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KTM 200 User Manual
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Repair manual KTM 125 / 200
Art No 320588 -E
125 / 200
REP
AIR MANUAL
ENGINE
KTM SPORTMOTORCYCLE AG
5230 Mattighofen
Austria
www
.ktm.at
2
Table of Contents
Removing and Refitting Engine
5
Important Information/Updating Instructions
7
Explanation - Updating
9
General Information
15
Idling Range
17
Opening up
17
Part-Throttle Range
17
Full Throttle Range
17
Carburetor Adjustment
18
Basic Information on Carburetor Wear
18
Bleeding of the Hydraulic Clutch
19
Check of the Exhaust Control (Engine Running)
21
Removing and Refitting Engine
23
Removing the Engine
25
Installing the Engine
26
Fixing the Cables to the Frame - Models with Separate Lubrication
27
Dismantling the Engine
29
Special Tools - Engine 125/200
31
Draining the Gear Oil
32
Dismounting the Clutch Slave Cylinder
32
Cylinder Head, Cylinder, Piston
32
Ignition
33
Engine Sprocket
33
Reed Valve Housing, Intake Flange and Clutch Cover
34
Reed Valve Housing, Intake Flange and Oil Pump (Separate Lubrication)
35
Removing Clutch and Primary Drive
35
Shift Drum Locating, Kickstarter
36
Dividing the Engine Housing
37
Removing Shift Mechanism and Transmission
38
Removing Crankshaft
38
Servicing Individual Components
39
Engine Housing
39
Right Housing Half
41
Left Housing Half
42
Crankshaft
43
Piston
43
Piston Ring End Gap
43
Checking Cylinder for Wear
44
Nikasil Coating of Cylinder
44
Dismounting and Checking the Exhaust Control System in the Cylinder
45
Preassembling the Cylinder
46
Dismounting the Exhaust Control System in the Clutch Cover, and Checking Parts for Wear
49
Preassembling the Clutch Cover
49
Disassembling and Checking the Water Pump
50
Preassembling the Water Pump
50
Checking Clutch for Wear
51
Reed Valve Housing, Intake Flange
52
Kickstarter
53
Preassembling the Kickstarter Shaft
53
Shifting Mechanism from Model 2001 on View
54
Shifting Mechanism
55
Preassembling the Shifting Shaft (up to Model 2000)
55
Preassembling the Shifting Shaft (Model 2001 Onwards)
55
Transmission
56
Assembling the Main Shaft
56
Assembling the Countershaft
57
Ignition - General Information
58
Spark Plug
58
Check Stator and Pulse Generator
58
Assembling the Engine
59
Shift Mechanism
59
Mounting the Crankshaft
61
Transmission, Shift Mechanism
61
Assembling the Engine Housing
62
Ignition System
62
Engine Sprocket Servicing
62
Shift Drum Locating Device
63
Kickstarter Servicing
64
Clutch Discs, Pressure Cap
65
Oil Pump, Reed Valve Housing and Intake Flange (Separate Lubrication)
66
Clutch Cover Servicing
67
Reed Valve Housing, Intake Flange Servicing
67
Piston, Cylinder
68
Adjusting Dimension „X“
68
Adjusting the Control Flap (Dimension „Z“)
69
Cylinder Head Servicing
69
Ignition Cover
70
Measuring Dimension „Y“
70
Mounting the Clutch Slave Cylinder
71
Filling in the Gear Oil
71
Electrical
73
Checking the Voltage Regulator-Rectifier (Shindengen)
74
Checking the Voltage Regulator (Kokusan)
74
Checking the Capacitor
74
Ignition Coil
74
CDI Unit
75
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
Troubleshooting
87
Trouble Shooting
89
Technical Specifications
91
Technical Data - Engine 125/200 ‘99
93
Technical Specifications Chassis 125 SX/EXC/EGS, 200 MXC/EXC/EGS ‘99
95
Technical Data - Engine 200 EGS Only Singapore '99
96
Technical Data - Engine 125 EXE/125 Supermoto 2000
97
Technical Specifications Chassis 125 EXE/125 Supermoto 2000
98
Technical Data - Engine 125/200 2000
99
Technical Specifications Chassis 125 SX/EXC, 200 MXC/EXC 2000
101
Technical Data - Engine 125/200 2001
102
Technical Specifications Chassis 125 SX/EXC, 200 MXC/EXC 2001
104
Technical Data - Engine 125/200 2002
105
Technical Specifications Chassis 125 SX/EXC, 200 MXC/EXC 2002
107
Technical Data - Engine 125/200 2003
108
Technical Specifications Chassis 125 SX/EXC, 200 SX/MXC/EXC 2003
110
Carburetor Setting KTM 125 SX/MXC/EXC USA ‘99 KEIHIN PWK 39
112
Carburetor Setting KTM 125 SX/EXC EUROPA ‘99 KEIHIN PWK 39
113
Carburetor Setting KTM 200 MXC/EXC EUR. USA ‘99 KEIHIN PWK 39
114
Carburetor Setting KTM 125 SX EUROPA/USA 2000 KEIHIN PWK 39
115
Carburetor Setting KTM 125 MXC/EXC EUR/USA 2000 KEIHIN PWK 38 AG
116
Carburetor Setting KTM 200 MXC/EXC EUR/USA 2000 KEIHIN PWK 38 AG
117
Carburetor Setting KTM 125 SX EUROPA/USA 2001 KEIHIN PWK 39
118
Carburetor Setting G KTM 125 MXC/EXC EUR/USA 2001 KEIHIN PWK 38 AG
119
Carburetor Setting KTM 200 MXC/EXC EUR/USA 2001 KEIHIN PWK 38 AG
120
Carburetor Setting KTM 125 SX EUROPA/USA 2002 KEIHIN PWK 39
121
Carburetor Setting KTM 125 EXC EUR 2002 KEIHIN PWK 38 AG
122
Carburetor Setting KTM 200 MXC/EXC EUR/USA 2002 KEIHIN PWK 38 AG
123
Carburetor Setting KTM 125 SX EUROPA/USA 2003 KEIHIN PWK 39
124
Carburetor Setting KTM 125 EXC EUR 2003 KEIHIN PWK 38 AG
125
Carburetor Setting KTM 200 SX EUROPA/USA 2003 KEIHIN PWK 39 AG
126
Carburetor Setting KTM 200 MXC/EXC EUR/USA 2003 KEIHIN PWK 38 AG
127
Lubrication and Maintenance Schedule
129
Periodic Lubrication and Maintenance Schedule
131
Periodic Maintenance Schedule 2001/02
132
Periodic Maintenance Schedule 125 Supermoto
134
Periodic Maintenance Schedule 2003 - 125/200 SX/MXC/EXC
136
Recommended Inspection of the 125/200 SX, MXC and EXC Engine Used for Enduro Competitions by the KTM Workshop
138
Recommended Inspection of the 125/200 SX, MXC and EXC Engine Used for Hobby-Enduro by the KTM Workshop
138
Wiring Diagrams
139
125/200 EXC '99 Wiring Diagram
141
125/200 EGS '99 Wiring Diagram
142
125/300/380 EXC '98, '99 Wiring Diagram
144
200 Exc '98, '99
145
125/200/250/300 Exc 2000
147
125-380 EXC 2000 Wiring Diagram
148
125 EXE 2000/2001, 125 Super Moto 2000/2001 Wiring Diagram
150
125-200 EXC 2001/2002 Wiring Diagram
152
KTM 125/200 EXC 2001/2002 Wiring Diagram
155
125-200 EXC 2003 Wiring Diagram
156
125/200 Exc 2003
158
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KTM 200 Specifications
General
Starter
Kickstarter
Transmission
6-speed
Engine Type
Single-cylinder, 2-stroke
Cooling System
Liquid-cooled
Lubrication
Premix (oil-fuel mixture)
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