KTM 125 Repair Manual

9-15C
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 = 0.055 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
125 =shapedring + O-ring 200=1.10 mm + O-ring
BASIC CARBURETOR SETTING
125 SX
125 EXC EU
125 EXC AUS
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
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
Keihin PWK 38 AG
051200
180 (178)
35 (45/48)
85
R 1475J (NOZ G/NOZ F)
III
6.5
1,5
slide stop 36mm
Keihin PWK 38 AG
041200
148 (180/185)
35 (45/48)
85
R 1472 N (NOZ G/NOZ F)
V
6.5
1,5
–

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)