KTM 200 - Cylinder Head, Cylinder, Piston Procedures

– Thoroughly clean the engine.
– Clamp the engine into the mounting rack.
– Remove the kickstarter and the shift lever.
– Remove bolt
1 and take off wire hanger 2.
Draining the gear oil
–Twist out the drain plug 3 and drain the gear oil.
Dismounting the clutch slave cylinder
– Remove the 2 bolts 4 and withdraw the clutch slave cylinder
together with the gasket.
– Pull push rod out of drive shaft.
Cylinder head, cylinder, piston
– Undo the 6 bolts 5 and remove the cylinder head together with the
gasket.
NOTE: on 125 SX/EXC-engines from model 2002 onwards an O-ring is
used instead of the gasket.
–Take the O-ring(s) out of the groove in the cylinder.
– Remove the 4 collar nuts
6 at the cylinder base and remove the
cylinder.
4-3C
1
2
3
5
6
4