KTM 125 Repair Manual

Repair manual KTM 125 / 200
Art No 3.206.005 -E
9-14C
Engine 125 SX 125 EXC 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 / gasolin 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 Dimension "X" 0.0 mm (0.0 in) 0.50 - 0.55 mm (0.22 in) 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 (0,024 in) Dimension "Z" 43 mm (1.67 in) 46 ,5 mm (1.83 in) Primary drive straight cut spur gears, primary ratio 23:73 Clutch multiple disc clutch in oil bath, hydraulic operated (Shell HF-E15) Transmission 6 speed, claw actuated Gear ratio 1st gear 13 : 32 „1S32“ 12 : 33 „1G33“ 13 : 32 „1S32“ 12 : 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 „6S22“ 22 : 24 „6S24“ „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 13t / 14t / 15t 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-3 Generator output no generator 12V / 110 W – 12V 110 W Ignition system USA KOKUSAN 2K-1 KOKUSAN 2K-2 Generator output no generator 12V 40 W Carburetor flat-slide carburetor, carburetor setting see table Air-filter wet foam type air filter insert
200 EXC SEPARATE LUBRICATION
Lubrication Separate lubrication Engine oil Shell Advance Ultra 2 or 2-stroke engine oil for a mixture ratio 1:50 and for separate lubrication Oil tank 1,3 liter (0,34 US Gallons)
(upper edge piston- upper edge cylinder
height of the control flap
TECHNICAL DATA - ENGINE 125 / 200 2002

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)