KTM 125 - Removing and Refitting Engine

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1 SERVICE-INFORMATIONS

2 GENERAL INFORMATION

3 REMOVING AND REFITTING ENGINE

4 DISASSEMBLING THE ENGINE

5 SERVICING INDIVIDUAL COMPONENTS

6 ASSEMBLING THE ENGINE

7 ELECTRICAL

8 TROUBLE SHOOTING

9 TECHNICAL SPECIFICATIONS

10 PERIODIC MAINTENANCE SCHEDULE

11 WIRING DIAGRAMS

Main Page

Removing and Refitting Engine5
Important Information/Updating Instructions7
Explanation - Updating9
General Information15
Idling Range17
Opening up17
Part-Throttle Range17
Full Throttle Range17
Carburetor Adjustment18
Basic Information on Carburetor Wear18
Bleeding of the Hydraulic Clutch19
Check of the Exhaust Control (Engine Running)21
Removing and Refitting Engine23
Removing the Engine25
Installing the Engine26
Fixing the Cables to the Frame - Models with Separate Lubrication27
Dismantling the Engine29
Special Tools - Engine 125/20031
Draining the Gear Oil32
Dismounting the Clutch Slave Cylinder32
Cylinder Head, Cylinder, Piston32
Ignition33
Engine Sprocket33
Reed Valve Housing, Intake Flange and Clutch Cover34
Reed Valve Housing, Intake Flange and Oil Pump (Separate Lubrication)35
Removing Clutch and Primary Drive35
Shift Drum Locating, Kickstarter36
Dividing the Engine Housing37
Removing Shift Mechanism and Transmission38
Removing Crankshaft38
Servicing Individual Components39
Engine Housing39
Right Housing Half41
Left Housing Half42
Crankshaft43
Piston43
Piston Ring End Gap43
Checking Cylinder for Wear44
Nikasil Coating of Cylinder44
Dismounting and Checking the Exhaust Control System in the Cylinder45
Preassembling the Cylinder46
Dismounting the Exhaust Control System in the Clutch Cover, and Checking Parts for Wear49
Preassembling the Clutch Cover49
Disassembling and Checking the Water Pump50
Preassembling the Water Pump50
Checking Clutch for Wear51
Reed Valve Housing, Intake Flange52
Kickstarter53
Preassembling the Kickstarter Shaft53
Shifting Mechanism from Model 2001 on View54
Shifting Mechanism55
Preassembling the Shifting Shaft (up to Model 2000)55
Preassembling the Shifting Shaft (Model 2001 Onwards)55
Transmission56
Assembling the Main Shaft56
Assembling the Countershaft57
Ignition - General Information58
Spark Plug58
Check Stator and Pulse Generator58
Assembling the Engine59
Shift Mechanism59
Mounting the Crankshaft61
Transmission, Shift Mechanism61
Assembling the Engine Housing62
Ignition System62
Engine Sprocket Servicing62
Shift Drum Locating Device63
Kickstarter Servicing64
Clutch Discs, Pressure Cap65
Oil Pump, Reed Valve Housing and Intake Flange (Separate Lubrication)66
Clutch Cover Servicing67
Reed Valve Housing, Intake Flange Servicing67
Piston, Cylinder68
Adjusting Dimension „X“68
Adjusting the Control Flap (Dimension „Z“)69
Cylinder Head Servicing69
Ignition Cover70
Measuring Dimension „Y“70
Mounting the Clutch Slave Cylinder71
Filling in the Gear Oil71
Electrical73
Checking the Voltage Regulator-Rectifier (Shindengen)74
Checking the Voltage Regulator (Kokusan)74
Checking the Capacitor74
Ignition Coil74
CDI Unit75
Static Ignition Values 125-200 SX, MXC, EXC (Kokusan 2K-1, 2K-3)77
Static Generator Values 125-200 EXC (Kokusan 2K-3)79
Static Ignition and Generator Values 1250200 MXC, EXC USA (Kokusan 2K-2)81
Static Ignition Values 125 EXE/125 Supermoto (Kokusal 2K-3)83
Statuc Generator Values 125 EXE/125 Supermoto (Kokusan 2K-3)85
Troubleshooting87
Trouble Shooting89
Technical Specifications91
Technical Data - Engine 125/200 ‘9993
Technical Specifications Chassis 125 SX/EXC/EGS, 200 MXC/EXC/EGS ‘9995
Technical Data - Engine 200 EGS Only Singapore '9996
Technical Data - Engine 125 EXE/125 Supermoto 200097
Technical Specifications Chassis 125 EXE/125 Supermoto 200098
Technical Data - Engine 125/200 200099
Technical Specifications Chassis 125 SX/EXC, 200 MXC/EXC 2000101
Technical Data - Engine 125/200 2001102
Technical Specifications Chassis 125 SX/EXC, 200 MXC/EXC 2001104
Technical Data - Engine 125/200 2002105
Technical Specifications Chassis 125 SX/EXC, 200 MXC/EXC 2002107
Technical Data - Engine 125/200 2003108
Technical Specifications Chassis 125 SX/EXC, 200 SX/MXC/EXC 2003110
Carburetor Setting KTM 125 SX/MXC/EXC USA ‘99 KEIHIN PWK 39112
Carburetor Setting KTM 125 SX/EXC EUROPA ‘99 KEIHIN PWK 39113
Carburetor Setting KTM 200 MXC/EXC EUR. USA ‘99 KEIHIN PWK 39114
Carburetor Setting KTM 125 SX EUROPA/USA 2000 KEIHIN PWK 39115
Carburetor Setting KTM 125 MXC/EXC EUR/USA 2000 KEIHIN PWK 38 AG116
Carburetor Setting KTM 200 MXC/EXC EUR/USA 2000 KEIHIN PWK 38 AG117
Carburetor Setting KTM 125 SX EUROPA/USA 2001 KEIHIN PWK 39118
Carburetor Setting G KTM 125 MXC/EXC EUR/USA 2001 KEIHIN PWK 38 AG119
Carburetor Setting KTM 200 MXC/EXC EUR/USA 2001 KEIHIN PWK 38 AG120
Carburetor Setting KTM 125 SX EUROPA/USA 2002 KEIHIN PWK 39121
Carburetor Setting KTM 125 EXC EUR 2002 KEIHIN PWK 38 AG122
Carburetor Setting KTM 200 MXC/EXC EUR/USA 2002 KEIHIN PWK 38 AG123
Carburetor Setting KTM 125 SX EUROPA/USA 2003 KEIHIN PWK 39124
Carburetor Setting KTM 125 EXC EUR 2003 KEIHIN PWK 38 AG125
Carburetor Setting KTM 200 SX EUROPA/USA 2003 KEIHIN PWK 39 AG126
Carburetor Setting KTM 200 MXC/EXC EUR/USA 2003 KEIHIN PWK 38 AG127
Lubrication and Maintenance Schedule129
Periodic Lubrication and Maintenance Schedule131
Periodic Maintenance Schedule 2001/02132
Periodic Maintenance Schedule 125 Supermoto134
Periodic Maintenance Schedule 2003 - 125/200 SX/MXC/EXC136
Recommended Inspection of the 125/200 SX, MXC and EXC Engine Used for Enduro Competitions by the KTM Workshop138
Recommended Inspection of the 125/200 SX, MXC and EXC Engine Used for Hobby-Enduro by the KTM Workshop138
Wiring Diagrams139
125/200 EXC '99 Wiring Diagram141
125/200 EGS '99 Wiring Diagram142
125/300/380 EXC '98, '99 Wiring Diagram144
200 Exc '98, '99145
125/200/250/300 Exc 2000147
125-380 EXC 2000 Wiring Diagram148
125 EXE 2000/2001, 125 Super Moto 2000/2001 Wiring Diagram150
125-200 EXC 2001/2002 Wiring Diagram152
KTM 125/200 EXC 2001/2002 Wiring Diagram155
125-200 EXC 2003 Wiring Diagram156
125/200 Exc 2003158

KTM 125 - Removing and Refitting Engine

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