Repair manual KTM 125 / 200
Art No 3.206.005 -E
5-12C
Checking clutch for wear
Thrust bearing 1- check it for score marks and easy operability.
Push rod
2- place it on a flat surfacecheck for bents.
Clutch springs
3- minimum length 38 mm (1.496 in) (new 39 mm / 1.535 in); if necessary exchange all 5 springs.
7 Lining discs
4- minimum thickness: 2.9 mm (0.114 in) (new 3,0 mm / 0.118 in). Discs must be plane.
4 Clutch discs - aluminium
5- discs must be plane; check for mechanical damage.
2 Clutch discs - steel
6- discs must be plane; check for mechanical damage.
Inner clutch hub
7- check the bearing surface of the lining disc for damage.
Check the bearing surfaces
A of the steel discs at the inner clutch hub. If the grooves are deeper than 0.5 mm (0.02 in) replace the
inner clutch hub.
Pressure cap
8- check the bearing surface B of the lining disc for damage.
Outer clutch hub
9- check the stop faces C of the lining discs for wear. The outer clutch hub must be replaced if the grooves are
more than 0.5 mm (0.02 in) deep (see below).
Mount the inner ring
bk and the needle cage bl and check for play.
1
2
3
4
5
6
9
C
8
A
B
7
10
11
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