KTM 125 Repair Manual

Repair manual KTM 125 / 200
Art No 3.206.005 -E
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.
– Dismount the brake cylinder cover.
– Remove the engine sprocket cover and the chain.
– Disconnect the electrical wires.
– 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.
3-2C

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)