9-18C
Repair manual KTM 125 / 200
Art No 3.206.005 -E
TIGHTENING TORQUES - ENGINE
Flange bolts - cylinder-head M 7 18 Nm
Nuts-cylinder base M 8 30 Nm
Flywheel collar nut M 12x1 60 Nm
Nut for primary sprocket (LH thread) M 16x1.5 180 Nm
Nut for inner clutch hub M 18x1.5 120 Nm
Crankcase and clutch cover bolts M 6 8 Nm
Spark plug M 14x1.25 20 Nm
Swingarm pivot M 14x1.5 100 Nm
Other bolts M 6 10 Nm
M 8 25 Nm
M 10 45 Nm
BASIC CARBURETOR SETTING
200 EXC AUS
200 EXC EU
200 MXC/EXC USA
Carburetor
Carburetor setting number
Main jet
Idling jet
Starting jet
Jet needle
Needle position from top
Throttle valve
Air adjustment screw open
Performance restrictor
Keihin PWK 38 AG
100202
180 (178)
35 (45/48)
85
R 1475J (NOZ E/NOZ F)
III
6.5
1,5
slide stop 36mm
Keihin PWK 38 AG
080202
178(180/185)
45 (48)
85
NOZ E (NOZ F)
III
6.5
1,5
–
200 SX
Keihin PWK 39
090202
190 (188,192)
48 (45)
85
R 1468G (R1469G)
III
5.5
1,5
–
BASIC CARBURETOR SETTING
125 EXC EU
125 EXC AUS
125 EXC SIX DAYS
Carburetor
Carburetor setting number
Main jet
Idling jet
Starting jet
Jet needle
Needle position from top
Throttle valve
Air adjustment screw open
Performance restrictor
Keihin PWK 38 AG
070202
148 (180/185)
35 (45/48)
85
R 1472 N (NOZ E/NOZ F)
V
6.5
1,5
–
Keihin PWK 38 AG
160202
180(185)
45 (48)
85
NOZ E (NOZ F)
IIII
6.5
1,5
–
125 SX
Keihin PWK 39
060202
185 (188/190)
48 (45)
85
R 1469 D (R 1470 D)
III
5.5 (6)
1,5
–
Piston fitting clearance 125 = 0.06 mm 200 = 0.055 mm
Piston ring end cap max. 0.40 mm
Connecting rod bearing - radial clearance
0.025–0.035 mm
Piston pin –
radial clearance
0,030 mm
Transmission shafts end float 0.20– 0.40 mm
Clutch springs - length new = 39 mm, minimum length = 38 mm
Clutch discs min. 2,9 mm (new 3,1 mm)
Crank stud - run out 0,02 mm
Crankshaft webs outer dimension 55 mm
TOLERANCES AND FITTING CLEARANCES
GASKET THICKNESSES
Crankcase 0,5 mm
Clutch cover 0,5 mm
Clutch driving cylinder 0.30 / 0.50 / 0.75 mm
Cylinder bottom gasket as required
Available bottom gasket
0.07 / 0.15 / 0.20 / 0.25 / 0.40 / 0.50 / 0.75 mm
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