KTM 125 Repair Manual

Repair manual KTM 125 / 200
Art No 3.206.005 -E
9-2C
Engine 125 SX 125 EXC 125 EGS 200 MXC 200 EXC, EGS Design Liquid-cooled single-cylinder two-stroke engine with intake and exhaust control Piston displacement 124.8 ccm 193 ccm Bore / stroke 54.25 / 54 mm (2.136 / 2.126 in) 64 / 60 mm (2.52 / 2.362 in) Fuel SUPER fuel, research octane no 98, mixed with high grade two stroke oil
SUPER fuel, research octane no 95, mixed with high grade two stroke oil
Oil / gasoline ratio 1:40 when using high grade two stroke oil (Shell Advance Racing X). When in doupt, please contact your importer Crankshaft bearing 1 deep-groove ball bearing / 1 cylinder roller bearing Conrod bearing needle bearing Piston pin bearing needle bearing Piston cast piston Piston ring one plain compression ring two plain compression rings Dimension "X"
0.60 mm (0.024 in) 0.55 mm (0.22 in)
Ignition timing 1.4 mm (0.055 in) (16.5°) BTDC 1.6 mm (0.063 in) (17°) BTDC Spark plug NGK R 6918-B8 NGK BR 8 EG Electrode gap 0.60 mm (0,024 in) Dimension "Z" 42 mm (1.65 in) 46 mm (1.81 in) Primary drive straight cut spur gears, primary ratio 23:73 Clutch multiple disc clutch in oil bath, hydraulic operated (Shell HF-E15) Transmission 6 speed, claw actuated
Gear ratio 1st gear 13 : 32 12 : 33 13 : 32 12 : 33 2nd gear 15 : 30 15 : 31 15 : 30 15 : 31 3rd gear 17 : 28 17 : 28 17 : 28 17 : 28 4th gear 19 : 26 19 : 26 19 : 26 19 : 26 5th gear 21 : 25 21 : 25 21 : 25 22 : 25 / 17 : 19
6th gear 22 : 24 20 : 20 22 : 23 22 : 20 Gear lubrication 0.7 l engine oil 20W-40 (Shell Advance VSX4) Available chain sprockets
13t / 14t / 15t for chain
5
/8 x
1
/4"
Coolant 1.2 litres, 40% anti freeze, 60% water, at least -25 °C (-13 °F) Ignition system KOKUSAN 2K-1 USA: KOKUSAN 2K-2 EU: 2K-3 KOKUSAN 2K-3 KOKUSAN 2K-2 KOKUSAN 2K-3 Generator output no generator 12V 40 W 12V / 110 W 12V 110 W 12V 40 W 12V 110 W Carburetor flat-slide carburetor, carburetor setting see table Air-filter wet foam type air filter insert
(upper edge piston - upper edge cylinder)
(height of the
control flap)
TECHNICAL DATA - ENGINE 125 / 200 ‘99

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)