KTM 125/200 Engine Repair Manual – PDF DOWNLOAD
FILE DETAILS:
KTM 125/200 Engine Repair Manual – PDF DOWNLOAD
Language :English
Pages :158
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
KTM 125/200 Engine Repair Manual – PDF DOWNLOAD
STORING THE REPAIR MANUAL IN THE BINDER
– Put the index into the binder.
– Put the front page of the repair manual (210×297 mm) into the transparent pocket provided for
this purpose on the outside of the binder.
– Put the spine label (170×45 mm) into the transparent pocket provided for this purpose on the
spine of the binder.
– Put the summary list of contents (150×297 mm) into the transparent pocket provided for this
purpose on the inside of the binder or insert this page on the beginning of the manual.
– Then insert the individual chapters of the manual between the sheets of the index according to
the page number printed in the right bottom corner of each page.
Example: page no. 3-5 3 = chapter 3 5 = page 5
All pages with a page number that begins with the digit 3, for example, must be put under the
index heading „Chapter 3“.
– Index sheets that have not been marked with a certain chapter are for your personal convenience.
The respective headings can be entered in the list of contents.
TABLE OF CONTENTS:
KTM 125/200 Engine Repair Manual – PDF DOWNLOAD
HOME 0
NOTES AND PREFACE 1
Title page and file spine 1
Important information 7
Updating instruction 7
Explanation update 9
Introduction 11
Reply fax for repair manuals 13
TABLE OF CONTENTS 5
SERVICE-INFORMATIONS 1
DERESTRICTION 0
INTERMEDIATE FLANGE 0
SHIFT SPRING 0
CHAIN TENSION 0
CONTROL FLAP AXLE 0
OILPUMP ADJUSTMENT 0
CRANKSHAFT MAIN BEARING 0
MASTER CYLINDER 0
GENERAL INFORMATION 15
OPERATING RANGES OF THE CARBURETOR 17
CARBURETOR ADJUSTMENT 18
BLEEDING OF THE HYDRAULIC CLUTCH 19
OIL PUMP ADJUSTING – MODELS WITH SEPARATE LUBRICATION 20
CHECK OF EXHAUST CONTROL 21
REMOVING AND REFITTING ENGINE 23
REMOVING THE ENGINE 25
REFITTING THE ENGINE 26
DISASSEMBLING 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 MODELS WITH 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
RIGHT HOUSING HALF 41
LEFT HOUSING HALF 42
CRANKSHAFT 43
CRANKSHAFT WEBS – MEASURE OUTER DIMENSION 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
CLUTCH COVER 49
PREASSEMBLING THE CLUTCH COVER 49
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
SHIFT MECHANISM 55
PREASSEMBLING THE SHIFT SHAFT 55
TRANSMISSION 56
ASSEMBLING THE MAIN SHAFT 56
ASSEMBLING THE COUNTERSHAFT 57
IGNITION 58
CHECK STATOR AND PULSE GENERATOR 58
ASSEMBLING THE ENGINE 59
MOUNTING THE CRANKSHAFT 61
TRANSMISSION SHAFT, SHIFT MECHANISM 61
ASSEMBLING THE ENGINE HOUSING 62
ENGINE SPROCKET 62
IGNITION SYSTEM 62
SHIFT DRUM LOCATING DEVICE 63
KICKSTARTER 64
PRIMARY DRIVE, CLUTCH 64
CLUTCH DISCS, PRESSURE CAP 65
OIL PUMP, REED VALVE HOUSING, INTAKE FLANGE (SEPARATE LUBRICATION) 66
REED VALVE HOUSING, INTAKE FLANGE 67
CLUTCH COVER 67
PISTON, CYLINDER 68
ADJUSTING DIMENSION „X“ 68
ADJUSTING THE CONTROL FLAP (DIMENSION „Z“) 69
CYLINDER HEAD 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 (KOKUSAN) 74
CDI UNIT 75
MEASUREMENTS WITH PEAK VOLTAGE ADAPTER 73
STATIC IGNITION VALUES 125-200 SX, MXC, EXC 76
STATIC GENERATOR VALUES 125-200 EXC 78
STATIC IGNITION VALUES/GENERATOR VALUES 125-200 MXC, EXC USA 80
STATIC IGNITION VALUES 125 EXE, SUPERMOTO 82
STATIC GENERATOR VALUES 125 EXE, SUPERMOTO 84
TROUBLE SHOOTING 87
TECHNICAL SPECIFICATIONS 91
MODEL 1999 91
TECHNICAL SPECIFICATIONS – ENGINE 125/200 93
TECHNICAL SPECIFICATIONS – CHASSIS 125/200 95
TECHNICAL SPECIFICATIONS – ENGINE 200 ONLY SINGAPORE 96
BASIC CARBURETOR SETTING – 200 ONLY SINGAPORE 96
MODEL 2000 91
TECHNICAL SPECIFICATIONS – ENGINE 125 EXE, SUPERMOTO 97
TECHNICAL SPECIFICATIONS – CHASSIS 125 EXE, SUPERMOTO 98
TECHNICAL SPECIFICATIONS – ENGINE 125/200 SX, MXC, EXC 99
TECHNICAL SPECIFICATIONS – CHASSIS 125/200 SX, MXC, EXC 101
MODEL 2001 91
TECHNICAL SPECIFICATIONS – ENGINE 125 EXE, SUPERMOTO 97
TECHNICAL SPECIFICATIONS – CHASSIS 125 EXE, SUPERMOTO 98
TECHNICAL SPECIFICATIONS – ENGINE 125/200 102
TECHNICAL SPECIFICATIONS – CHASSIS 125/200 104
MODEL 2002 91
TECHNICAL SPECIFICATIONS – ENGINE 125/200 105
TECHNICAL SPECIFICATIONS – CHASSIS 125/200 107
MODEL 2003 91
TECHNICAL SPECIFICATIONS – ENGINE 125/200 108
TECHNICAL SPECIFICATIONS – CHASSIS 125/200 110
CARBURATOR SPECIFICATION 91
MODEL 1999 112
MODEL 2000 115
MODEL 2001 118
MODEL 2002 121
MODEL 2003 124
PERIODIC MAINTENANCE SCHEDULE 129
125 / 200 UP TO 2000 131
125 / 200 SX, MXC, EXC 2001 / 2002 132
125 EXE, SUPERMOTO 134
125 / 200 SX, MXC, EXC 2003 136
WIRING DIAGRAMS 139
WIRING DIAGRAMS 1999 139
125/200 EXC (EUROPE) 141
125/200 EGS 142
125 EXC (USA) 144
200 EXC (USA) 145
WIRING DIAGRAMS 2000 139
125/200 EXC (USA) 147
125/200 EXC (EUROPA) 148
125 EXE, SUPERMOTO 150
WIRING DIAGRAMS 2001 139
125/200 EXC (EUROPA) 152
125/200 EXC (USA) 155
125 EXE, SUPERMOTO 150
WIRING DIAGRAMS 2002 139
125/200 EXC (EUROPA) 152
125/200 EXC (USA) 155
WIRING DIAGRAMS 2003 139
125/200 EXC (EUROPA) 156
125/200 EXC (USA) 158
S.M 13/3/2025
