KTM 125 Repair Manual

Repair manual KTM 125 / 200
Art No 3.206.005 -E
Reed valve housing, intake flange and oil pump (separate
lubrication)
– When dismounting the clutch cover 2 additionally remove the bolt
1
– Pull the oil pump wheel A off the oil pump
– 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.
– 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.
Removing clutch and primary drive
– 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.
4-6C
A
B
C
1
2
3
4
A
C
C
E
B
D
B

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)