 21“51M
1,0 bar (14psi)
1,0 bar (14psi)
1,0 bar (14psi)
1,0 bar (14psi)
–
1,5 bar (21psi)
–
1,5 bar (21psi)
Air pressure offroad
Air pressure road driver only
Rear tires
100/90 - 19“ 57M
120/90 - 18“ 65R
–
120/90 - 18“ 65R
Rear tires USA
100/90 - 19“ 57M
100/100 - 18“ 59M
100/100 - 18“ 59M
100/100 - 18“ 59M
1,0 bar (14psi)
1,0 bar (14psi)
1,0 bar (14psi)
1,0 bar (14psi)
–
2,0 bar (28psi)
–
2,0 bar (28psi)
Air pressure offroad
Air pressure road driver only
Fuel tank capacity
7,5 liter (2 US Gallons)
9,5 liter (2,5 US Gallons)
12 liter (3,2 US Gallons)
9,5/12 liter (2,5/3,2 US Gallons)
Final drive ratio
13:50t
14:38t
–
14:45t / 14:48t
Final drive ratio USA
13:50t
13:50t
14:48t
14:48t
Chain
5/8 x 1/4 "
Available final sprockets
38t, 40t, 42t, 45t, 48t, 50t, 52t
Steering head angle
63°
Art No 3.206.005 -E
Wheel base
1461 ± 10 mm (57,3 ± 0,4 in)
Seat height, unloaded
925 mm (36,5 in)
Ground clearance, unloaded
385 mm (15,2 in)
Dead-weight *
92 kg (203 lbs)
100 kg (221 lbs)
–
101 kg (223 lbs)
Dead-weight USA *
92 kg (203 lbs)
96 kg (212 lbs)
96 kg (212 lbs)
97 kg (214 lbs)
* Dead-weight without fuel
STANDARD ADJUSTMENT - FORK
Compression adjuster
Rebound adjuster
Repair manual KTM 125 / 200
200 EXC
Central chrome-moly-steel frame
WP 0518U783
WP 0518U784
16
14
TIGHTENING TORQUES - CHASSIS
Collar nut front wheel spindle
M 16x1,5
40 Nm (30 ft.lb)
Brake caliper front
M8
25 Nm (19 ft.lb)
+ Loctite 243
12
12
3,8 N/mm
3,8 N/mm
Clamping bolts upper fork bridge
M8
20 Nm (15 ft.lb)
Spring preload
6 mm (0.24in)
6,5 mm (0.26in)
Clamping bolts lower fork bridge
M8
15 Nm (11 ft.lb)
Air chamber length
140 mm (5.5in)
150 mm (5.9in)
Clamping bolts fork stubs
M8
Capacity per fork leg
approx. 840 ccm
approx. 830 ccm
Collar nut rear wheel spindle
M 20x1.5
80 Nm (59 ft.lb)
SAE 5
SAE 5
Hexagon nut swing arm bolt
M 14x1.5
100 Nm (74 ft.lb)
Spring
Fork oil
STANDARD ADJUSTMENT - SHOCK ABSORBER
WP 1218U717
WP 1218U719
Compression adjuster
4
5
Rebound adjuster
20
20
PDS2–250
PDS1-250
5 mm (0.2 in)
5 mm (0.2 in)
Spring
Spring preload
10 Nm
(7 ft.lb)
Collar bolt handlebar clamp
M8
20 Nm (15 ft.lb)
Allen head bolt handlebar support
M 10
40 Nm (30 ft.lb)
Shock absorber top
M 12
60 Nm (44 ft.lb)
Shock absorber bottom
M 12
60 Nm (44 ft.lb)
Screw adjusting ring spring preload
M6
Other bolts on chassis
M6
M8
M 10
8 Nm
(6 ft.lb)
10 Nm (7 ft.lb)
25 Nm (19 ft.lb)
45 Nm (33 ft.lb)
Lubrication
Engine oil
Oil tank
Engine
Design
Piston displacement
Bore / stroke
Fuel
Oil / gasolin ratio
Crankshaft bearing
Connecting rod bearing
Piston pin bearing
Piston
Piston ring
edge pistonDimension "X" (upper
upper edge cylinder
Ignition timing
Spark plug
Electrode gap
of the
Dimension "Z" height
control flap
Primary drive
Clutch
Transmission
Gear ratio
1st gear
2nd gear
3rd gear
4th gear
5th gear
6th gear
Gear lubrication
Available chain sprockets
Coolant
Ignition system
Generator output
Ignition system USA
Generator output
Carburetor
Air-filter
KOKUSAN 2K-1
no generator
KOKUSAN 2K-1
no generator
12 : 33 „1G33“
13 : 32 „1S32“
12 : 33 „1G33“
„2S15“ 15 : 31 „2G31“
„2S15“ 15 : 30 „2S30“
„2S15“ 15 : 31 „2G31“
„3S17“ 17 : 28 „3S28“
„3S17“ 17 : 28 „3S28“
„3S17“ 17 : 28 „3S28“
„4S19“ 19 : 26 „4S26“
„4S19“ 19 : 26 „4S26“
„4S19“ 19 : 26 „4S26“
„5S21“ 21 : 25 „5S25“
„5S21“ 21 : 25 „5S25“
„5G17“ 17 : 19 „5G19“
„6G20“ 20 : 20 „6G20“
„6S22“ 22 : 23 „6S23“
„6G22“ 22 : 20 „6G20“
0.7 l gear oil 80W (Shell Gear EP 80)
0.7 l engine oil 20W-40 (Shell Advance VSX4)
0.7 l gear oil 80W (Shell Gear EP 80)
13t / 14t / 15t for chain 5/8 x 1/4"
1.2 litres, 40% anti freeze, 60% water, at least -25 °C (-13 °F)
KOKUSAN 2K-3
–
KOKUSAN 2K-3
12V / 110 W
–
12V 110 W
KOKUSAN 2K-2
12V 40 W
flat-slide carburetor, carburetor setting see table
wet foam type air filter insert
200 EXC Separate lubrication
Separate lubrication
Shell Advance Ultra 2 or 2-stroke engine oil for a mixture ratio 1:50 and for separate lubrication
1,3 liter (0,34 US Gallons)
13 : 32 „1S32“
„2S15“ 15 : 30 „2S30“
„3S17“ 17 : 28 „3S28“
„4S19“ 19 : 26 „4S26“
„5S21“ 21 : 25 „5S25“
„6S22“ 22 : 24 „6S24“
0.7 l engine oil 20W-40 (Shell Advance VSX4)
125 EXC
200 MXC
200 EXC
Liquid-cooled single-cylinder two-stroke engine with intake and exhaust control
124.8 ccm
193 ccm
54 / 54,5 mm (2.126 / 2.145 in)
64 / 60 mm (2.52 / 2.362 in)
unleaded SUPER fuel, research octane no 95, mixed with high grade two stroke oil
1:40-1:60 when using high grade two stroke oil (Shell Advance Racing X). When in doupt, please contact your importer
1 deep-groove ball bearing / 1 cylinder roller bearing
needle bearing
needle bearing
cast piston
one plain compression ring
two plain compression rings
0.0 mm (0.0 in)
0.55 mm (0.22 in)
1.4 mm (0.055 in) (16.5°) BTDC
1.6 mm (0.063 in) (17°) BTDC
NGK BR9 EVX
NGK BR 8 EG
0.60 mm (0,024 in)
42,5 mm (1.67 in)
46 ,5 mm (1.83 in)
straight cut spur gears, primary ratio 23:73
multiple disc clutch in oil bath, hydraulic operated (Shell HF-E15)
6 speed, claw actuated
125 SX
TECHNICAL DATA - ENGINE 125 / 200 2001
9-11C
9-12C
TIGHTENING TORQUES - ENGINE
Flange bolts - cylinder-head
Nuts-cylinder base
Flywheel collar nut
Nut for primary sprocket (LH thread)
Nut for inner clutch hub
Crankcase and clutch cover bolts
Spark plug
Other bolts
M7
M8
M 12x1
M 16x1.5
M 18x1.5
M6
M 14x1.25
M6
M8
M 10
18 Nm
30 Nm
60 Nm
180 Nm
120 Nm
8 Nm
20 Nm
10 Nm
25 Nm
45 Nm
(13 ft.lb)
(22 ft.lb)
(44 ft.lb)
(133 ft.lb)
(88 ft.lb)
(6 ft.lb)
(14 ft.lb)
(7 ft.lb)
(19 ft.lb)
(33 ft.lb)
TOLERANCES AND FITTING CLEARANCES
Art No 3.206.005 -E
Piston fitting clearance
Piston ring end cap
Connecting rod bearing - radial clearance
Transmission shafts end float
Clutch springs - length
125 = 0.06 mm 200 = 0.085 mm
max. 0.40 mm
0.025– 0.035 mm
0.20– 0.40 mm
new = 39 mm, minimum length = 38 mm
GASKET THICKNESSES
Crankcase
Clutch cover
Clutch driving cylinder
Cylinder bottom gasket
Available bottom gasket
Cylinder-head gasket
0,5 mm
0,5 mm
0.30 / 0.50 / 0.75 mm
as required
0.07 / 0.15 / 0.20 / 0.25 / 0.40 / 0.5 0 / 0.75 mm
1.10 mm + O-ring
Repair manual KTM 125 / 200
BASIC CARBURETOR SETTING
Carburetor
Carburetor setting number
Main jet
Idling jet
Starting jet
Jetneedle
Needle position from top
Throttle valve
Air adjustment screw open
Performance restrictor
125 SX
125 EXC USA
200 MXC/EXC USA
200 EXC AUS
200 EXC SGP
Keihin PWK 39
250200
185 (182/188)
48 (45/50)
85
R 1469 D (R 1470 D)
III
55
1,5
–
Keihin PWK 38 AG
270200
180 (185)
45 (48)
85
NOZ G (NOZ H)
III
6.5
1,5
–
Keihin PWK 38 AG
280200
180 (185)
45 (48)
85
NOZ G (NOZ H)
III
6.5
1,5
slide stop 36mm
125 EXC EU
200 EXC EU
Keihin PWK 38 AG
Keihin PWK 38 AG
260200
290200
148 (180/185)
180 (185)
35 (45/48)
35 (45/48)
85
85
R 1472 N (NOZ G/NOZ H) R 1475 J (NOZ G/NOZ H)
IV
III
6.5
6.5
1,5
1,5
–
slide stop 36mm
9-13C
TECHNICAL SPECIFICATIONS CHASSIS
125 SX
125 SX / EXC, 200 MXC / EXC 2001
125 EXC
Frame
200 MXC
200 EXC
Central chrome-moly-steel frame
Fork
White Power – Up Side Down 43 MA
Wheel travel front/rear
295/320 mm (11,3/12,6 in)
Rear suspension
WP Progressive Damping System shock absorber, aluminium swingarm
Front brake
Disc brake with carbon-steel brake disc Ø 260 mm (10.2 in), brake caliper floated
Rear brake
Disc brake with carbon-steel brake disc Ø 220 mm (8.7 in), brake caliper floated
Brake discs
Wear limit max. 0,4 mm (0,016 in)
Front tires
80/100 - 21“51M
90/90 - 21“ 54R
–
90/90 - 21“ 54R
Front tires USA
80/100 - 21“51M
80/100 - 21“51M
80/100 - 21“51M
80/100 - 21“51M
1,0 bar (14psi)
1,0 bar (14psi)
1,0 bar (14psi)
1,0 bar (14psi)
–
1,5 bar (21psi)
–
1,5 bar (21psi)
Air pressure offroad
Air pressure road driver only
Rear tires
100/90 - 19“ 57M
120/90 - 18“ 65R
–
120/90 - 18“ 65R
Rear tires USA
100/90 - 19“ 57M
100/100 - 18“ 59M
100/100 - 18“ 59M
100/100 - 18“ 59M
1,0 bar (14psi)
1,0 bar (14psi)
1,0 bar (14psi)
1,0 bar (14psi)
–
2,0 bar (28psi)
–
2,0 bar (28psi)
Air pressure offroad
Air pressure road driver only
Fuel tank capacity
7,5 liter (2 US Gal)
8,5 liter (2,2 US Gal)
11 liter (2,9 US Gal)
8,5/11 liter (2,2/2,9 US Gal)
Final drive ratio
13:50t
14:38t
–
14:42t / 14:48t
Final drive ratio USA
13:50t
13:50t
14:48t
14:48t
Chain
5/8 x 1/4 "
Available final sprockets
38t, 40t, 42t, 45t, 48t, 50t, 52t
Steering head angle
63°
Wheel base
1461 ± 10 mm (57,3 ± 0,4 in)
Seat height, unloaded
925 mm (36,5 in)
Ground clearance, unloaded
Dead-weight *
385 mm (15,2 in)
92 kg (203 lbs)
100 kg (221 lbs)
–
101 kg (223 lbs)
* Dead-weight without fuel
STANDARD ADJUSTMENT - FORK
M 16x1,5
40 Nm (30 ft.lb)
Brake caliper front
M8
25 Nm (19 ft.lb)
3,8 N/mm
Clamping bolts upper fork bridge
M8
20 Nm (15 ft.lb)
5 mm (0.2 in)
5 mm (0.2 in)
Clamping bolts lower fork bridge
M8
15 Nm (11 ft.lb)
130 mm (5.1 in)
150 mm (5.9 in)
SAE 5
SAE 5
WP 0518V701
WP 0518V702
Compression adjuster
16
16
Rebound adjuster
16
12
3,8 N/mm
Spring
Spring preload
Air chamber length
Fork oil
STANDARD ADJUSTMENT - SHOCK ABSORBER
WP 1218V728
WP 1218V729
Compression adjuster
5
5
Rebound adjuster
25
23
PDS2–250
PDS1-250
5 mm (0.2 in)
6 mm (0.2 in)
Spring
Spring preload
TIGHTENING TORQUES - CHASSIS
Collar nut front wheel spindle
+ Loctite 243
Clamping bolts fork stubs
M8
10 Nm
(7 ft.lb)
Collar nut rear wheel spindle
M 20x1.5
80 Nm (59 ft.lb)
Hexagon nut swing arm bolt
M 14x1.5
100 Nm (74 ft.lb)
Collar bolt handlebar clamp
M8
20 Nm (15 ft.lb)
Allen head bolt handlebar support
M 10
40 Nm (30 ft.lb)
Shock absorber top
M 12
60 Nm (44 ft.lb)
Shock absorber bottom
M 12
60 Nm (44 ft.lb)
Screw adjusting ring spring preload
M6
Other bolts on chassis
M6
M8
M 10
+ Loctite 243
8 Nm
(6 ft.lb)
10 Nm (7 ft.lb)
25 Nm (19 ft.lb)
45 Nm (33 ft.lb)
Lubrication
Engine oil
Oil tank
Engine
Design
Piston displacement
Bore / stroke
Fuel
Oil / gasolin ratio
Crankshaft bearing
Connecting rod bearing
Piston pin bearing
Piston
Piston ring
edge pistonDimension "X" (upper
upper edge cylinder
Ignition timing
Spark plug
Electrode gap
of the
Dimension "Z" height
control flap
Primary drive
Clutch
Transmission
Gear ratio
1st gear
2nd gear
3rd gear
4th gear
5th gear
6th gear
Gear lubrication
Available chain sprockets
Coolant
Ignition system
Generator output
Ignition system USA
Generator output
Carburetor
Air-filter
TECHNICAL DATA - ENGINE 125 / 200 2002
Art No 3.206.005 -E
KOKUSAN 2K-1
no generator
KOKUSAN 2K-1
no generator
12 : 33 „1G33“
13 : 32 „1S32“
12 : 33 „1G33“
„2S15“ 15 : 31 „2G31“
„2S15“ 15 : 30 „2S30“
„2S15“ 15 : 31 „2G31“
„3S17“ 17 : 28 „3S28“
„3S17“ 17 : 28 „3S28“
„3S17“ 17 : 28 „3S28“
„4S19“ 19 : 26 „4S26“
„4S19“ 19 : 26 „4S26“
„4S19“ 19 : 26 „4S26“
„5S21“ 21 : 25 „5S25“
„5S21“ 21 : 25 „5S25“
„5G17“ 21 : 25 „5G19“
„6G20“ 20 : 20 „6G20“
„6S22“ 20 : 23 „6S23“
„6G22“ 20 : 20 „6G20“
0.7 l gear oil 80W (Shell Gear EP 80) 0.7 l engine oil 20W-40 (Shell Advance VSX4)
0.7 l gear oil 80W (Shell Gear EP 80)
13t / 14t / 15t for chain 5/8 x 1/4"
1.2 litres, 40% anti freeze, 60% water, at least -25 °C (-13 °F)
KOKUSAN 2K-3
–
KOKUSAN 2K-3
12V / 110 W
–
12V 110 W
KOKUSAN 2K-2
12V 40 W
flat-slide carburetor, carburetor setting see table
wet foam type air filter insert
200 EXC SEPARATE LUBRICATION
Separate lubrication
Shell Advance Ultra 2 or 2-stroke engine oil for a mixture ratio 1:50 and for separate lubrication
1,3 liter (0,34 US Gallons)
13 : 32 „1S32“
„2S15“ 15 : 30 „2S30“
„3S17“ 17 : 28 „3S28“
„4S19“ 19 : 26 „4S26“
„5S21“ 21 : 25 „5S25“
„6S22“ 22 : 24 „6S24“
0.7 l engine oil 20W-40 (Shell Advance VSX4)
125 EXC
200 MXC
200 EXC
Liquid-cooled single-cylinder two-stroke engine with intake and exhaust control
124.8 ccm
193 ccm
54 / 54,5 mm (2.126 / 2.145 in)
64 / 60 mm (2.52 / 2.362 in)
unleaded SUPER fuel, research octane no 95, mixed with high grade two stroke oil
1:40-1:60 when using high grade two stroke oil (Shell Advance Racing X). When in doupt, please contact your importer
1 deep-groove ball bearing / 1 cylinder roller bearing
needle bearing
needle bearing
cast piston
one plain compression ring
two plain compression rings
0.0 mm (0.0 in)
0.50 - 0.55 mm (0.22 in)
1.4 mm (0.055 in) (16.5°) BTDC
1.6 mm (0.063 in) (17°) BTDC
NGK BR9 EVX
NGK BR 8 EG
0.60 mm (0,024 in)
43 mm (1.67 in)
46 ,5 mm (1.83 in)
straight cut spur gears, primary ratio 23:73
multiple disc clutch in oil bath, hydraulic operated (Shell HF-E15)
6 speed, claw actuated
125 SX
Repair manual KTM 125 / 200
9-14C
9-15C
TIGHTENING TORQUES - ENGINE
Flange bolts - cylinder-head
Nuts-cylinder base
Flywheel collar nut
Nut for primary sprocket (LH thread)
Nut for inner clutch hub
Crankcase and clutch cover bolts
Spark plug
Other bolts
M7
M8
M 12x1
M 16x1.5
M 18x1.5
M6
M 14x1.25
M6
M8
M 10
18 Nm
30 Nm
60 Nm
180 Nm
120 Nm
8 Nm
20 Nm
10 Nm
25 Nm
45 Nm
(13 ft.lb)
(22 ft.lb)
(44 ft.lb)
(133 ft.lb)
(88 ft.lb)
(6 ft.lb)
(14 ft.lb)
(7 ft.lb)
(19 ft.lb)
(33 ft.lb)
TOLERANCES AND FITTING CLEARANCES
Piston fitting clearance
Piston ring end cap
Connecting rod bearing - radial clearance
Transmission shafts end float
Clutch springs - length
125 = 0.06 mm 200 = 0.055 mm
max. 0.40 mm
0.025– 0.035 mm
0.20– 0.40 mm
new = 39 mm, minimum length = 38 mm
GASKET THICKNESSES
Crankcase
Clutch cover
Clutch driving cylinder
Cylinder bottom gasket
Available bottom gasket
Cylinder-head gasket
0,5 mm
0,5 mm
0.30 / 0.50 / 0.75 mm
as required
0.07 / 0.15 / 0.20 / 0.25 / 0.40 / 0.5 0 / 0.75 mm
125 =shapedring + O-ring 200=1.10 mm + O-ring
BASIC CARBURETOR SETTING
Carburetor
Carburetor setting number
Main jet
Idling jet
Starting jet
Jetneedle
Needle position from top
Throttle valve
Air adjustment screw open
Performance restrictor
125 SX
200 MXC/EXC USA
Keihin PWK 39
020201
185 (182/188/190)
48 (45/50)
85
R 1469 D (R 1470 D)
III
5.5 (6)
1,5
–
Keihin PWK 38 AG
010201
178 (180/185)
45 (48)
85
NOZ F (NOZ G)
III
6.5
1,5
–
200 EXC AUS
200 EXC SGP
200 EXC EU
125 EXC EU
125 EXC AUS
Keihin PWK 38 AG
Keihin PWK 38 AG
041200
051200
148 (180/185)
180 (178)
35 (45/48)
35 (45/48)
85
85
R 1475J (NOZ G/NOZ F) R 1472 N (NOZ G/NOZ F)
V
III
6.5
6.5
1,5
1,5
–
slide stop 36mm
9-16C
TECHNICAL SPECIFICATIONS CHASSIS
125 SX
125 SX / EXC, 200 MXC / EXC 2002
125 EXC
Frame
200 MXC
Fork
WP – USD 48 MA
White Power – Up Side Down 43 MA
Wheel travel front/rear
295/320 mm (11,3/12,6 in)
Rear suspension
WP PDS 5018 (Progressive Damping System) shock absorber, aluminium swingarm
Front brake
Disc brake with carbon-steel brake disc Ø 260 mm (10.2 in), brake caliper floated
Rear brake
Disc brake with carbon-steel brake disc Ø 220 mm (8.7 in), brake caliper floated
Brake discs
Wear limit max. 0,4 mm (0,016 in)
Front tires
80/100 - 21“51M
90/90 - 21“ 54R
–
90/90 - 21“ 54R
Front tires USA
80/100 - 21“51M
80/100 - 21“51M
80/100 - 21“51M
80/100 - 21“51M
1,0 bar (14psi)
1,0 bar (14psi)
1,0 bar (14psi)
1,0 bar (14psi)
–
1,5 bar (21psi)
–
1,5 bar (21psi)
Air pressure offroad
Air pressure road driver only
Rear tires
100/90 - 19“ 57M
120/90 - 18“ 65R
–
120/90 - 18“ 65R
Rear tires USA
100/90 - 19“ 57M
100/100 - 18“ 59M
100/100 - 18“ 59M
100/100 - 18“ 59M
1,0 bar (14psi)
1,0 bar (14psi)
1,0 bar (14psi)
1,0 bar (14psi)
–
2,0 bar (28psi)
–
2,0 bar (28psi)
Air pressure offroad
Air pressure road driver only
Fuel tank capacity
7,5 liter (2 US Gal)
8,5 liter (2,2 US Gal)
11 liter (2,9 US Gal)
8,5/11 liter (2,2/2,9 US Gal)
Final drive ratio
13:50t
14:38t
–
14:45t / 14:48t
Final drive ratio USA
13:50t
13:50t
14:48t
14:48t
Chain
5/8 x 1/4 "
Available final sprockets
38t, 40t, 42t, 45t, 48t, 50t, 52t
Bulps
Art No 3.206.005 -E
200 EXC
Central chrome-moly-steel frame
headlight
HS1 12V 35/35W
parking light
12V 5W (Sockel W2, 1x9,5d)
instrument light
12V 1,2W (Sockel W2, 1x4,6d)
brake- rear light
12V 21/5W (Sockel BaY15d)
flasher light
12V 10W (Sockel Ba15s)
license plate illmination
12V 1,2W (Sockel 1x4,6d)
Steering head angle
63°
Wheel base
1461 ± 10 mm (57,3 ± 0,4 in)
Seat height, unloaded
925 mm (36,5 in)
Ground clearance, unloaded
385 mm (15,2 in)
Dead-weight *
92 kg (203 lbs)
100 kg (221 lbs)
–
101 kg (223 lbs)
Dead-weight USA *
92 kg (203 lbs)
96 kg (212 lbs)
96 kg (212 lbs)
97 kg (214 lbs)
* Dead-weight without fuel
Repair manual KTM 125 / 200
STANDARD ADJUSTMENT - FORK
Compression adjuster
Rebound adjuster
Spring
Spring preload
Air chamber length
Fork oil
WP 4860 MXMA
WP 4357 MXMA
1418W708
0518W710
20
20
Spring preload
40 Nm (30 ft.lb)
M8
25 Nm (19 ft.lb)
M8
20 Nm (15 ft.lb)
15 Nm (11 ft.lb)
+ Loctite 243
16
12
3,8 N/mm
Clamping bolts lower fork bridge
M8
5 mm (0.2in)
5 mm (0.2in)
Clamping bolts fork stubs
M8
100 mm (5.1in)
140 mm (5.9in)
Collar nut rear wheel spindle
M 20x1.5
80 Nm (59 ft.lb)
SAE 5
SAE 5
Hexagon nut swing arm bolt
M 14x1.5
100 Nm (74 ft.lb)
1218W734
1218W735
15 LS (low speed)
15
25
25
PDS6–260
PDS5-260
4 mm (0.2 in)
5 mm (0.2 in)
10 Nm
(7 ft.lb)
Collar bolt handlebar clamp
M8
20 Nm (15 ft.lb)
Allen head bolt handlebar support
M 10
40 Nm (30 ft.lb)
Shock absorber top
M 12
60 Nm (44 ft.lb)
Shock absorber bottom
M 12
60 Nm (44 ft.lb)
Screw adjusting ring spring preload
M6
Other bolts on chassis
M6
M8
M 10
+ Loctite 243
WP 5018 PDS-MCC
2 HS (high speed)
Spring
M 16/20x1,5
Brake caliper front
4,0 N/mm
WP 5018 PDS-DCC
Rebound adjuster
Collar nut front wheel spindle
Clamping bolts upper fork bridge
STANDARD ADJUSTMENT - SHOCK ABSORBER
Compression adjuster
TIGHTENING TORQUES - CHASSIS
8 Nm
(6 ft.lb)
10 Nm (7 ft.lb)
25 Nm (19 ft.lb)
45 Nm (33 ft.lb)
2003
Engine
125 SX
125 EXC
200 SX
200 MXC
200 EXC
Design
Liquid-cooled, single-cylinder, two-stroke engine with intake and exhaust control
Piston displacement
124.8 ccm
193 ccm
Bore / stroke
54 / 54.5 mm (2.126 / 2.145 in)
64 / 60 mm (2.52 / 2.362 in)
Fuel
unleaded SUPER fuel, research octane no 95, mixed with high grade, two- stroke oil
Oil / gasoline ratio
1:40-1:60 when using high grade, two- stroke oil (Shell Advance Racing X). When in doupt, please contact your importer
Crankshaft bearing
1 deep-groove ball bearing / 1 cylinder roller bearing
Connecting rod bearing
needle bearing
Piston pin bearing
needle bearing
Piston
cast piston
Piston ring
one plain compression ring
two plain compression rings
one plain compression ring
two plain compression rings
(upper edge pistonDimension “X“ upper edge cylinder)
0,0 mm
Ignition timing
1.4 mm (0.055 in) (16.5°) BTDC
1.6 mm (0.063 in) (17°) BTDC
Spark plug
NGK BR9 EVX
NGK BR 8 EG
Electrode gap
0,60 mm
of the conDimension “Z“ (height
43 mm (1.67 in)
46 mm (1,81 in)
46,5 mm (1.85 in)
trol flap)
Primary drive
straight cut spur gears, primary ratio 23:73
Clutch
multiple disc clutch in oil bath, hydraulically operated (Shell HF-E15)
Transmission
5 speed, claw actuated
6 speed, claw actuated
Gear ratio
1st gear
13 : 32 „1S32“
12 : 33 „1G33“
13 : 32 „1S32“
13 : 33 „1G33“
2nd gear
„2S15“ 15 : 30 „2S30“
„2S15“ 15 : 31 „2G31“
„2S15“ 15 : 30 „2S30“
„2S15“ 15 : 31 „2G31“
3rd gear
„3S17“ 17 : 28 „3S28“
„3S17“ 17 : 28 „3S28“
„3S17“ 17 : 28 „3S28“
„3S17“ 17 : 28 „3S28“
4th gear
„4S19“ 19 : 26 „4S26“
„4S19“ 19 : 26 „4S26“
„4S19“ 19 : 26 „4S26“
„4S19“ 19 : 26 „4S26“
5th gear
„5S21“ 21 : 25 „5S25“
„5S21“ 21 : 25 „5S25“
„5S21“ 21 : 25 „5S25“
„5G17“ 21 : 25 „5G19“
6th gear
„6G20“ 20 : 20 „6G20“
„6S22“ 20 : 23 „6S23“
„6G22“ 20 : 20 „6G20“
Gear lubrication
0.7 l engine oil 20W-40 (Shell Advance VSX4) 0.7 l gear oil 80W (Shell Gear EP 80) 0.7 l engine oil 20W-40 (Shell Advance VSX4)
0.7 l gear oil 80W (Shell Gear EP 80)
Available chain sprockets
13Z / 14Z / 15Z for chain 5/8 x 1/4"
Coolant
1.2 litres, 40% anti freeze, 60% water, at least -25 °C (-13 °F)
Ignition system
KOKUSAN 2K-1
KOKUSAN 2K-3
KOKUSAN 2K-1
–
KOKUSAN 2K-3
Generator output
no genaerator
12V / 110 W
no genaerator
–
12V 110 W
Ignition system USA
KOKUSAN 2K-1
KOKUSAN 2K-2
KOKUSAN 2K-1
KOKUSAN 2K-2
Generator output
no genaerator
12V 40 W
no genaerator
12V 40 W
Carburetor
flat-slide carburetor, carburetor setting see table
Air-filter
wet foam type air filter insert
TECHNICAL DATA - ENGINE 125 / 200
9-17C
9-18C
TIGHTENING TORQUES - ENGINE
Flange bolts - cylinder-head
Nuts-cylinder base
Flywheel collar nut
Nut for primary sprocket (LH thread)
Nut for inner clutch hub
Crankcase and clutch cover bolts
Spark plug
M7
M8
M 12x1
M 16x1.5
M 18x1.5
M6
M 14x1.25
18 Nm
30 Nm
60 Nm
180 Nm
120 Nm
8 Nm
20 Nm
Swingarm pivot
Other bolts
M 14x1.5
M6
M8
M 10
100 Nm
10 Nm
25 Nm
45 Nm
BASIC CARBURETOR SETTING
200 EXC AUS
200 EXC EU
Art No 3.206.005 -E
Carburetor
Keihin PWK 38 AG
Carburetor setting number
100202
Main jet
180 (178)
Idling jet
35 (45/48)
Starting jet
85
Jet needle
R 1475J (NOZ E/NOZ F)
Needle position from top
III
Throttle valve
6.5
Air adjustment screw open
1,5
Performance restrictor
slide stop 36mm
200 MXC/EXC USA
200 SX
Keihin PWK 38 AG
080202
178(180/185)
45 (48)
85
NOZ E (NOZ F)
III
6.5
1,5
–
Keihin PWK 39
090202
190 (188,192)
48 (45)
85
R 1468G (R1469G)
III
5.5
1,5
–
125 EXC SIX DAYS
125 SX
Keihin PWK 38 AG
160202
180(185)
45 (48)
85
NOZ E (NOZ F)
IIII
6.5
1,5
–
Keihin PWK 39
060202
185 (188/190)
48 (45)
85
R 1469 D (R 1470 D)
III
5.5 (6)
1,5
–
BASIC CARBURETOR SETTING
125 EXC EU
125 EXC AUS
Carburetor
Keihin PWK 38 AG
Carburetor setting number
070202
Main jet
148 (180/185)
Idling jet
35 (45/48)
Starting jet
85
Jet needle
R 1472 N (NOZ E/NOZ F)
Needle position from top
V
Throttle valve
6.5
Air adjustment screw open
1,5
Performance restrictor
–
Repair manual KTM 125 / 200
TOLERANCES AND FITTING CLEARANCES
Piston fitting clearance
Piston ring end cap
Connecting rod bearing - radial clearance
Piston pin – radial clearance
Transmission shafts end float
Clutch springs - length
Clutch discs
Crank stud - run out
Crankshaft webs outer dimension
125 = 0.06 mm 200 = 0.055 mm
max. 0.40 mm
0.025– 0.035 mm
0,030 mm
0.20– 0.40 mm
new = 39 mm, minimum length = 38 mm
min. 2,9 mm (new 3,1 mm)
0,02 mm
55 mm
GASKET THICKNESSES
Crankcase
Clutch cover
Clutch driving cylinder
Cylinder bottom gasket
Available bottom gasket
0,5 mm
0,5 mm
0.30 / 0.50 / 0.75 mm
as required
0.07 / 0.15 / 0.20 / 0.25 / 0.40 / 0.5 0 / 0.75 mm
Front tires USA
HS1 12V 35/35W
12V 5W (base W2, 1x9,5d)
12V 1,2W (base W2, 1x4,6d)
12V 21/5W (base BaY15d)
12V 10W (base Ba15s)
12V 1,2W (base 1x4,6d)
instrument light
brake- rear light
flasher light
license plate illumination
925 mm (36,5 in)
385 mm (15,2 in)
Ground clearance, unloaded
1461 ± 10 mm (57,3 ± 0,4 in)
63°
1.0 bar (14psi)
–
100/100 - 18“ 59M
–
–
1.0 bar (14psi)
80/100 - 21“51M
–
14:48t
11 liters (2.9 US Gallons)
parking light
38t, 40t, 42t, 45t, 48t, 50t, 52t
5/8 x 1/4 "
14:48t
14:48t
7.5 liters (2 US Gallons)
headlight
14:38t
13:50t
9 liters (2.3 US Gallons)
13:50t
13:50t
7.5 liters (2 US Gallons)
1.0 bar (14psi)
–
100/90 - 19“ 57M
–
100/90 - 19“ 57M
1.0 bar (14psi)
Seat height, unloaded
Wheel base
Steering head angle
Bulbs
Available final sprockets
Chain
Final drive ratio
Final drive ratio USA
Air pressure road driver only
Fuel tank capacity
1.0 bar (14psi)
2.0 bar (28psi)
100/100 - 18“ 59M
1.5 bar (21psi)
120/90 - 18“ 65R
1.0 bar (14psi)
80/100 - 21“51M
1.0 bar (14psi)
–
100/90 - 19“ 57M
Rear tires USA
Air pressure offroad
–
100/90 - 19“ 57M
Air pressure road driver only
Rear tires
1.0 bar (14psi)
80/100 - 21“51M
80/100 - 21“51M
80/100 - 21“51M
Front tires
Air pressure offroad
Wear limit max. 0.4 mm (0.016 in)
–
Disc brake with carbon-steel brake disc Ø 220 mm (8.7 in), brake caliper floated
Brake discs
80/100 - 21“51M
Disc brake with carbon-steel brake disc Ø 260 mm (10.2 in), brake caliper floated
Rear brake
90/90 - 21“ 54R
WP PDS 5018 (Progressive Damping System) shock absorber, aluminium swingarm
Front brake
200 MXC
Rear suspension
300/335 mm (11.8/13.2 in)
White Power – Upside down 48 MA
Wheel travel front/rear
Fork
200 SX
200 EXC
14:45t / 14:48t
14:48t
9/11 liter (2.3/2.9 US gallons)
1.0 bar (14psi)
2.0 bar (28psi)
100/100 - 18“ 59M
1.5 bar (21psi)
120/90 - 18“ 65R
1.0 bar (14psi)
80/100 - 21“51M
90/90 - 21“ 54R
200 SX / MXC / EXC 2003
Central chrome-moly-steel frame
125 EXC
125 SX / EXC,
Frame
125 SX
TECHNICAL SPECIFICATIONS CHASSIS
9-19C
9-20C
STANDARD ADJUSTMENT - FORK
WP 4860 MXMA
WP 4860 MXMA
1418X725
1418X735
Compression adjuster
20
22
Rebound adjuster
20
20
4.0 N/mm
3.8 N/mm
Spring
Spring preload
Air chamber length
5 mm (0.2in)
5 mm (0.2in)
100 mm (5.1in)
110 mm (4,3in)
SAE 5
SAE 5
Fork oil
STANDARD ADJUSTMENT - SHOCK ABSORBER
Compression adjuster
WP 5018 PDS-DCC
WP 5018 PDS-MCC
1218X756
1218X757
17 LS (low speed)
17
2 HS (high speed)
Rebound adjuster
28
28
71-90/260
66-86/260
6 mm (0.2 in)
7 mm (0.2 in)
Spring
Repair manual KTM 125 / 200
Art No 3.206.005 -E
Spring preload
TIGHTENING TORQUES - CHASSIS
Collar bolt, front wheel spindle
Brake caliper, front
M 24x1,5
M8
40 Nm
Loctite 243 + 25 Nm
Brake disk, front
M 6 10.9
Loctite 243 + 15 Nm
Brake disk, rear
M6
Loctite 243 + 15 Nm
Clamping bolts, upper fork bridge
M8
20 Nm
Clamping bolts, lower fork bridge
M8
15 Nm
Clamping bolts, fork stubs
M8
10 Nm
Collar nut, rear wheel spindle
M 20x1,5
80 Nm
Hexagon nut, swing arm bolt
M 14x1,5
100 Nm
Hexagon collar bolt, handlebar clamp
M8
20 Nm
Allan head bolt, handlebar support
M 10
Loctite 243 + 40 Nm
Shock absorber, top
M 12
60 Nm
Shock absorber, bottom
M 12
60 Nm
Sprocket bolts
M8
Loctite 243 + 35 Nm
Ball joint for push rod
M6
Loctite 243 + 10 Nm
Engine mounting bolt
M 10
45 Nm
Engine brace
M8
33 Nm
Screw adjusting ring spring preload shock abs.
M6
8 Nm
M4,5 /M5
5 Nm
Other bolts on chassis
M6
M8
M 10
10 Nm
25 Nm
45 Nm
Other collar nuts on chassis
M6
M8
M 10
15 Nm
30 Nm
50 Nm
Spoke nipple
LSCHR
LD
NADEL
POS
HD
LSCHR
LD
NADEL
POS
HD
LSCHR
LD
NADEL
POS
HD
LSCHR
LD
NADEL
POS
HD
2300 m
7500 ft
1500 m
5000 ft
750 m
2500 ft
300 m
1000 ft
LSCHR
LD
POS
HD
=
=
=
=
AS
IJ
NEEDLE
POS
MJ
AS
IJ
NEEDLE
POS
MJ
AS
IJ
NEEDLE
POS
MJ
AS
IJ
NEEDLE
POS
MJ
AS
IJ
NEEDLE
POS
MJ
Luftregulierschraube offen
Leerlaufdüse
Clip Position von oben
Hauptdüse
Meeresniveau
Sea level
301 m
1001 ft
751 m
2501 ft
1501 m
5001 ft
2301 m
7501 ft
LSCHR
LD
NADEL
POS
HD
TEMPERATURE
5.
3.
1.
1/2
55
NOZF
5
185
3/4
55
NOZG
4
182
1
52
NOZG
4
180
1 1/4
50
NOZG
4
178
1 1/2
48
NOZH
3
175
4.
2.
-2°F to 20°F
-20°C bis -7°C
AS
IJ
POS
MJ
=
=
=
=
1
50
NOZG
4
180
1 1/4
50
NOZH
3
178
1 1/2
48
NOZH
3
175
1 3/4
45
NOZH
3
172
2
42
NOZH
2
170
42°F to 60°F
6°C bis 15°C
1 1/2
48
NOZH
3
175
1 3/4
45
NOZI
3
172
2
42
NOZH
2
170
2 1/4
40
NOZI
1
168
2 1/2
38
NOZI
1
165
79°F to 98°F
25°C bis 38°C
1 3/4
45
NOZI
2
172
2
42
NOZI
2
170
2 1/4
40
NOZI
1
168
2 1/2
38
NOZI
1
165
2 3/4
38
NOZI
1
165
99°F to 120°F
37°C bis 49°C
KEIHIN PWK 39
NICHT FÜR STRASSENBETRIEB
Kraftstoff: Super bleifrei (125:ROZ 98/200:ROZ95)
NOT FOR HIGHWAY USE
Fuel: Super unleaded (125:ROZ 98/200:ROZ95)
1 1/4
50
NOZH
3
178
1 1/2
48
NOZH
3
175
1 3/4
45
NOZH
3
172
2
42
NOZI
2
170
2 1/4
40
NOZI
1
168
61°F to 78°F
16°C bis 24°C
USA ‘99
Air screw open from fully-seated
Idling jet
Clip position from top
Main jet
3/4
52
NOZG
4
182
1
52
NOZG
4
180
1 1/4
50
NOZG
4
178
1 1/2
48
NOZH
3
175
1 3/4
45
NOZH
3
172
19°F to 41°F
-6°C bis 5°C
KTM 125 SX / MXC / EXC
3000 m
10000 ft
ALTITUDE
MEERESHÖHE
VERGASERREGULIERUNG
CARBURETOR SETTING
9-21C
LSCHR
LD
NADEL
POS
HD
LSCHR
LD
NADEL
POS
HD
LSCHR
LD
NADEL
POS
HD
LSCHR
LD
NADEL
POS
HD
2300 m
7500 ft
1500 m
5000 ft
750 m
2500 ft
300 m
1000 ft
LSCHR
LD
POS
HD
=
=
=
=
AS
IJ
NEEDLE
POS
MJ
AS
IJ
NEEDLE
POS
MJ
AS
IJ
NEEDLE
POS
MJ
AS
IJ
NEEDLE
POS
MJ
AS
IJ
NEEDLE
POS
MJ
Luftregulierschraube offen
Leerlaufdüse
Clip Position von oben
Hauptdüse
Meeresniveau
Sea level
301 m
1001 ft
751 m
2501 ft
1501 m
5001 ft
2301 m
7501 ft
LSCHR
LD
NADEL
POS
HD
Art No 3.206.005 -E
5.
3.
1.
3/4
50
NOZD
4
200
1
50
NOZF
4
195
1 1/4
50
NOZF
4
192
1 1/2
48
NOZF
3
190
1 1/2
48
NOZG
3
190
4.
2.
-2°F to 20°F
-20°C bis -7°C
AS
IJ
POS
MJ
=
=
=
=
1 1/2
48
NOZF
3
190
1 3/4
48
NOZG
3
190
1 3/4
48
NOZH
3
188
1 3/4
45
NOZH
2
185
1 3/4
45
NOZH
2
185
42°F to 60°F
6°C bis 15°C
1 1/2
48
NOZG
3
190
1 3/4
48
NOZH
3
188
1 3/4
45
NOZH
2
185
2
45
NOZH
2
182
2
45
NOZH
2
180
79°F to 98°F
25°C bis 38°C
1 3/4
48
NOZH
2
188
1 3/4
45
NOZH
2
185
2
45
NOZH
2
182
2
45
NOZH
2
180
2 1/4
45
NOZH
2
180
99°F to 120°F
37°C bis 49°C
KEIHIN PWK 39
NICHT FÜR STRASSENBETRIEB
Kraftstoff: Euro-Super bleifrei ROZ 98
NOT FOR HIGHWAY USE
Fuel: Euro-Super unleaded ROZ 98
1 1/2
48
NOZF
3
190
1 3/4
48
NOZG
3
190
1 3/4
45
NOZH
2
185
2
45
NOZH
2
182
2
45
NOZH
2
180
61°F to 78°F
16°C bis 24°C
Air screw open from fully-seated
Idling jet
Clip position from top
Main jet
1
50
NOZD
4
198
1 1/4
50
NOZF
4
192
1 1/2
48
NOZF
3
190
1 1/2
48
NOZG
3
190
1 3/4
48
NOZH
3
188
19°F to 41°F
-6°C bis 5°C
KTM 125 SX / EXC EUROPA ‘99
TEMPERATUR
3000 m
10000 ft
ALTIDUDE
MEERESHÖHE
VERGASERREGULIERUNG
CARBURETOR SETTING
Repair manual KTM 125 / 200
9-22C
LSCHR
LD
NADEL
POS
HD
LSCHR
LD
NADEL
POS
HD
LSCHR
LD
NADEL
POS
HD
LSCHR
LD
NADEL
POS
HD
2300 m
7500 ft
1500 m
5000 ft
750 m
2500 ft
300 m
1000 ft
LSCHR
LD
POS
HD
=
=
=
=
AS
IJ
NEEDLE
POS
MJ
AS
IJ
NEEDLE
POS
MJ
AS
IJ
NEEDLE
POS
MJ
AS
IJ
NEEDLE
POS
MJ
AS
IJ
NEEDLE
POS
MJ
Luftregulierschraube offen
Leerlaufdüse
Clip Position von oben
Hauptdüse
Meeresniveau
Sea level
301 m
1001 ft
751 m
2501 ft
1501 m
5001 ft
2301 m
7501 ft
LSCHR
LD
NADEL
POS
HD
5.
3.
1.
1
48
NOZF
4
188
1 1/4
48
NOZG
4
185
1 1/2
48
NOZG
3
182
1 1/4
45
NOZG
3
182
1 3/4
45
NOZH
2
180
4.
2.
-2°F to 20°F
-20°C bis -7°C
AS
IJ
POS
MJ
=
=
=
=
1 1/2
48
NOZG
3
182
1 1/4
45
NOZG
3
182
1 1/2
45
NOZH
2
180
1 3/4
45
NOZH
2
178
1 3/4
42
NOZI
2
175
42°F to 60°F
6°C bis 15°C
1 1/4
45
NOZG
3
182
1 1/2
45
NOZH
2
180
1 3/4
45
NOZH
2
178
1 3/4
42
NOZI
2
175
2
42
NOZI
1
172
1 1/2
45
NOZH
2
180
1 3/4
45
NOZH
2
178
1 3/4
42
NOZI
2
175
2
42
NOZI
1
172
2
42
NOZI
1
170
79°F to 98°F
25°C bis 38°C
1 3/4
45
NOZH
2
178
1 3/4
42
NOZI
2
175
2
42
NOZI
1
172
2
42
NOZI
1
170
1 3/4
40
NOZI
1
170
99°F to 120°F
37°C bis 49°C
NICHT FÜR STRASSENBETRIEB
Kraftstoff: Euro-Super bleifrei ROZ 95
NOT FOR HIGHWAY USE
Fuel: Euro-Super unleaded ROZ 95
61°F to 78°F
16°C bis 24°C
Air screw open from fully-seated
Idling jet
Clip position from top
Main jet
1 1/4
48
NOZG
4
185
1
48
NOZG
3
182
1 1/4
45
NOZG
3
182
1 3/4
45
NOZH
2
180
1 3/4
45
NOZH
2
178
19°F to 41°F
-6°C bis 5°C
KTM 200 MXC / EXC EUR. USA ‘99 KEIHIN PWK 39
TEMPERATURE
3000 m
10000 ft
ALTITUDE
MEERESHÖHE
VERGASERREGULIERUNG
CARBURETOR SETTING
9-23C
LSCHR
LD
NADEL
POS
HD
LSCHR
LD
NADEL
POS
HD
LSCHR
LD
NADEL
POS
HD
LSCHR
LD
NADEL
POS
HD
2300 m
7500 ft
1500 m
5000 ft
750 m
2500 ft
300 m
1000 ft
LSCHR
LD
POS
HD
=
=
=
=
AS
IJ
NEEDLE
POS
MJ
AS
IJ
NEEDLE
POS
MJ
AS
IJ
NEEDLE
POS
MJ
AS
IJ
NEEDLE
POS
MJ
AS
IJ
NEEDLE
POS
MJ
Luftregulierschraube offen
Leerlaufdüse
Clip Position von oben
Hauptdüse
Meeresniveau
Sea level
301 m
1001 ft
751 m
2501 ft
1501 m
5001 ft
2301 m
7501 ft
LSCHR
LD
NADEL
POS
HD
Art No 3.206.005 -E
5.
3.
1.
1/2
55
R1467D
5
195
3/4
52
R1467D
4
192
1
50
R1467D
3
190
1 1/4
48
R1468D
3
188
1 1/2
45
R1468D
2
185
4.
2.
-2°F to 20°F
-20°C bis -7°C
AS
IJ
POS
MJ
=
=
=
=
1
50
R1467D
3
190
1 1/4
48
R1468D
3
188
1 1/2
45
R1468D
2
185
1 3/4
42
R1469D
3
182
2
40
R1469D
2
180
42°F to 60°F
6°C bis 15°C
1 1/2
45
R1468D
2
185
1 3/4
42
R1469D
3
182
2
40
R1469D
2
180
2 1/4
38
R1469D
2
178
2 1/2
38
R1469D
1
175
79°F to 98°F
25°C bis 38°C
1 3/4
42
R1469D
3
182
2
40
R1469D
2
180
2 1/4
38
R1469D
2
178
2 1/2
38
R1469D
1
175
2 3/4
38
R1469D
1
175
99°F to 120°F
37°C bis 49°C
NICHT FÜR STRASSENBETRIEB
Kraftstoff: Euro-Super bleifrei ROZ 95
NOT FOR HIGHWAY USE
Fuel: Euro-Super unleaded ROZ 95
1 1/4
48
R1468D
3
188
1 1/2
45
R1468D
2
185
1 3/4
42
R1469D
3
182
2
40
R1469D
2
180
2 1/4
38
R1469D
3
178
61°F to 78°F
16°C bis 24°C
Air screw open from fully-seated
Idling jet
Clip position from top
Main jet
3/4
52
R1467D
4
192
1
50
R1467D
3
190
1 1/4
48
R1468D
3
188
1 1/2
45
R1468D
2
185
1 3/4
42
R1469D
3
182
19°F to 41°F
-6°C bis 5°C
KTM 125 SX EUROPA / USA 2000 KEIHIN PWK 39
TEMPERATUR
3000 m
10000 ft
ALTIDUDE
MEERESHÖHE
VERGASERREGULIERUNG
CARBURETOR SETTING
Repair manual KTM 125 / 200
9-24C
LSCHR
LD
NADEL
POS
HD
LSCHR
LD
NADEL
POS
HD
LSCHR
LD
NADEL
POS
HD
LSCHR
LD
NADEL
POS
HD
2300 m
7500 ft
1500 m
5000 ft
750 m
2500 ft
300 m
1000 ft
LSCHR
LD
POS
HD
=
=
=
=
AS
IJ
NEEDLE
POS
MJ
AS
IJ
NEEDLE
POS
MJ
AS
IJ
NEEDLE
POS
MJ
AS
IJ
NEEDLE
POS
MJ
AS
IJ
NEEDLE
POS
MJ
Luftregulierschraube offen
Leerlaufdüse
Clip Position von oben
Hauptdüse
Meeresniveau
Sea level
301 m
1001 ft
751 m
2501 ft
1501 m
5001 ft
2301 m
7501 ft
LSCHR
LD
NADEL
POS
HD
5.
3.
1.
1/2
55
NOZF
5
185
3/4
55
NOZG
4
182
1
52
NOZG
4
180
1 1/4
50
NOZG
4
178
1 1/2
48
NOZH
3
175
4.
2.
-2°F to 20°F
-20°C bis -7°C
AS
IJ
POS
MJ
=
=
=
=
1
50
NOZG
4
180
1 1/4
50
NOZH
3
178
1 1/2
48
NOZH
3
175
1 3/4
45
NOZH
3
172
2
42
NOZH
2
170
42°F to 60°F
6°C bis 15°C
1 1/2
48
NOZH
3
175
1 3/4
45
NOZI
3
172
2
42
NOZH
2
170
2 1/4
40
NOZI
1
168
2 1/2
38
NOZI
1
165
79°F to 98°F
25°C bis 38°C
1 3/4
45
NOZI
2
172
2
42
NOZI
2
170
2 1/4
40
NOZI
1
168
2 1/2
38
NOZI
1
165
2 3/4
38
NOZI
1
165
99°F to 120°F
37°C bis 49°C
NICHT FÜR STRASSENBETRIEB
Kraftstoff: Euro-Super bleifrei ROZ 95
NOT FOR HIGHWAY USE
Fuel: Euro-Super unleaded ROZ 95
1 1/4
50
NOZH
3
178
1 1/2
48
NOZH
3
175
1 3/4
45
NOZH
3
172
2
42
NOZI
2
170
2 1/4
40
NOZI
1
168
61°F to 78°F
16°C bis 24°C
Air screw open from fully-seated
Idling jet
Clip position from top
Main jet
3/4
52
NOZG
4
182
1
52
NOZG
4
180
1 1/4
50
NOZG
4
178
1 1/2
48
NOZH
3
175
1 3/4
45
NOZH
3
172
19°F to 41°F
-6°C bis 5°C
KTM 125 MXC/EXC EUR/USA 2000 KEIHIN PWK 38 AG
TEMPERATUR
3000 m
10000 ft
ALTIDUDE
MEERESHÖHE
VERGASERREGULIERUNG
CARBURETOR SETTING
9-25C
LSCHR
LD
NADEL
POS
HD
LSCHR
LD
NADEL
POS
HD
LSCHR
LD
NADEL
POS
HD
LSCHR
LD
NADEL
POS
HD
2300 m
7500 ft
1500 m
5000 ft
750 m
2500 ft
300 m
1000 ft
LSCHR
LD
POS
HD
=
=
=
=
AS
IJ
NEEDLE
POS
MJ
AS
IJ
NEEDLE
POS
MJ
AS
IJ
NEEDLE
POS
MJ
AS
IJ
NEEDLE
POS
MJ
AS
IJ
NEEDLE
POS
MJ
Luftregulierschraube offen
Leerlaufdüse
Clip Position von oben
Hauptdüse
Meeresniveau
Sea level
301 m
1001 ft
751 m
2501 ft
1501 m
5001 ft
2301 m
7501 ft
LSCHR
LD
NADEL
POS
HD
Art No 3.206.005 -E
5.
3.
1.
1
48
NOZF
4
188
1 1/4
48
NOZG
4
185
1 1/2
48
NOZG
3
182
1 1/4
45
NOZG
3
182
1 3/4
45
NOZH
2
180
4.
2.
-2°F to 20°F
-20°C bis -7°C
AS
IJ
POS
MJ
=
=
=
=
1 1/2
48
NOZG
3
182
1 1/4
45
NOZG
3
182
1 1/2
45
NOZH
2
180
1 3/4
45
NOZH
2
178
1 3/4
42
NOZI
2
175
42°F to 60°F
6°C bis 15°C
1 1/2
45
NOZH
2
180
1 3/4
45
NOZH
2
178
1 3/4
42
NOZI
2
175
2
42
NOZI
1
172
2
42
NOZI
1
170
79°F to 98°F
25°C bis 38°C
1 3/4
45
NOZH
2
178
1 3/4
42
NOZI
2
175
2
42
NOZI
1
172
2
42
NOZI
1
170
1 3/4
40
NOZI
1
170
99°F to 120°F
37°C bis 49°C
NICHT FÜR STRASSENBETRIEB
Kraftstoff: Euro-Super bleifrei ROZ 95
NOT FOR HIGHWAY USE
Fuel: Euro-Super unleaded ROZ 95
1 1/4
45
NOZG
3
182
1 1/2
45
NOZH
2
180
1 3/4
45
NOZH
2
178
1 3/4
42
NOZI
2
175
2
42
NOZI
1
172
61°F to 78°F
16°C bis 24°C
Air screw open from fully-seated
Idling jet
Clip position from top
Main jet
1 1/4
48
NOZG
4
185
1
48
NOZG
3
182
1 1/4
45
NOZG
3
182
1 3/4
45
NOZH
2
180
1 3/4
45
NOZH
2
178
19°F to 41°F
-6°C bis 5°C
KTM 200 MXC/EXC EUR/USA 2000 KEIHIN PWK 38 AG
TEMPERATUR
3000 m
10000 ft
ALTIDUDE
MEERESHÖHE
VERGASERREGULIERUNG
CARBURETOR SETTING
Repair manual KTM 125 / 200
9-26C
LSCHR
LD
NADEL
POS
HD
LSCHR
LD
NADEL
POS
HD
LSCHR
LD
NADEL
POS
HD
LSCHR
LD
NADEL
POS
HD
2300 m
7500 ft
1500 m
5000 ft
750 m
2500 ft
300 m
1000 ft
AS
IJ
NEEDLE
POS
MJ
AS
IJ
NEEDLE
POS
MJ
AS
IJ
NEEDLE
POS
MJ
AS
IJ
NEEDLE
POS
MJ
AS
IJ
NEEDLE
POS
MJ
LSCHR = Luftregulierschraube offen
LD
= Leerlaufdüse
POS
= Clip Position von oben
HD
= Hauptdüse
Schieber= 5,5
Meeresniveau
Sea level
301 m
1001 ft
751 m
2501 ft
1501 m
5001 ft
2301 m
7501 ft
LSCHR
LD
NADEL
POS
HD
5.
3.
1.
1/2
55
R1467D
5
195
3/4
52
R1467D
4
192
1
50
R1467D
3
190
1 1/4
48
R1468D
3
188
1 1/2
45
R1468D
2
185
4.
2.
-2°F to 20°F
-20°C bis -7°C
AS =
IJ
=
POS =
MJ =
Slide =
1
50
R1468D
3
190
1 1/4
48
R1468D
3
188
1 1/2
45
R1468D
2
185
1 3/4
42
R1469D
3
182
2
40
R1469D
2
180
42°F to 60°F
6°C bis 15°C
1 1/2
45
R1468D
2
185
1 3/4
42
R1469D
2
182
2
40
R1469D
2
180
2 1/4
38
R1469D
2
178
2 1/2
38
R1470D
1
175
79°F to 98°F
25°C bis 38°C
1 3/4
42
R1470D
2
182
2
40
R1469D
2
180
2 1/4
38
R1469D
2
178
2 1/2
38
R1470D
1
175
2 3/4
38
R1470D
1
172
99°F to 120°F
37°C bis 49°C
NICHT FÜR STRASSENBETRIEB
Kraftstoff: Euro-Super bleifrei ROZ 95
NOT FOR HIGHWAY USE
Fuel: Euro-Super unleaded ROZ 95
1 1/4
48
R1468D
3
188
1 1/2
45
R1468D
3
185
1 3/4
42
R1469D
2
182
2
40
R1469D
2
180
2 1/4
38
R1470D
2
178
61°F to 78°F
16°C bis 24°C
Air screw open from fully-seated
Idling jet
Clip position from top
Main jet
5,5
3/4
52
R1467D
4
192
1
50
R1467D
3
190
1 1/4
48
R1468D
3
188
1 1/2
45
R1468D
2
185
1 3/4
42
R1469D
3
182
19°F to 41°F
-6°C bis 5°C
KTM 125 SX EUROPA / USA 2001 KEIHIN PWK 39
TEMPERATUR
3000 m
10000 ft
ALTIDUDE
MEERESHÖHE
VERGASERREGULIERUNG
CARBURETOR SETTING
9-27C
LSCHR
LD
NADEL
POS
HD
LSCHR
LD
NADEL
POS
HD
LSCHR
LD
NADEL
POS
HD
LSCHR
LD
NADEL
POS
HD
2300 m
7500 ft
1500 m
5000 ft
750 m
2500 ft
300 m
1000 ft
AS
IJ
NEEDLE
POS
MJ
AS
IJ
NEEDLE
POS
MJ
AS
IJ
NEEDLE
POS
MJ
AS
IJ
NEEDLE
POS
MJ
AS
IJ
NEEDLE
POS
MJ
LSCHR = Luftregulierschraube offen
LD
= Leerlaufdüse
POS
= Clip Position von oben
HD
= Hauptdüse
Schieber= 6,5
Meeresniveau
Sea level
301 m
1001 ft
751 m
2501 ft
1501 m
5001 ft
2301 m
7501 ft
LSCHR
LD
NADEL
POS
HD
Art No 3.206.005 -E
5.
3.
1.
1/2
55
NOZF
5
185
3/4
55
NOZG
4
182
1
52
NOZG
4
180
1 1/4
50
NOZG
4
178
1 1/2
48
NOZH
3
175
4.
2.
-2°F to 20°F
-20°C bis -7°C
AS =
IJ
=
POS =
MJ =
Slide =
1
50
NOZG
4
180
1 1/4
50
NOZH
3
178
1 1/2
48
NOZH
3
175
1 3/4
45
NOZH
3
172
2
42
NOZH
2
170
42°F to 60°F
6°C bis 15°C
1 1/2
48
NOZH
3
175
1 3/4
45
NOZI
2
172
2
42
NOZH
2
170
2 1/4
40
NOZI
1
168
2 1/2
38
NOZI
1
165
79°F to 98°F
25°C bis 38°C
1 3/4
45
NOZI
2
172
2
42
NOZI
2
170
2 1/4
40
NOZI
1
168
2 1/2
38
NOZI
1
165
2 3/4
38
NOZI
1
165
99°F to 120°F
37°C bis 49°C
NICHT FÜR STRASSENBETRIEB
Kraftstoff: Euro-Super bleifrei ROZ 95
NOT FOR HIGHWAY USE
Fuel: Euro-Super unleaded ROZ 95
1 1/4
50
NOZH
3
178
1 1/2
48
NOZH
3
175
1 3/4
45
NOZH
2
172
2
42
NOZI
2
170
2 1/4
40
NOZI
1
168
61°F to 78°F
16°C bis 24°C
Air screw open from fully-seated
Idling jet
Clip position from top
Main jet
6,5
3/4
52
NOZG
4
182
1
52
NOZG
4
180
1 1/4
50
NOZG
4
178
1 1/2
48
NOZH
3
175
1 3/4
45
NOZH
3
172
19°F to 41°F
-6°C bis 5°C
KTM 125 MXC/EXC EUR/USA 2001 KEIHIN PWK 38 AG
TEMPERATUR
3000 m
10000 ft
ALTIDUDE
MEERESHÖHE
VERGASERREGULIERUNG
CARBURETOR SETTING
Repair manual KTM 125 / 200
9-28C
LSCHR
LD
NADEL
POS
HD
LSCHR
LD
NADEL
POS
HD
LSCHR
LD
NADEL
POS
HD
LSCHR
LD
NADEL
POS
HD
2300 m
7500 ft
1500 m
5000 ft
750 m
2500 ft
300 m
1000 ft
AS
IJ
NEEDLE
POS
MJ
AS
IJ
NEEDLE
POS
MJ
AS
IJ
NEEDLE
POS
MJ
AS
IJ
NEEDLE
POS
MJ
AS
IJ
NEEDLE
POS
MJ
LSCHR = Luftregulierschraube offen
LD
= Leerlaufdüse
POS
= Clip Position von oben
HD
= Hauptdüse
Schieber= 6,5
Meeresniveau
Sea level
301 m
1001 ft
751 m
2501 ft
1501 m
5001 ft
2301 m
7501 ft
LSCHR
LD
NADEL
POS
HD
5.
3.
1.
1
48
NOZF
5
188
1 1/4
48
NOZF
4
185
1 1/2
48
NOZG
3
182
1 1/4
45
NOZG
3
182
1 3/4
45
NOZH
2
180
4.
2.
-2°F to 20°F
-20°C bis -7°C
AS =
IJ
=
POS =
MJ =
Slide =
1 1/2
48
NOZG
3
182
1 1/4
45
NOZG
3
182
1 1/2
45
NOZH
2
180
1 3/4
45
NOZH
2
178
1 3/4
42
NOZI
2
175
42°F to 60°F
6°C bis 15°C
1 1/2
45
NOZH
2
180
1 3/4
45
NOZH
2
178
1 3/4
42
NOZI
2
175
2
42
NOZI
1
172
2
42
NOZI
1
170
79°F to 98°F
25°C bis 38°C
1 3/4
45
NOZH
2
178
1 3/4
42
NOZI
2
175
2
42
NOZI
1
172
2
42
NOZI
1
170
1 3/4
40
NOZI
1
170
99°F to 120°F
37°C bis 49°C
NICHT FÜR STRASSENBETRIEB
Kraftstoff: Euro-Super bleifrei ROZ 95
NOT FOR HIGHWAY USE
Fuel: Euro-Super unleaded ROZ 95
1 1/4
45
NOZG
3
182
1 1/2
45
NOZG
3
180
1 3/4
45
NOZH
2
178
1 3/4
42
NOZI
2
175
2
42
NOZI
1
172
61°F to 78°F
16°C bis 24°C
Air screw open from fully-seated
Idling jet
Clip position from top
Main jet
6,5
1 1/4
48
NOZF
4
185
1
48
NOZF
4
182
1 1/4
45
NOZG
3
182
1 3/4
45
NOZH
2
180
1 3/4
45
NOZH
2
178
19°F to 41°F
-6°C bis 5°C
KTM 200 MXC/EXC EUR/USA 2001 KEIHIN PWK 38 AG
TEMPERATUR
3000 m
10000 ft
ALTIDUDE
MEERESHÖHE
VERGASERREGULIERUNG
CARBURETOR SETTING
9-29C
LSCHR
LD
NADEL
POS
HD
LSCHR
LD
NADEL
POS
HD
LSCHR
LD
NADEL
POS
HD
LSCHR
LD
NADEL
POS
HD
2300 m
7500 ft
1500 m
5000 ft
750 m
2500 ft
300 m
1000 ft
AS
IJ
NEEDLE
POS
MJ
AS
IJ
NEEDLE
POS
MJ
AS
IJ
NEEDLE
POS
MJ
AS
IJ
NEEDLE
POS
MJ
AS
IJ
NEEDLE
POS
MJ
LSCHR = Luftregulierschraube offen
LD
= Leerlaufdüse
POS
= Clip Position von oben
HD
= Hauptdüse
Schieber = 5,5
Zerstäuber= 6 mm
Meeresniveau
Sea level
301 m
1001 ft
751 m
2501 ft
1501 m
5001 ft
2301 m
7501 ft
LSCHR
LD
NADEL
POS
HD
Art No 3.206.005 -E
5.
3.
1.
1/2
55
R1468D
5
195
3/4
52
R1468D
4
192
1
50
R1468D
3
190
1 1/4
48
R1469D
3
188
1 1/2
45
R1469D
3
185
4.
2.
-2°F to 20°F
-20°C bis -7°C
1
50
R1469D
3
190
1 1/4
48
R1469D
3
188
1 1/2
45
R1469D
2
185
1 3/4
42
R1470D
3
182
2
40
R1470D
2
180
42°F to 60°F
6°C bis 15°C
AS
= Air screw open from fully-seated
IJ
= Idling jet
POS = Clip position from top
MJ
= Main jet
Slide = 5,5
Atomizer = 6 mm
3/4
52
R1468D
4
192
1
50
R1468D
3
190
1 1/4
48
R1469D
3
188
1 1/2
45
R1469D
3
185
1 3/4
42
R1470D
3
182
19°F to 41°F
-6°C bis 5°C
1 1/2
45
R1469D
2
185
1 3/4
42
R1470D
2
182
2
40
R1470D
2
180
2 1/4
38
R1470D
2
178
2 1/2
38
R1471D
1
175
79°F to 98°F
25°C bis 38°C
1 3/4
42
R1470D
2
182
2
40
R1470D
2
180
2 1/4
38
R1470D
2
178
2 1/2
38
R1471D
1
175
2 3/4
38
R1471D
1
172
99°F to 120°F
37°C bis 49°C
KEIHIN PWK 39
NICHT FÜR STRASSENBETRIEB
Kraftstoff: Euro-Super bleifrei ROZ 95
NOT FOR HIGHWAY USE
Fuel: Euro-Super unleaded ROZ 95
1 1/4
48
R1469D
3
188
1 1/2
45
R1469D
3
185
1 3/4
42
R1470D
2
182
2
40
R1470D
2
180
2 1/4
38
R1470D
2
178
61°F to 78°F
16°C bis 24°C
KTM 125 SX EUROPA / USA 2002
TEMPERATUR
3000 m
10000 ft
ALTIDUDE
MEERESHÖHE
VERGASERREGULIERUNG
CARBURETOR SETTING
Repair manual KTM 125 / 200
9-30C
LSCHR
LD
NADEL
POS
HD
LSCHR
LD
NADEL
POS
HD
LSCHR
LD
NADEL
POS
HD
LSCHR
LD
NADEL
POS
HD
2300 m
7500 ft
1500 m
5000 ft
750 m
2500 ft
300 m
1000 ft
AS
IJ
NEEDLE
POS
MJ
AS
IJ
NEEDLE
POS
MJ
AS
IJ
NEEDLE
POS
MJ
AS
IJ
NEEDLE
POS
MJ
AS
IJ
NEEDLE
POS
MJ
LSCHR = Luftregulierschraube offen
LD
= Leerlaufdüse
POS
= Clip Position von oben
HD
= Hauptdüse
Schieber = 6,5
Zerstäuber= 5 mm
Meeresniveau
Sea level
301 m
1001 ft
751 m
2501 ft
1501 m
5001 ft
2301 m
7501 ft
LSCHR
LD
NADEL
POS
HD
5.
3.
1.
1/2
55
NOZE
5
190
3/4
52
NOZF
4
188
1
50
NOZF
4
185
1 1/4
48
NOZF
4
182
1 1/2
45
NOZG
3
180
4.
2.
-2°F to 20°F
-20°C bis -7°C
1
50
NOZF
4
185
1 1/4
48
NOZG
3
182
1 1/2
45
NOZG
3
180
1 3/4
42
NOZG
3
178
2
40
NOZG
2
175
42°F to 60°F
6°C bis 15°C
AS
= Air screw open from fully-seated
IJ
= Idling jet
POS = Clip position from top
MJ
= Main jet
Slide = 6,5
Atomizer= 5 mm
3/4
52
NOZF
4
188
1
50
NOZF
4
185
1 1/4
48
NOZF
4
182
1 1/2
45
NOZG
3
180
1 3/4
42
NOZG
3
178
19°F to 41°F
-6°C bis 5°C
1 1/2
45
NOZG
3
180
1 3/4
42
NOZG
2
178
2
40
NOZG
2
175
2 1/4
38
NOZH
1
172
2 1/2
35
NOZH
1
170
79°F to 98°F
25°C bis 38°C
1 3/4
42
NOZH
2
178
2
40
NOZH
2
175
2 1/4
38
NOZH
1
172
2 1/2
35
NOZH
1
170
2 3/4
32
NOZI
1
168
99°F to 120°F
37°C bis 49°C
NICHT FÜR STRASSENBETRIEB
Kraftstoff: Euro-Super bleifrei ROZ 95
NOT FOR HIGHWAY USE
Fuel: Euro-Super unleaded ROZ 95
1 1/4
48
NOZG
3
182
1 1/2
45
NOZG
3
180
1 3/4
42
NOZG
2
178
2
40
NOZH
2
175
2 1/4
38
NOZH
1
172
61°F to 78°F
16°C bis 24°C
KTM 125 EXC EUR 2002 KEIHIN PWK 38 AG
TEMPERATUR
3000 m
10000 ft
ALTIDUDE
MEERESHÖHE
VERGASERREGULIERUNG
CARBURETOR SETTING
9-31C
LSCHR
LD
NADEL
POS
HD
300 m
1000 ft
AS
IJ
NEEDLE
POS
MJ
AS
IJ
NEEDLE
POS
MJ
AS
IJ
NEEDLE
POS
MJ
AS
IJ
NEEDLE
POS
MJ
AS
IJ
NEEDLE
POS
MJ
LSCHR = Luftregulierschraube offen
LD
= Leerlaufdüse
POS
= Clip Position von oben
HD
= Hauptdüse
Schieber = 6,5
Zerstäuber= 5 mm
Meeresniveau
Sea level
301 m
1001 ft
LSCHR
LD
NADEL
POS
HD
LSCHR
LD
NADEL
POS
HD
LSCHR
LD
NADEL
POS
HD
LSCHR
LD
NADEL
POS
HD
Art No 3.206.005 -E
5.
3.
1.
1
50
NOZD
5
188
1 1/4
48
NOZD
4
185
1 1/2
48
NOZE
3
182
1 1/4
45
NOZF
3
180
1 3/4
45
NOZF
2
178
4.
2.
-2°F to 20°F
-20°C bis -7°C
1 1/2
48
NOZE
3
182
1 1/4
45
NOZF
3
180
1 1/2
45
NOZF
2
178
1 3/4
45
NOZG
2
175
1 3/4
42
NOZH
2
172
42°F to 60°F
6°C bis 15°C
AS
= Air screw open from fully-seated
IJ
= Idling jet
POS = Clip position from top
MJ
= Main jet
Slide = 6,5
Atomizer= 5 mm
1 1/4
48
NOZD
4
185
1
48
NOZE
4
182
1 1/4
45
NOZF
3
180
1 3/4
45
NOZF
2
178
1 3/4
45
NOZG
2
175
19°F to 41°F
-6°C bis 5°C
1 1/2
45
NOZF
2
178
1 3/4
45
NOZG
2
175
1 3/4
42
NOZH
2
172
2
42
NOZH
1
170
2
42
NOZI
1
168
79°F to 98°F
25°C bis 38°C
1 3/4
45
NOZG
2
175
1 3/4
42
NOZH
2
172
2
42
NOZH
1
170
2
42
NOZI
1
168
1 3/4
40
NOZI
1
165
99°F to 120°F
37°C bis 49°C
NICHT FÜR STRASSENBETRIEB
Kraftstoff: Euro-Super bleifrei ROZ 95
NOT FOR HIGHWAY USE
Fuel: Euro-Super unleaded ROZ 95
1 1/4
45
NOZF
3
180
1 1/2
45
NOZF
3
178
1 3/4
45
NOZG
2
175
1 3/4
42
NOZH
2
172
2
42
NOZH
1
170
61°F to 78°F
16°C bis 24°C
KTM 200 MXC/EXC EUR/USA 2002 KEIHIN PWK 38 AG
TEMPERATUR
750 m
2500 ft
751 m
2501 ft
1500 m
5000 ft
1501 m
5001 ft
2300 m
7500 ft
2301 m
7501 ft
3000 m
10000 ft
ALTIDUDE
MEERESHÖHE
VERGASERREGULIERUNG
CARBURETOR SETTING
Repair manual KTM 125 / 200
9-32C
LSCHR
LD
NADEL
POS
HD
LSCHR
LD
NADEL
POS
HD
LSCHR
LD
NADEL
POS
HD
LSCHR
LD
NADEL
POS
HD
2300 m
7500 ft
1500 m
5000 ft
750 m
2500 ft
300 m
1000 ft
AS
IJ
NEEDLE
POS
MJ
AS
IJ
NEEDLE
POS
MJ
AS
IJ
NEEDLE
POS
MJ
AS
IJ
NEEDLE
POS
MJ
AS
IJ
NEEDLE
POS
MJ
LSCHR = Luftregulierschraube offen
LD
= Leerlaufdüse
POS
= Clip Position von oben
HD
= Hauptdüse
Schieber= 5,5
Zerstäuber= 6 mm
Meeresniveau
Sea level
301 m
1001 ft
751 m
2501 ft
1501 m
5001 ft
2301 m
7501 ft
LSCHR
LD
NADEL
POS
HD
5.
3.
1.
1/2
55
R1468D
5
195
3/4
52
R1468D
4
192
1
50
R1468D
3
190
1 1/4
48
R1469D
3
188
1 1/2
45
R1469D
2
185
4.
2.
-2°F to 20°F
-20°C bis -7°C
1
50
R1469D
3
190
1 1/4
48
R1469D
3
188
1 1/2
45
R1469D
2
185
1 3/4
42
R1470D
3
182
2
40
R1470D
2
180
42°F to 60°F
6°C bis 15°C
1 1/2
45
R141469D
2
185
1 3/4
42
R1470D
2
182
2
40
R1470D
2
180
2 1/4
38
R1470D
2
178
2 1/2
38
R1471D
1
175
79°F to 98°F
25°C bis 38°C
1 3/4
42
R1470D
2
182
2
40
R1470D
2
180
2 1/4
38
R1470D
2
178
2 1/2
38
R1471D
1
175
2 3/4
38
R1471D
1
172
99°F to 120°F
37°C bis 49°C
NICHT FÜR STRASSENBETRIEB
Kraftstoff: Euro-Super bleifrei ROZ 95
NOT FOR HIGHWAY USE
Fuel: Euro-Super unleaded ROZ 95
1 1/4
48
R1469D
3
188
1 1/2
45
R1469D
3
185
1 3/4
42
R1470D
2
182
2
40
R1470D
2
180
2 1/4
38
R1470D
2
178
61°F to 78°F
16°C bis 24°C
AS = Air screw open from fully-seated
IJ
= Idling jet
POS = Clip position from top
MJ = Main jet
Slide = 5,5
Atomizer = 6 mm
3/4
52
R1468D
4
192
1
50
R1468D
3
190
1 1/4
48
R1469D
3
188
1 1/2
45
R1469D
2
185
1 3/4
42
R1470D
3
182
19°F to 41°F
-6°C bis 5°C
KTM 125 SX EUROPA / USA 2003 KEIHIN PWK 39
TEMPERATUR
3000 m
10000 ft
ALTIDUDE
MEERESHÖHE
VERGASERREGULIERUNG
CARBURETOR SETTING
9-33C
LSCHR
LD
NADEL
POS
HD
LSCHR
LD
NADEL
POS
HD
LSCHR
LD
NADEL
POS
HD
LSCHR
LD
NADEL
POS
HD
2300 m
7500 ft
1500 m
5000 ft
750 m
2500 ft
300 m
1000 ft
AS
IJ
NEEDLE
POS
MJ
AS
IJ
NEEDLE
POS
MJ
AS
IJ
NEEDLE
POS
MJ
AS
IJ
NEEDLE
POS
MJ
AS
IJ
NEEDLE
POS
MJ
LSCHR = Luftregulierschraube offen
LD
= Leerlaufdüse
POS
= Clip Position von oben
HD
= Hauptdüse
Schieber= 6,5
Zerstäuber= 5 mm
Meeresniveau
Sea level
301 m
1001 ft
751 m
2501 ft
1501 m
5001 ft
2301 m
7501 ft
LSCHR
LD
NADEL
POS
HD
Art No 3.206.005 -E
5.
3.
1.
1/2
55
NOZC
5
190
3/4
52
NOZD
4
188
1
50
NOZD
4
185
1 1/4
48
NOZD
4
182
1 1/2
45
NOZE
3
180
4.
2.
-2°F to 20°F
-20°C bis -7°C
1
50
NOZD
4
185
1 1/4
48
NOZE
3
182
1 1/2
45
NOZE
3
180
1 3/4
42
NOZE
3
178
2
40
NOZE
2
175
42°F to 60°F
6°C bis 15°C
1 1/2
45
NOZE
3
180
1 3/4
42
NOZE
2
178
2
40
NOZE
2
175
2 1/4
38
NOZF
1
172
2 1/2
35
NOZF
1
170
79°F to 98°F
25°C bis 38°C
1 3/4
42
NOZF
2
178
2
40
NOZF
2
175
2 1/4
38
NOZF
1
172
2 1/2
35
NOZF
1
170
2 3/4
32
NOZG
1
168
99°F to 120°F
37°C bis 49°C
NICHT FÜR STRASSENBETRIEB
Kraftstoff: Euro-Super bleifrei ROZ 95
NOT FOR HIGHWAY USE
Fuel: Euro-Super unleaded ROZ 95
1 1/4
48
NOZE
3
182
1 1/2
45
NOZE
3
180
1 3/4
42
NOZE
2
178
2
40
NOZF
2
175
2 1/4
38
NOZF
1
172
61°F to 78°F
16°C bis 24°C
AS = Air screw open from fully-seated
IJ
= Idling jet
POS = Clip position from top
MJ = Main jet
Slide = 6,5
Atomizer= 5 mm
3/4
52
NOZD
4
188
1
50
NOZD
4
185
1 1/4
48
NOZD
4
182
1 1/2
45
NOZE
3
180
1 3/4
42
NOZE
3
178
19°F to 41°F
-6°C bis 5°C
KTM 125 EXC EUR 2003 KEIHIN PWK 38 AG
TEMPERATUR
3000 m
10000 ft
ALTIDUDE
MEERESHÖHE
VERGASERREGULIERUNG
CARBURETOR SETTING
Repair manual KTM 125 / 200
9-34C
LSCHR
LD
NADEL
POS
HD
LSCHR
LD
NADEL
POS
HD
LSCHR
LD
NADEL
POS
HD
LSCHR
LD
NADEL
POS
HD
2300 m
7500 ft
1500 m
5000 ft
750 m
2500 ft
300 m
1000 ft
AS
IJ
NEEDLE
POS
MJ
AS
IJ
NEEDLE
POS
MJ
AS
IJ
NEEDLE
POS
MJ
AS
IJ
NEEDLE
POS
MJ
AS
IJ
NEEDLE
POS
MJ
LSCHR = Luftregulierschraube offen
LD
= Leerlaufdüse
POS
= Clip Position von oben
HD
= Hauptdüse
Schieber= 5,5
Zerstäuber= 6 mm
Meeresniveau
Sea level
301 m
1001 ft
751 m
2501 ft
1501 m
5001 ft
2301 m
7501 ft
LSCHR
LD
NADEL
POS
HD
5.
3.
1.
1/2
58
R1466G
5
200
3/4
55
R1467G
4
198
1
52
R1467G
3
195
1 1/4
50
R1468G
3
192
1 1/2
48
R1468G
2
190
4.
2.
-2°F to 20°F
-20°C bis -7°C
1
52
R1468G
3
195
1 1/4
50
R1468G
3
192
1 1/2
48
R1468G
2
190
1 3/4
45
R1469G
3
188
2
42
R1469G
2
185
42°F to 60°F
6°C bis 15°C
1 1/2
48
R1468G
2
190
1 3/4
45
R1469G
2
188
2
42
R1469G
2
185
2 1/4
40
R1469G
2
182
2 1/2
40
R1470G
1
180
79°F to 98°F
25°C bis 38°C
1 3/4
45
R1469G
2
188
2
42
R1469G
2
185
2 1/4
4
1469G
2
182
2 1/2
38
R1470G
1
180
2 3/4
38
R1470G
1
178
99°F to 120°F
37°C bis 49°C
NICHT FÜR STRASSENBETRIEB
Kraftstoff: Euro-Super bleifrei ROZ 95
NOT FOR HIGHWAY USE
Fuel: Euro-Super unleaded ROZ 95
1 1/4
50
R1468G
3
192
1 1/2
48
R1468G
3
190
1 3/4
45
R1469G
2
188
2
42
R1469G
2
185
2 1/4
40
R1469G
2
182
61°F to 78°F
16°C bis 24°C
AS = Air screw open from fully-seated
IJ
= Idling jet
POS = Clip position from top
MJ = Main jet
Slide = 5,5
Atomizer= 6 mm
3/4
55
R1467G
4
198
1
52
R1467G
3
195
1 1/4
50
R1468G
3
192
1 1/2
48
R1468G
2
190
1 3/4
45
R1469G
3
188
19°F to 41°F
-6°C bis 5°C
KTM 200 SX EUROPA / USA 2003 KEIHIN PWK 39 AG
TEMPERATUR
3000 m
10000 ft
ALTIDUDE
MEERESHÖHE
VERGASERREGULIERUNG
CARBURETOR SETTING
9-35C
LSCHR
LD
NADEL
POS
HD
300 m
1000 ft
AS
IJ
NEEDLE
POS
MJ
AS
IJ
NEEDLE
POS
MJ
AS
IJ
NEEDLE
POS
MJ
AS
IJ
NEEDLE
POS
MJ
AS
IJ
NEEDLE
POS
MJ
LSCHR = Luftregulierschraube offen
LD
= Leerlaufdüse
POS
= Clip Position von oben
HD
= Hauptdüse
Schieber= 6,5
Zerstäuber= 5 mm
Meeresniveau
Sea level
301 m
1001 ft
LSCHR
LD
NADEL
POS
HD
LSCHR
LD
NADEL
POS
HD
LSCHR
LD
NADEL
POS
HD
LSCHR
LD
NADEL
POS
HD
Art No 3.206.005 -E
5.
3.
1.
1
50
NOZC
5
188
1 1/4
48
NOZD
4
185
1 1/2
48
NOZD
3
182
1 1/4
45
NOZE
3
180
1 3/4
45
NOZE
2
178
4.
2.
-2°F to 20°F
-20°C bis -7°C
1 1/2
48
NOZD
3
182
1 1/4
45
NOZE
3
180
1 1/2
45
NOZE
2
178
1 3/4
45
NOZF
2
175
1 3/4
42
N0ZG
2
172
42°F to 60°F
6°C bis 15°C
1 1/2
45
NOZE
2
178
1 3/4
45
NOZF
2
175
1 3/4
42
NOZG
2
172
2
42
NOZG
1
170
2
42
NOZH
1
168
79°F to 98°F
25°C bis 38°C
1 3/4
45
NOZG
2
175
1 3/4
42
NOZG
2
172
2
42
NOZG
1
170
2
42
NOZH
1
168
1 3/4
40
NOZH
1
165
99°F to 120°F
37°C bis 49°C
NICHT FÜR STRASSENBETRIEB
Kraftstoff: Euro-Super bleifrei ROZ 95
NOT FOR HIGHWAY USE
Fuel: Euro-Super unleaded ROZ 95
1 1/4
45
NOZE
3
180
1 1/2
45
NOZE
3
178
1 3/4
45
NOZF
2
175
1 3/4
42
NOZG
2
172
2
42
NOZG
1
170
61°F to 78°F
16°C bis 24°C
AS = Air screw open from fully-seated
IJ
= Idling jet
POS = Clip position from top
MJ = Main jet
Slide = 6,5
Atomizer= 5 mm
1 1/4
48
NOZD
4
185
1
48
NOZD
4
182
1 1/4
45
NOZE
3
180
1 3/4
45
NOZE
2
178
1 3/4
45
NOZF
2
175
19°F to 41°F
-6°C bis 5°C
KTM 200 MXC/EXC EUR/USA 2003 KEIHIN PWK 38 AG
TEMPERATUR
750 m
2500 ft
751 m
2501 ft
1500 m
5000 ft
1501 m
5001 ft
2300 m
7500 ft
2301 m
7501 ft
3000 m
10000 ft
ALTIDUDE
MEERESHÖHE
VERGASERREGULIERUNG
CARBURETOR SETTING
Repair manual KTM 125 / 200
9-36C
10-1C
LUBRICATION AND MAINTENANCE SCHEDULE 10
INDEX
Repair manual 125 / 200
Art No 3.206.005-E
LUBRICATION AND MAINTENANCE SCHEDULE
125 / 200 UP TO 2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-2
125 / 200 SX, MXC, EXC 2001 / 2002 . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-3
125 EXE, SUPERMOTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-5
125 / 200 SX, MXC, EXC 2003 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-7
10-2C
Repair manual KTM 125 / 200
Art No 3.206.005 -E
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at least
once a year
after 4000 km
(2500 miles) or once a year
Check transmission oil level
Change transmission oil
Check spark plug and electrode gap
Change spark plug
Functional testing of the exhaust control system
Check intake manifold for leaks and cracks
Drain and clean carburetor float chamber
Adjust idling
Check breather hoses of engine case and gas tank for correct position without buckles
Clean and check airfilter element, box and carburetor connection boot
Check chain, sprockets, guides and chain wear
Clean and lubricate chain
Check chain tension
Check coolant level
Check quality of antifreeze
Check cooling system for leaks - visual inspection
Check exhaust system for cracks and leaks
Replace glass fiber yarn of silencer
Check of the exhaust suspension system
Check brake fluid level front and rear
Change brake fluid
Check thickness of disc brake pads
Check brake discs
Inspect condition and installation of front and rear brake hoses
Check free travel and free movability of hand brake lever and foot brake lever
Check the oil level in the master cylinder of the hydraulic clutch
Change the oil of the hydraulic clutch
Check telescopic fork action
Check telescopic fork for leaks
Push up the protective bellows and remove the dirt; the drain holes must be free of obstructions (Marzocchi fork)
Clean the dust scrabbers of the telescopic force (WP Extreme fork)
Undo the bleeder screws at the fork legs
Change oil of telescopic fork
Service telescopic fork completely
Check steering head bearing free play
Clean and regrease steering head bearing
Check setting and damping of shock absorber
Service shock absorber completely
Grease swingarm needle bearings (don’t grease the pivot bearing for the shock absorber)
Check for even spoke tension and rim alignment
Check wheel bearings
Check tires for cuts and air pressure
Check cables for damage and free movement
Adjust and oil control cables
Check electrical system
Check battery holder and connections (CH, Singapore)
Check adjustment of headlight
Apply contact spray to light switches, flasher switches and ignition lock
Check all bolts, nuts, bolts and clamps for proper tightness
Clean and lubricate control lever pivot points
after washing
AT A REGULAR COMPETITION USE OF THE BIKE, THE 4000 KM (2500
MILES) SERVICE IS TO BE DONE AFTER EVERY RACE
before each start
125-200 6.98
after 2000 km
(1250 miles) or 20 hours
KTM
dealer
1st service after 1000 km
(600 miles) or 10 hours
KTM
rider
PERIODIC LUBRICATION AND MAINTENANCE SCHEDULE
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10-3C
PERIODIC MAINTENANCE SCHEDULE 2001/02
WHEELS
CHASSIS
BRAKES
ADD-ON-PARTS
CARBURETOR
ENGINE
A washed motorcycle can be checked more quickly which saves money!
Check gear box oil level
Change gear box oil
Check spark plugs, adjust distance between electrodes
Renew spark plugs
Check the carburettor connection boot for cracks and leaks
Check idle speed setting
Check that vent hoses are not damaged or bent
Check cooling system for leaks, check quantity of anti freeze
Check exhaust system for leaks and fitment
Check cables for damage, smooth operation, bends; adjust and lubricate
Check oil level of the clutch master cylinder
Clean air filter and filter box
Check electric wires for damage and bends
Check headlamp setting
Check function of electric systems (low-, high beam, brake light, indicator,
indicator lamps, speedometer illumination, horn, emergency OFF switch or button
Check brake fluid level, lining thickness, brake lining
Check brake lines for damage and leaks
Check/adjust smooth operation and free travel of handbrake/foot brake lever
Check tightness of brake system bolts
Check shock absorber and fork for leaks and function
Clean dust bellows
Bleed fork legs
Check swing arm bearings
Check/adjust steering head bearings
Check tightness of all chassis bolts (triple clamps, fork leg axle passage
axle nuts and bolts, swing arm bearings, shock absorber)
Check spoke tension and rim join
Check tyres and air pressure
Check chain, rear sprockets and chain guides for wear, fitment and tension
Lubricate chain
Check clearance of wheel bearings
IMPORTANT RECOMMENDED MAINTENANCE WORK
Check function of exhaust control
Complete maintenance of shock absorber
Complete maintenance of fork
Clean and grease steering head bearings and gasket elements
Clean and adjust carburetor
Replace glass fibre yarn filling of the exhaust main silencer
Treat electric contacts and switches with contact grease
Change hydraulic clutch fluid
Change brake fluid
125/200 SX/MXC/EXC
1. service after
after
after
10 hours
4000 kilometer
20 hours
or
or
or
1000 kilometer 2000 kilometer once a year
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THAT CAN BE CARRIED OUT BY EXTRA ORDER
at least
once a year
●
●
every 2 years
or 20000 km
●
●
●
●
●
●
●
IF MOTORCYCLE IS USED FOR COMPETITION 4000KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE!
SERVICE INTERVALLS SHOULD NEVER BE EXCEED BY MORE THAN 5 HOURS OR 500 KM!
MAINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE OF CARE AND CHECKS DONE BY THE RIDER!
10-4C
CARRIED
OUT BY THE
Repair manual KTM 125 / 200
Art No 3.206.005 -E
Check gear box oil level
Check brake fluid level
Check brake pads for wear
Check lights for function
Check horn for function
Lubricate and adjust cables and nipples
Bleed fork legs regulary
Remove and clean dust bellows regulary
Clean and lubricate chain, check tension and adjust if necessary
Clean air filter and filter box
Check tires for pressure and wear
Check cooling liquid level
Check fuel lines for leaks
Empty and clean float chamber
Check all control elements for smooth operation
Check brake performance
Treat blank metal parts (with the exception of brake and exhaust systems)
with wax-based anti corrosion agent
Treat ignition and steering locks and light switches with contact spray
Check tightness of bolts, nuts and hose clamps regular
RIDER
Once a year
TO BE
For crosscountry use
MAINTENANCE
After every
cleaning
AND
Before each
start
IMPORTANT CHECKS
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
10-5C
125 EXE
125 SUPERMOTO
every
1. Service after 2. Service after
4000 km
1000 km
or
4000 km
once a year
PERIODIC MAINTENANCE SCHEDULE
WHEELS
CHASSIS
BRAKES
ADD-ON-PARTS
CARBURATOR ENGINE
A washed motorcycle can be checked more quickly which saves money!
Check oil level in oil tank and verify kink-less arrangement of bleeder hose
Change transmission oil
Check spark plug, set electrode gap, replace plug if necessary
Check carburetor connection boots for cracks and leaks
Check idle setting and emission values
Check bleeder hoses for damage and kink-free arrangement
Check cooling system for leaks, antifreeze protection
Check exhaust system for leaks and suspension
Check actuating cables for damage, smooth operation, and kink-less arrangement,
and adjust and lubricate
Check oil level in master cylinder of hydraulic clutch
Clean air filter and air filter box
Check cables for damage and kink-less arrangement
Check headlamp adjustment
Check electrical system for proper operation
(low/high beams, stop light, turn indicators, tell-tale lamps,
speedometer illumination, horn, battery holder, and connections)
Check brake fluid level, lining thickness, and brake discs
Check brake lines for damage and leaks
Check/adjust smooth operation, free travel of handbrake/footbrake levers
Check bolts of brake system for tight fit
Check suspension strut and fork for leaks and proper function
Clean dust sleeves
Bleed fork legs
Check swinging-fork pivot
Check/adjust steering-head bearing
Check all chassis bolts for tight fit (fork plates, fork leg, axle nuts/bolts,
swinging-fork pivot, suspension strut)
Check spoke tension and rim join
Check tire condition and inflation pressure
Check chain, chain wheels, chain wheel guides for wear, tight fit, and tension
Lubricate chain
Check wheel bearings for play
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IMPORTANT RECOMMENDED MAINTENANCE PROCEDURES TO BE PERFORMED BASED ON A SEPARATE SUPPLEMENTARY ORDER
Verify proper function of exhaust control
Perform complete fork maintenance
Perform complete suspension strut maintenance
Clean and lubricate the steering-head bearing and sealing elements
Clean and adjust the carburetor
Replace the glass-fiber yarn packing of the main silencer
Treat the electrical contacts and switches with contact spray
Replace the oil of the hydraulic clutch
Replace the brake fluid
SERVICE INTERVALLS SHOULD NEVER
MAINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS
at least
once a year
●
every 2 year
or 20000 km
●
●
●
●
●
●
●
●
BE EXCEED BY MORE THAN 500 KM!
IS NOT A SUBSTITUTE OF CARE AND CHECKS DONE BY THE RIDER!
10-6C
CARRIED
OUT BY THE
Art No 3.206.005 -E
Repair manual KTM 125 / 200
Check oil level in oil tank and bleeder hose for its kink-less arrangement
Check transmission oil level
Check brake fluid level
Check brake pads for wear
Check lighting system for proper operation
Check horn for proper operation
Lubricate and adjust actuating cables and nipples
Bleed fork legs in regular intervals
Remove and clean dust sleeves in regular intervals
Clean and lubricate chain, check tension and readjust it if necessary
Clean air filter and filter box
Check tire inflation pressure and wear
Check coolant level
Check fuel lines for leaks
Drain and clean float chamber
Verify smooth operation of all controls
Check brake performance
Treat exposed metal components (except for brake and exhaust systems) with
wax-based anti-corrosion agents
Treat ignition/steering lock and light switch with contact spray
Check all bolts, nuts, and hose clamps for their tight fit in regular intervals
RIDER
Once a year
TO BE
For crosscountry use
MAINTENANCE
After every
cleaning
AND
Before each
start
IMPORTANT CHECKS
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
10-7C
PERIODIC MAINTENANCE SCHEDULE 2003
WHEELS
CHASSIS
BRAKES
ADD-ON-PARTS
CARBURETOR
ENGINE
A clean motorcycle can be checked more quickly which saves money!
Check gear box oil level
Change gear box oil
Check spark plugs, adjust distance between electrodes
Renew spark plugs
Check the carburetor connection boot for cracks and leaks
Check idle speed setting
Check that vent hoses are not damaged or bent
Check cooling system for leaks, check quantity of antifreeze
Check exhaust system for leaks and fitment
Check cables for damage, smooth operation, bends; adjust and lubricate
Check oil level of the clutch master cylinder
Clean air filter and filter box
Check electric wires for damage and bends
Check headlamp setting
Check function of electric systems (low beam, high beam, brake light, indicator,
indicator lamps, speedometer illumination, horn, emergency OFF switch or button
Check brake fluid level, lining thickness, brake lining
Check brake lines for damage and leaks
Check/adjust smooth operation and free travel of handbrake/foot brake lever
Check tightness of brake system bolts
Check shock absorber and fork for leaks and function
Clean dust bellows
Bleed fork legs
Check swing arm bearings
Check/adjust steering head bearings
Check tightness of all chassis bolts (triple clamps, fork leg axle passage
axle nuts and bolts, swing arm bearings, shock absorber)
Check spoke tension and rim joint
Check tires and air pressure
Check chain, rear sprockets and chain guides for wear, fitment and tension
Lubricate chain
Check clearance of wheel bearings
IMPORTANT RECOMMENDED MAINTENANCE WORK
Check function of exhaust control
Complete maintenance of shock absorber
Complete maintenance of fork
Clean and grease steering head bearings and gasket elements
Clean and adjust carburetor
Replace glass fibre- yarn filling of the exhaust main silencer
Treat electric contacts and switches with contact grease
Change hydraulic clutch fluid
Change brake fluid
125/200 SX/MXC/EXC
1st service
after
after
after 10 hours
4000 kilometer
20 hours
or
or
or
1000 kilometers 2000 kilometers once a year
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●
●
THAT CAN BE CARRIED OUT BY EXTRA ORDER
at least
once a year
●
●
every 2 years
or 20000 km
●
●
●
●
●
●
●
IF MOTORCYCLE IS USED FOR COMPETITION 4000KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE!
SERVICE INTERVALS SHOULD NEVER BE EXCEEDED BY MORE THAN 5 HOURS OR 500 KM!
MAINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE FOR CARE AND CHECKS DONE BY THE RIDER!
10-8C
CARRIED
OUT BY THE
Repair manual KTM 125 / 200
Art No 3.206.005 -E
Check gear box oil level
Check brake fluid level
Check brake pads for wear
Check lights for function
Check horn for function
Lubricate and adjust cables and nipples
Bleed fork legs regulary
Remove and clean dust bellows regularly
Clean and lubricate chain, check tension and adjust if necessary
Clean air filter and filter box
Check tires for pressure and wear
Check cooling liquid level
Check fuel lines for leaks
Empty and clean float chamber
Check all control elements for smooth operation
Check brake performance
Treat blank metal parts (with the exception of brake and exhaust systems)
with wax-based anti corrosion agent
Treat ignition and steering locks and light switches with contact spray
Check tightness of bolts, nuts and hose clamps regularly
RIDER
Once a year
TO BE
For crosscountry use
MAINTENANCE
After every
cleaning
AND
Before each
start
IMPORTANT CHECKS
●
●
●
●
●
●
●
●
●
●
●
●
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●
10-9C
RECOMMENDED INSPECTION OF THE 125/200 SX, MXC AND EXC ENGINE
USED FOR ENDURO COMPETITIONS BY THE KTM WORKSHOP
(ADDITIONAL ORDER FOR THE KTM WORKSHOP)
Check the reed-type intake valve for wear
Check the clutch shoes for wear
Check the length of the clutch springs
Check the cylinder and piston for wear
Check the exhaust control for proper functioning and smooth running
Check the eccentricity of the crankshaft journal
Check the radial clearance of the conrod bearings
Check the radial clearance of the piston pin main bearing
Check the crankshaft main bearing for wear
Replace the crankshaft bearings and conrod bearings
Check the entire transmission including roller and bearings for wear
30
hours
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45
hours
●
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60
hours
●
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●
90
hours
●
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●
120
hours
●
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●
●
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●
135
hours
●
●
●
●
●
●
●
●
RECOMMENDED INSPECTION OF THE 125/200 SX, MXC AND EXC ENGINE
USED FOR HOBBY- ENDURO BY THE KTM WORKSHOP
(ADDITIONAL ORDER FOR THE KTM WORKSHOP)
Check the reed-type intake valve for wear
Check the clutch shoes for wear
Check the length of the clutch springs
Check the cylinder and piston for wear
Check the exhaust control for proper functioning and smooth running
Check the eccentricity of the crankshaft journal
Check the radial clearance of the conrod bearings
Check the radial clearance of the piston pin main bearing
Check the crankshaft main bearing for wear
Replace the crankshaft bearings and conrod bearings
Check the entire transmission including roller and bearings for wear
60
hours
90
hours
120
hours
180
hours
240
hours
270
hours
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NOTE: IF THE INSPECTION ESTABLISHES THAT PERMISSIBLE TOLERANCES ARE EXCEEDED, THE RESPECTIVE COMPONENTS MUST BE REPLACED.
●
●
11-1C
WIRING DIAGRAMS
INDEX
WIRING DIAGRAMS 1999
125/200 EXC (EUROPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-2
125/200 EGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-3
125 EXC (USA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5
200 EXC (USA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
Art No 3.206.005-E
WIRING DIAGRAMS 2000
125/200 EXC (USA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-8
125/200 EXC (EUROPA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-9
125 EXE, SUPERMOTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-11
WIRING DIAGRAMS 2001
125/200 EXC (EUROPA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-13
125/200 EXC (USA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-15
125 EXE, SUPERMOTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-11
WIRING DIAGRAMS 2002
125/200 EXC (EUROPA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-13
125/200 EXC (USA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-15
Repair manual 125 / 200
WIRING DIAGRAMS 2003
125/200 EXC (EUROPA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-16
125/200 EXC (USA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-18
11
Repair manual KTM 125 / 200
Art No 3.206.005 -E
11-2C
11-3C
Repair manual KTM 125 / 200
Art No 3.206.005 -E
11-4C
11-5C
Repair manual KTM 125 / 200
Art No 3.206.005 -E
11-6C
SPORTMOTORCYCLES
Repair manual KTM 125 / 200
Art No 3.206.005 -E
11-8C
11-9C
SPORTMOTORCYCLES
Repair manual KTM 125 / 200
Art No 3.206.005 -E
11-10C
11-11C
ge-bl
r
v
s
o
27
s
4
ge-bl
8
br
7
5
v
s
br
6
br
g
bl
ge-bl
br
2
22.11.99 Hasl.
13
1
ge-bl
br
g
bl
s-ge
ge-r
ge-bl
br
v
r-w
g
o
bl
3
Datum, Name:
Europa
br
19
9
ge-s
ge-bl
br
SPORTMOTORCYCLES
Land:
Kabelstrangnummer:
vorne:512.11.075.000
hinten:503.14.040.100
125 EXE 2000/2001
125 Super Moto 2000/2001
Modell:
bl
SERVICE
o
ge-bl
14
23
g
bl
ge
10 r
br
w
s-ge
g
bl
ge
r
br
ge-bl
11
g-w
s-ge
17
16
ge-s
br
bl-w
s-w
28
KOKUSAN
2K3
s-w
bl-w
15
s-ge
s-r
r-w
o
r
g
w
ge
G
18
30
20
ge-r
g-w
w
12
ge-bl
br
br
21
br
54
58
25
26
br
31
24
29
s
br
g-w
w
v
br
g-w
ge-bl
8
s
22
ge-r
br
v
s
ge-r
br
v
s
ge
11-12C
KTM 125 EXE 2000/2001, 125 SUPERMOTO 2000/2001
Art No 3.206.005 -E
Deutsch
1 Scheinwerfer
2 Standlicht
3 Blinker li vo
4 Blinker re vo
5 Tachobeleuchtung
6 Fernlichtkontrolle
7 Blinkerkontrolle
8 4-pol.Stecker
9 Zündschloss
10 zum Kombischalter
11 Bremslichtsch. vo
12 Bremslichtsch. hi
13 Horn
14 Blinkgeber
15 CDI-Einheit
16 Zündkerze
17 Zündspule
18 Generator
19 Ölkontrolleuchte
20 Spannungsregler
21 Batterie 3Ah
22 Stecksicherung 10A
23 6-pol.Stecker
24 Blinker li hi
25 Blinker re hi
26 Brems-Schlusslicht
27 Blinkerschalter
28 Ölstandgeber
29 3-pol. Stecker
30 kontaktstift 3.Gang
Deutsch
Englisch
bl blau
br braun
ge gelb
gr grau
g grün
o orange
r rot
s schwarz
v violett
w weiss
bl blue
br brown
ge yellow
gr grey
g green
o orange
r red
s black
v violet
w white
Englisch
Italienisch
Französisch
1 headlight
2 parking light
3 turn indic.left fr.
4 turn indic.right fr.
5 speedometer light
6 high beam indicator
7 turn indicator
8 multip.cont.plug (4)
9 ignition lock
10 to combinat. switch
11 stoplight switch f.
12 stoplight switch r.
13 horn
14 turn indicator
15 CDI-unit
16 spark plug
17 ignition coil
18 generator
19 oil level tell tale
20 voltage regulator
21 battery 3Ah
22 fuse 10A
23 multip.cont.plug (6)
24 blinker left rear
25 blinker right rear
26 rear-stoplight
27 blink switch
28 oil level sensor
29 multip.cont.plug (3)
30 gear switch 3.gear
1 faro
2 luce di posizione
3 lampegg.ant.sn.
4 lampegg.ant.dx.
5 luce di tachimetro
6 spia abbagliante
7 spia lampeggiatori
8 connettore a 4 poli
9 accensione
10 multicomando
11 int.luce arresto ant
12 int.luce arresto post
13 clacson
14 trasmett. di lampeg.
15 CDI-seatola
16 candela
17 bobina d'accens.
18 dinamo
19 contr.d.liv.d'olio
20 regol. di tens.
21 batteria 3Ah
22 fusibile 10A
23 connettore a 6 poli
24 lampegg.post.sn
25 lampegg.post.dx.
26 fanal.post.di freno
27 int. lampeggiatori
28 liv.d'olio transmet.
29 connettore a 3 poli
30 secondo marcia
1 phare
2 feu de position
3 clignoteur av gauche
4 clignoteur av.droit
5 eclair.comp.vitesse
6 temoin feu route
7 temoin de clignoteur
8 connect.multiple (4)
9 contact.d'allum.
10 commodo
11 contact de stop av.
12 contact Harr.de stop
13 klaxon
14 centrale clignot.
15 boitier CDI
16 bougie
17 bobine d'allumage
18 generateur
19 contr.de niv d huile
20 regulateur
21 batterie 3Ah
22 fusible 10A
23 connect.multiple (6)
24 clign.arr.gauche
25 clign.arr.droite
26 feu arr.et de stop
27 contact.d.clignoteur
28 niv.d'huile transmet
29 connect.multiple (3)
30 cont.d.boite d.vites
Italienisch
Französisch
bl blu
br marrone
ge giallo
gr grigio
g verde
o arancione
r rosso
s nero
v violetto
w bianco
bl bleu
br brun
ge jaune
gr gris
g vert
o orange
r rouge
s noir
v violet
w blanc
Zündschloss
ZADI (503.11.065.000)
rbl w gr o
s
Repair manual KTM 125 / 200
aus
Kontaktbelegung Lichtschalter (Typ CEV 9610)
ge w s/ r
ge
LICHT
Abblendl.
Fernlicht
HUPE
ZÜNDUNG AUS
5
2
1
3
6
4
bl azul
br marron
ge amarillo
gr gris
g verde
o naranja
r rojo
s negro
v violeta
w blanco
Blinkerschalter
ein
g bl
Spanisch
br
o
v
Spanisch
1 faro
2 luz de posicion
3 interm. izquierdo delantero
4 intermitente derecho delantero
5 luz tacometro
6 lampara aviso luces largas
7 lampara aviso intermitentes
8 conector multiple (4)
9 llave de contacto
10 interruptor combinado
11 interr. luz de freno del.
12 interr. luz. de fren tras.
13 claxon
14 conjunto del intermintente
15 unidad cdi
16 bujia
17 bobina de encendido
18 generador
19 contr.del nivel del aceite
20 regulador de tension
21 bateria 12V 3Ah
22 fusible principal 10A
23 conector multiple (6)
24 intermitente izquierdo trasero
25 intermitente derecho trasero
26 luz de freno trasero
27 interuptor clignoteur
28 sensor.del nivel del aceite
29 conector multiple (3)
30 interruptor de cambio (3)
11-13C
125-200 EXC 2001/2002
Repair manual KTM 125 / 200
Art No 3.206.005 -E
11-14C
KTM 125-200 EXC 2001/2002
Art No 3.206.005 -E
KTM 125/200 EXC 2001/2002
Repair manual KTM 125 / 200
11-15C
11-16C
125-200 EXC 2003
Repair manual KTM 125 / 200
Art No 3.206.005 -E
11-17C
KTM 125-200 EXC 2003
125/200 EXC 2003
11-18C

Accompanying Data:

KTM 125 EXC Engine, Motorcycle PDF Owner’s Manual (Updated: Friday 28th of April 2023 08:08:59 AM)

Rating: 4.1 (rated by 92 users)

Compatible devices: 85 SX 2018, 690 Enduro R 2017, 125 EXC EU 2010, 450 SX-F EU, 690 SMC USA 2010, 690 Supermoto Limited Edition EU 2009, Freeride E-XC 2019, 2011 990 Supermoto T USA.

Recommended Documentation:

Text Version of Owner’s Manual

(Ocr-Read Summary of Contents, UPD: 28 April 2023)

Recommended Instructions:

SP-P410M, A430i, PMA-1500AE, 42 SERIES, imageCLASS MF8170c, Travel Pack #4

Additional Information:

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Operating Impressions, Questions and Answers: