KTM 125 Repair Manual

Repair manual KTM 125 / 200
Art No 3.206.005 -E
9-12C
TIGHTENING TORQUES - ENGINE
Flange bolts - cylinder-head M 7 18 Nm (13 ft.lb)
Nuts-cylinder base M 8 30 Nm (22 ft.lb)
Flywheel collar nut M 12x1 60 Nm (44 ft.lb)
Nut for primary sprocket (LH thread) M 16x1.5 180 Nm (133 ft.lb)
Nut for inner clutch hub M 18x1.5 120 Nm (88 ft.lb)
Crankcase and clutch cover bolts M 6 8 Nm (6 ft.lb)
Spark plug M 14x1.25 20 Nm (14 ft.lb)
Other bolts M 6 10 Nm (7 ft.lb)
M 8 25 Nm (19 ft.lb)
M 10 45 Nm (33 ft.lb)
Piston fitting clearance 125 = 0.06 mm 200 = 0.085 mm
Piston ring end cap max. 0.40 mm
Connecting rod bearing - radial clearance 0.025–0.035 mm
Transmission shafts end float 0.20– 0.40 mm
Clutch springs - length new = 39 mm, minimum length = 38 mm
TOLERANCES AND FITTING CLEARANCES
GASKET THICKNESSES
Crankcase 0,5 mm
Clutch cover 0,5 mm
Clutch driving cylinder 0.30 / 0.50 / 0.75 mm
Cylinder bottom gasket as required
Available bottom gasket 0.07 / 0.15 / 0.20 / 0.25 / 0.40 / 0.50 / 0.75 mm
Cylinder-head gasket 1.10 mm + O-ring
BASIC CARBURETOR SETTING
125 SX 125 EXC EU
125 EXC USA
200 MXC/EXC USA
Carburetor
Carburetor setting number
Main jet
Idling jet
Starting jet
Jetneedle
Needle position from top
Throttle valve
Air adjustment screw open
Performance restrictor
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
–
200 EXC AUS
200 EXC SGP
Keihin PWK 38 AG
280200
180 (185)
45 (48)
85
NOZ G (NOZ H)
III
6.5
1,5
slide stop 36mm
Keihin PWK 38 AG
260200
148 (180/185)
35 (45/48)
85
R 1472 N (NOZ G/NOZ H)
IV
6.5
1,5
–
200 EXC EU
Keihin PWK 38 AG
290200
180 (185)
35 (45/48)
85
R 1475 J (NOZ G/NOZ H)
III
6.5
1,5
slide stop 36mm

KTM 125 Specifications

General

Bore x Stroke	54 mm x 54.5 mm
Starter	Kickstarter
Transmission	6-speed
Engine Type	Single-cylinder, 2-stroke
Displacement	124.8 cm³
Cooling System	Liquid cooled
Fuel System	Carburetor
Lubrication	Premix (oil-fuel mixture)