KTM 125 Repair Manual
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KTM 125 Repair Manual

KTM 125 Repair Manual

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125 / 200
REPAIR MANUAL
ENGINE
KTM SPORTMOTORCYCLE AG
5230 Mattighofen
Austria
www.ktm.at

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Summary of Contents for KTM 125

  • Page 1 125 / 200 REPAIR MANUAL ENGINE KTM SPORTMOTORCYCLE AG 5230 Mattighofen Austria www.ktm.at...
  • Page 3 125/200 REPAIR MANUAL ENGINE...

  • Page 5: Removing And Refitting Engine

    1 SERVICE-INFORMATIONS 2 GENERAL INFORMATION 3 REMOVING AND REFITTING ENGINE 4 DISASSEMBLING THE ENGINE 5 SERVICING INDIVIDUAL COMPONENTS 6 ASSEMBLING THE ENGINE 7 ELECTRICAL 8 TROUBLE SHOOTING 9 TECHNICAL SPECIFICATIONS 10 PERIODIC MAINTENANCE SCHEDULE 11 WIRING DIAGRAMS...
  • Page 7 11-1C 11-15 11-15C bis 11-18C KTM REPAIR MANUAL IN LOOSE-LEAF FORM STORING THE REPAIR MANUAL IN THE BINDER – Put the index into the binder. – Put the front page of the repair manual (210x297 mm) into the transparent pocket provided for this purpose on the outside of the binder.
  • Page 9 X P L A N AT I O N P D AT I N G 3.205.74-E Repair Manual 125/200 SX, MXC, EXC Basicversion Modelyear 1999 (Engine number with first digit “9“) 3/1999 3.205.88-E Updating of Rep.Manual 3.205.74-E Modelyear 2000/2001 (2000: Engine number with first digit “0“) (2001: Engine number with first digit “1“)
  • Page 11 „NOTE” POINTS OUT USEFUL TIPS. Use only ORIGINAL KTM SPARE PARTS when replacing parts. The KTM high performance engine is only able to meet user expectations if the maintenance work is performed regularly and professionally. KTM Austria’s certificate of achievement for its quality system ISO 9001 is the beginning of an ongoing total reengineered quality plan for a brighter tomorrow.
  • Page 13 REPLY FAX FOR REPAIR MANUALS We have made every effort to make our repair manuals as accurate as possible but it is always possible for a mistake or two to creep in. To keep improving the quality of our repair manuals, we request mechanics and shop foremen to assist us as follows: If you find any errors or inaccuracies in one of our repair manual –...
  • Page 15 2-1C GENERAL INFORMATION INDEX OPERATING RANGES OF THE CARBURETOR ......2-2 CARBURETOR ADJUSTMENT ........2-3 BLEEDING OF THE HYDRAULIC CLUTCH .
  • Page 17 2-2C main jet jet needle jet needle idle jet throttle valve air control screw idle adjusting screw mixture too lean: not enough fuel in proportion to air mixture too rich: too much fuel in proportion to air Idling range Operation with closed throttle valve. This range is influenced by the position of the air control screw and the idle adjusting screw .

  • Page 18: Carburetor Adjustment

    The original carburetor setting was adapted for an altitude of approx. 500 meters (1600 ft.) above sea level, and the ambient temperature of approx. 20° C (68° F), mainly for off-road use and central European premium-grade fuel (125: ROZ 98 / 200: ROZ 95).

  • Page 19: Bleeding Of The Hydraulic Clutch

    2-4C Bleeding of the hydraulic clutch – Remove screws and take off cover together with rubber bellows. – At the slave cylinder of the clutch, remove the bleeder nipple Instead of mount the bleeder syringe which is filled with SAE 10 biodegradable hydraulic oil (ex.
  • Page 20 – If the oil pump has been adjusted correctly, the mark must coincide with the notch on the cable pulley (except 125 EXE and 125 Supermoto). – On 125 EXE- and 125 Supermoto-models the notch must coincide with the edge C.
  • Page 21 2-6C Check of the exhaust control (engine running) – Remove the left side cover from the cylinder. – Start engine. – Mark of the control segment is near by mark of the guide plate. CAUTION ASE POSITION MUST BE ADJUSTED WITH A DEPTH GAUGE SHOWN IN CHAPTER 6-10 - „Z“.
  • Page 23 3-1C REMOVING AND REFITTING ENGINE INDEX REMOVING THE ENGINE ........3-2 REFITTING THE ENGINE .
  • Page 25 3-2C Removing the engine NOTE: The cylinder head and the cylinder can be removed without previously removing the engine. It is also possible to work on the clutch, the primary drive and the shift drum locating device without previously removing the engine. The water pump can be removed and installed without previously removing the clutch cover.
  • Page 26 3-3C Installing the engine – Lift the engine into the frame from the left side, slightly grease and mount the swingarm pivot. Tighten collar nut with 100 Nm (74 ft.lb.). – Twist in the engine mounting bolts. – Mount the engine brace. –...

  • Page 27: Models With Separate Lubrication

    3-4C – Connect the radiator hoses to the engine and fill the cooling system with a mixture of 40 % antifreeze and 60 % water. For this purpose twist out the bleeder screws at the cylinder head and at the right radiator.

  • Page 29: Table Of Contents

    INDEX SPECIAL TOOLS – ENGINE 125/200 .......4-2 DRAINING THE GEAR OIL ........4-3 DISMOUNTING THE CLUTCH SLAVE CYLINDER .
  • Page 31 SELBSTGEFERTIGT WOODEN FORK PLATE HOME MADE PART. NO. DESCRIPTIOIN 560.12.001.000 Universal engine work stand 503.29.003.000 Clutch holder 125 / 200 503.29.004.000 Holding spanner for primary gear wheel 546.29.009.044 Magneto extractor M27x1 Kokusan 510.12.011.000 Circlip plier 546.29.012.100 Holding spanner for flywheel Kokusan 2K-1/2/3/4 501.12.013.000...

  • Page 32: Draining The Gear Oil

    – Undo the 6 bolts 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.

  • Page 33: Ignition

    4-4C – Cover the crankcase. – Place the piston onto an appropriate wooden support and remove both piston pin retainers. – Press the piston pin out of the piston without applying excessive force. An appropriate mandrel can be used if necessary. –...

  • Page 34: Reed Valve Housing, Intake Flange And Clutch Cover

    4-5C Reed valve housing, intake flange and clutch cover – Remove 5 bolts together with the corrugated washers, remove the intake flange and the reed valve housing. NOTE: The following step need not be performed unless you intend to take the centrifugal timer out of the clutch cover. –...

  • Page 35: Removing Clutch And Primary Drive

    4-6C Reed valve housing, intake flange and oil pump (separate lubrication) – When dismounting the clutch cover additionally remove the bolt – Pull the oil pump wheel off the oil pump – Remove the cover from the oil pump housing. –...

  • Page 36: Shift Drum Locating, Kickstarter

    4-7C – Open the lock washer of the inner clutch hub. – Mount the clutch holder on the inner clutch hub and undo the hexagon nut. – Remove the clutch holder. – Take the hexagon nut, the detent edged ring and the inner clutch hub off the main shaft.

  • Page 37: Dividing The Engine Housing

    4-8C – Carefully unhook the kickstarter spring from bore (pretensioned spring) and release it. – Rotate the kickstarter shaft approximately 1/4 turn counterclockwise and pull it out of the housing. Keep in mind the stop disc behind ! – Undo 3 bolts and remove the gear shifting gate together with the ratchet carrier .

  • Page 38: Removing Shift Mechanism And Transmission

    4-9C Removing shift mechanism and transmission – Pull out the shift rails and swing the shift forks including rollers sideways. – Pull the shift roller out of the grooved ball bearing. – Take the shift forks out of the housing. NOTE: When dismounting the shift forks, make sure that you do not lose the rollers on the shift forks.

  • Page 39: Table Of Contents

    5-1C SERVICING INDIVIDUAL COMPONENTS INDEX RIGHT HOUSING HALF ........5-2 LEFT HOUSING HALF .

  • Page 41: Right Housing Half

    5-2C Right housing half Remove the shaft seal rings and use a hot plate to heat the housing half to a temperature of approximately 150° C. NOTE: At a temperature of 150° C it is usually sufficient to tap the housing half onto a plane wooden surface and the bearings will simply drop out of the bearing seats.

  • Page 42: Left Housing Half

    5-3C Left housing half Remove the shaft seal rings and use a hot plate to heat the housing half to a temperature of approximately 150° C. NOTE: At a temperature of 150° C it is usually sufficient to tap the housing half onto a plane wooden surface and the bearings will simply drop out of the bearing seats.

  • Page 43: Crankshaft

    – The smallest cylinder diameter minus the largest piston diameter determines the piston fitting clearance. Piston fitting clearance: 0,06 mm (125) / 0,055 mm (200) Piston ring end gap – Insert pisto ring into the cylinder and adjust. Piston ring must be approx.

  • Page 44: Checking Cylinder For Wear

    64.013 - 64.025 mm ....2 If the cylinder diameter is larger than 54.275 mm (125 up to 2000), 54,025 (125 2001 onwards) or 64.025 mm (200), the Nikasil cylinder must be reconditioned or replaced.

  • Page 45: System In The Cylinder

    Check the control flap axles for wear, especially at the pins. NOTE: to prevent sticking of the control flap on 125 EXE- and 125 Supermoto models, there are nitrogenized control flap axles (bright surface) available which subseed the original fitted axles (dark surface).

  • Page 46: Preassembling The Cylinder

    5-7C Control flap Clean the control flap and check the pins in the control flap for tight fit. Measure the distance between the two pins (see illustration). When mounted, the control flap must not scrape against the exhaust port. Distance : min.
  • Page 47 5-8C – Grease the pins in the cylinder and mount the 3 roller guides with the large collar facing the cylinder. – Turn the control rollers and the adjusting roller of the control flap so that the marks are on the outside (facing the control segment). –...
  • Page 48 5-9C...

  • Page 49: Clutch Cover

    5-10C Dismounting the exhaust control system in the clutch cover, and checking parts for wear. – Undo 2 bolts and remove the closure cap together with the gasket and the copper seal rings. – Press the grooved ball bearing below out of the clutch cover. For this purpose, push the rocker arm of the centrifugal timer forward (in the direction of the grooved ball bearing).

  • Page 50: Water Pump

    5-11C Disassembling and checking the water pump – Remove the 2 bolts of the water pump cover and take off the water pump cover. – Pull the water pump and the O-ring out of the clutch cover. – Clamp the water pump with the water pump wheel facing upwards into the vise (use protective jaws).

  • Page 51: Checking Clutch For Wear

    5-12C Checking clutch for wear Thrust bearing - check it for score marks and easy operability. Push rod - place it on a flat surfacecheck for bents. Clutch springs - minimum length 38 mm (1.496 in) (new 39 mm / 1.535 in); if necessary exchange all 5 springs. 7 Lining discs - minimum thickness: 2.9 mm (0.114 in) (new 3,0 mm / 0.118 in).

  • Page 52: Reed Valve Housing, Intake Flange

    5-13C Reed valve housing, intake flange NOTE: The reed paddles slowly lose their tension during operation, thus reducing the overall performance. Damaged or worn reed paddles must therefore be replaced. The entire reed valve housing must be exchanged if the sealing surfaces of the reed valve housing are also damaged.

  • Page 53: Kickstarter

    5-14C Kickstarter Take all components off the kickstarter shaft and clean them. Kickstarter gear Check the bearing for play and grooves. Intermediate kickstarter gear Check the bearing for play and grooves. Locking pawl Check for wear and damage. Kickstarter shaft Check for wear and damage, paying particular attention to pivot points and teeth.
  • Page 54 5-15C Shifting mechanism from model 2001 on Needle bearing from model 2002...
  • Page 55 5-16C Shifting mechanism Shift forks Check the blade for wear. Shift roller Check the shift grooves for wear. Ensure that the shift roller rests properly in the grooved ball bearing Check the grooved ball bearing in the shift roller for wear. To replace it, remove the Seeger circlip ring and pull the grooved ball bearing out of the shift roller (slide seat).

  • Page 56: Transmission

    5-17C ! ATTENTION ! When replacing gears, watch out for this mark ! Transmission Clamp the main shaft or counter shaft, respectively, into the vise (use protective jaws). Remove the gears and check the following parts for wear and grooves: ●...

  • Page 57: Assembling The Countershaft

    5-18C ! ATTENTION ! When replacing gears, watch out for this mark ! Transmission Clamp the main shaft or counter shaft, respectively, into the vise (use protective jaws). Remove the gears and check the following parts for wear and grooves: ●...
  • Page 58 5-19C Ignition General information The measurements described below will only reveal severe problems. Coil short circuits leading to weak ignition sparks or low generator output, respectively, can only be detected with the help of an ignition test bench. In the case of malfunction always check the cables and the plug and socket connections of the ignition system first.

  • Page 59: Shift Mechanism

    6-1C ASSEMBLING THE ENGINE INDEX MOUNTING THE CRANKSHAFT ........6-2 TRANSMISSION SHAFT, SHIFT MECHANISM .
  • Page 61 6-2C – Clamp the right housing half onto the mounting rack. Mounting the crankshaft – Oil the grooved ball bearing of the crankshaft. – Insert the crankshaft into the grooved ball bearing from above and carefully push it as far as it will go. CAUTION HE CONROD MUST BE DIRECTED TOWARDS THE CYLINDER WHEN THE CRANKSHAFT IS INSERTED...
  • Page 62 6-3C M6x... mm Assembling the engine housing – Remove the engine holder at the mounting rack. – Make sure that both dowels are properly located in the right housing half. – Slightly grease the sealing surface of the housing and mount a new gasket. –...
  • Page 63 6-4C – Mount the rotor. – Mount the detent edged ring and the nut. – Hold the rotor with the holding spanner and tighten the hexagon nut with 60 Nm / 44 ft.lb.). Shift drum locating device – Mount the locking drum on the shift roller.
  • Page 64 6-5C – Grease the shaft seal ring of the shift shaft. – Oil the shift shaft and insert it into the housing. Do not forget the stop disc! When mounting the shift shaft make sure that both legs of the return spring rest against the prolongation of the shift rail Kickstarter –...
  • Page 65 6-6C – Mount the outer clutch hub and the supporting disc (20x39.6x3 mm) on the main shaft. – Mount the inner clutch hub, a new lock washer and the hexagon nut on the main shaft. – Mount the clutch holder and tighten the hexagon nut with 120 Nm (88 ft.lb.).
  • Page 66 6-7C Oil pump, reed valve housing and intake flange (separate lubrication) – Insert the reed valve housing into the engine case, and position the intake flange such that the bolt can be mounted. Mount the bolt, but only tighten it such that it is still possible to rotate the intake flange.
  • Page 67 6-8C Clutch cover – Check if both dowels have been mounted in the engine housing. – Grease the shaft seal ring of the kickstarter shaft and fix the clutch cover gasket with a small quantity of grease. – Fix the O-ring in the housing with a small quantity of grease.
  • Page 68 6-9C Piston, cylinder – Carefully oil the sliding points of all components before mounting. – Insert the needle bearing into the conrod eye, mount the piston (the arrow on the piston head indicates the direction of the exhaust port). – Mount the piston pin and the wire circlips with the open side facing downwards (see illustration).
  • Page 69 125 SX/EXC/EXE up to model 2000: Z = 42.0 mm + 0.2/- 0.6 mm 125 SX/EXC/EXE model 2001: Z = 42.5 mm + 0.2/- 0.6 mm 125 SX/EXC from model 2002: Z = 43 mm + 0.2/- 0.6 mm...
  • Page 70 6-11C Ignition cover – Apply silicone to several points of the gasket to fix it in the ignition cover. – Fix the ignition cover with 4 collar bolts. – Use the collar bolt to mount the wire bracket for the carburetor air hoses on the housing.
  • Page 71 6-12C Mounting the clutch slave cylinder – Verify that the ball has been correctly mounted in the piston of the clutch slave cylinder. – Put a new gasket in place, and mount the clutch slave cylinder. Apply Loctite 243 onto the bolt's thread.
  • Page 73 125-200 SX, MXC, EXC .....7-4 STATIC IGNITION VALUES 125-200 EXC ......7-6 STATIC GENERATOR VALUES 125-200 MXC, EXC USA .
  • Page 74 7-2C Checking the voltage regulator-rectifier (Shindengen) – Start the engine and switch on the low beam. – Connect a voltmeter to the two terminals of the capacitor (red/white cable = positive, brown cable = negative). – Accelerate the engine to a speed of 5000 r.p.m. and read off the voltage.
  • Page 75 7-3C CDI unit Check the cables and plug and socket connections of the CDI unit. The CDI unit function can only be checked on an ignition test bench. CAUTION EVER USE A COMMERCIAL MEASURING DEVICE TO CHECK THE UNIT OMMER CIAL MEASURING DEVICES CAN DESTROY HIGHLY SENSITIVE ELECTRONIC COMPO NENTS...
  • Page 76 7-4C S P O R T M O T O R C Y C L E S...
  • Page 77 7-5C STATIC IGNITION VALUES 125-200 SX, MXC, EXC (KOKUSAN 2K-1, 2K-3) Measuring conditions: – cold engine – seat and tank removed – all connectors and the ground connection in a non-corroding condition, connectors tightly connected – spark plug screwed out and spark plug connector attached to ground –...
  • Page 78 7-6C S P O R T M O T O R C Y C L E S...
  • Page 79 7-7C STATIC GENERATOR VALUES 125-200 EXC (KOKUSAN 2K-3) Measuring conditions: – cold engine – seat and tank removed – all connectors and the ground connection in a non-corroding condition, connectors tightly connected – light switch turned off – kick the kick starter forcefully at least 5 times for each measurement...
  • Page 80 7-8C...
  • Page 81 7-9C STATIC IGNITION AND GENERATOR VALUES 125-200 MXC, EXC USA (KOKUSAN 2K-2) Measuring conditions: – cold engine – seat and tank removed – all connectors and the ground connection in a non-corroding condition, connectors tightly connected – spark plug screwed out and spark plug connector attached to ground –...
  • Page 82 7-10C Land: Kabelstrangnummer: 125 EXE 2000/2001 Datum, Name: Modell SERVICE vorne:512.11.075.000 Europa 125 Super Moto 2000/2001 22.11.99 Hasl. hinten:503.14.040.100 S P O R T M O T O R C Y C L E S ge-bl ge-bl s-ge s-ge ge-s...
  • Page 83 7-11C STATIC IGNITION VALUES 125 EXE / 125 SUPERMOTO (KOKUSAN 2K-3) Measuring conditions: – cold engine – seat and tank removed – all connectors and the ground connection in a non-corroding condition, connectors tightly connected – spark plug screwed out and spark plug connector attached to ground –...
  • Page 84 7-12C Land: Kabelstrangnummer: Datum, Name: 125 EXE 2000/2001 Modell SERVICE vorne:512.11.075.000 Europa 125 Super Moto 2000/2001 22.11.99 Hasl. hinten:503.14.040.100 S P O R T M O T O R C Y C L E S ge-bl ge-bl s-ge s-ge ge-s...
  • Page 85 7-13C STATIC GENERATOR VALUES 125 EXE / 125 SUPERMOTO (KOKUSAN 2K-3) Measuring conditions: – cold engine – seat and tank removed – all connectors and the ground connection in a non-corroding condition, connectors tightly connected – battery loaded, ignition switch to position 1 (light turned off) –...
  • Page 87 TROUBLE SHOOTING INDEX TROUBLE SHOOTING 125 / 200 ....... . .8-2...

  • Page 89: Trouble Shooting

    8-2C TROUBLE SHOOTING If you let the specified maintenance work on your motorcycle be carried out, disturbances can hardly be expected. Should an error occur nevertheless, we advise you to use the trouble shooting chart in order to find the cause of error. TROUBLE CAUSE REMEDY...
  • Page 90 8-3C TROUBLE CAUSE REMEDY Engine enough Reed paddles tensionless Replace reed paddles or reed valve housing power damaged, surface of reed valve housing damaged Wear Overhaul engine Electronical ignition timing faulty Have ignition system checked Engine revs not high and Carburetor overflows if level adjust Clean carburetor, if necessary replace float needle and adjust running with four stroke...

  • Page 91: Technical Specifications

    MODEL 1999 TECHNICAL SPECIFICATIONS – ENGINE 125/200 ....9-2 TECHNICAL SPECIFICATIONS – CHASSIS 125/200 ....9-4 TECHNICAL SPECIFICATIONS –...
  • Page 93 9-2C...
  • Page 94 9-3C...
  • Page 95 9-4C TECHNICAL SPECIFICATIONS CHASSIS 125 SX / EXC / EGS, 200 MXC / EXC / EGS ‘99 125 SX 125 EXC 125 EGS 200 MXC 200 EXC 200 EGS Frame Central chrome-moly-steel frame Fork WP Extreme Marzocchi Magnum 45 Code 91...
  • Page 96 9-5C TECHNICAL DATA - ENGINE 200 EGS ONLY SINGAPORE ‘99 Engine 200 EGS Singapore Design Liquid-cooled single-cylinder two-stroke engine with intake and exhaust control Piston displacement 193 ccm Bore / stroke 64 / 60 mm (2.52 / 2.362 in) Fuel SUPER fuel, research octane no 95 Lubrication Separate lubrication...
  • Page 97 9-6C TECHNICAL DATA - ENGINE 125 EXE / 125 SUPERMOTO 2000 Engine 125 EXE Design Liquid-cooled single-cylinder two-stroke engine with intake and exhaust control Piston displacement 124.8 ccm Bore / stroke 54,0 / 54,5 mm (2.125 / 2.145 in) Fuel...
  • Page 98 9-7C TECHNICAL SPECIFICATIONS CHASSIS 125 EXE / 125 SUPERMOTO 2000 125 EXE 125 Supermoto Frame Central chrome-moly-steel frame Fork White Power – Up Side Down 40 TA Wheel travel front/rear 220/260 mm (8,7/10,2 in) Rear suspension WP Progressive Damping System shock absorber, aluminium swingarm...
  • Page 99 9-8C...
  • Page 100 (19 ft.lb) M 10 45 Nm (33 ft.lb) TOLERANCES AND FITTING CLEARANCES Piston fitting clearance 125 = 0.06 mm 200 = 0.085 mm Piston ring end cap max. 0.40 mm Connecting rod bearing - radial clearance 0.025– 0.035 mm Transmission shafts end float 0.20–...
  • Page 101 9-10C TECHNICAL SPECIFICATIONS CHASSIS 125 SX / EXC, 200 MXC / EXC 2000 125 SX 125 EXC 200 MXC 200 EXC Frame Central chrome-moly-steel frame Fork White Power – Up Side Down 43 MA Wheel travel front/rear 295/320 mm (11,3/12,6 in)
  • Page 102 9-11C...
  • Page 103 (19 ft.lb) M 10 45 Nm (33 ft.lb) TOLERANCES AND FITTING CLEARANCES Piston fitting clearance 125 = 0.06 mm 200 = 0.085 mm Piston ring end cap max. 0.40 mm Connecting rod bearing - radial clearance 0.025– 0.035 mm Transmission shafts end float 0.20–...
  • Page 104 9-13C TECHNICAL SPECIFICATIONS CHASSIS 125 SX / EXC, 200 MXC / EXC 2001 125 SX 125 EXC 200 MXC 200 EXC Frame Central chrome-moly-steel frame Fork White Power – Up Side Down 43 MA Wheel travel front/rear 295/320 mm (11,3/12,6 in)
  • Page 105 9-14C...
  • Page 106 Available bottom gasket 0.07 / 0.15 / 0.20 / 0.25 / 0.40 / 0.5 0 / 0.75 mm Cylinder-head gasket 125 =shapedring + O-ring 200=1.10 mm + O-ring BASIC CARBURETOR SETTING 200 EXC AUS 125 EXC EU 125 SX...
  • Page 107 9-16C TECHNICAL SPECIFICATIONS CHASSIS 125 SX / EXC, 200 MXC / EXC 2002 125 SX 125 EXC 200 MXC 200 EXC Frame Central chrome-moly-steel frame Fork WP – USD 48 MA White Power – Up Side Down 43 MA Wheel travel front/rear...
  • Page 108 9-17C...
  • Page 109 Air adjustment screw open Performance restrictor slide stop 36mm – – BASIC CARBURETOR SETTING 125 EXC EU 125 EXC SIX DAYS 125 SX 125 EXC AUS Carburetor Keihin PWK 38 AG Keihin PWK 38 AG Keihin PWK 39 Carburetor setting number...
  • Page 110 9-19C...
  • Page 111 9-20C STANDARD ADJUSTMENT - FORK WP 4860 MXMA WP 4860 MXMA 1418X725 1418X735 Compression adjuster Rebound adjuster Spring 4.0 N/mm 3.8 N/mm Spring preload 5 mm (0.2in) 5 mm (0.2in) Air chamber length 100 mm (5.1in) 110 mm (4,3in) Fork oil SAE 5 SAE 5 STANDARD ADJUSTMENT - SHOCK ABSORBER...
  • Page 112 9-21C...
  • Page 113 9-22C...
  • Page 114 9-23C...
  • Page 115 9-24C...
  • Page 116 9-25C...
  • Page 117 9-26C...
  • Page 118 9-27C...
  • Page 119 9-28C...
  • Page 120 9-29C...
  • Page 121 9-30C...
  • Page 122 9-31C...
  • Page 123 9-32C...
  • Page 124 9-33C...
  • Page 125 9-34C...
  • Page 126 9-35C...
  • Page 127 9-36C...
  • Page 129 125 / 200 SX, MXC, EXC 2003 ........10-7...
  • Page 131 10-2C PERIODIC LUBRICATION AND MAINTENANCE SCHEDULE rider dealer 125-200 6.98 AT A REGULAR COMPETITION USE OF THE BIKE, THE 4000 KM (2500 MILES) SERVICE IS TO BE DONE AFTER EVERY RACE ● Check transmission oil level ● ● ● Change transmission oil ●...
  • Page 132 10-3C PERIODIC MAINTENANCE SCHEDULE 2001/02 125/200 SX/MXC/EXC 1. service after after after 10 hours 4000 kilometer 20 hours A washed motorcycle can be checked more quickly which saves money! 1000 kilometer once a year 2000 kilometer ● Check gear box oil level ●...
  • Page 133 10-4C MPORTANT HECKS AND AINTENANCE TO BE ARRIED OUT BY THE IDER ● Check gear box oil level ● Check brake fluid level ● Check brake pads for wear ● Check lights for function ● Check horn for function ● Lubricate and adjust cables and nipples ●...
  • Page 134 10-5C 125 EXE PERIODIC MAINTENANCE SCHEDULE 125 SUPERMOTO every 1. Service after 4000 km 2. Service after A washed motorcycle can be checked more quickly which saves money! 1000 km 4000 km once a year ● ● ● Check oil level in oil tank and verify kink-less arrangement of bleeder hose ●...
  • Page 135 10-6C MPORTANT HECKS AND AINTENANCE TO BE ARRIED OUT BY THE IDER ● Check oil level in oil tank and bleeder hose for its kink-less arrangement ● Check transmission oil level ● Check brake fluid level ● Check brake pads for wear ●...
  • Page 136 10-7C PERIODIC MAINTENANCE SCHEDULE 2003 125/200 SX/MXC/EXC 1st service after after after 10 hours 20 hours 4000 kilometer A clean motorcycle can be checked more quickly which saves money! 1000 kilometers 2000 kilometers once a year ● Check gear box oil level ●...
  • Page 137 10-8C MPORTANT HECKS AND AINTENANCE TO BE ARRIED OUT BY THE IDER ● Check gear box oil level ● Check brake fluid level ● Check brake pads for wear ● Check lights for function ● Check horn for function ● Lubricate and adjust cables and nipples ●...
  • Page 138 10-9C 125/200 SX, MXC ECOMMENDED INSPECTION OF THE ENGINE USED FOR ENDURO COMPETITIONS BY THE WORKSHOP ADDITIONAL ORDER FOR THE WORKSHOP hours hours hours hours hours hours ● ● ● ● ● ● Check the reed-type intake valve for wear ●...

  • Page 139: Wiring Diagrams

    125/200 EXC (EUROPA) ........11-13...
  • Page 141 11-2C...
  • Page 142 11-3C...
  • Page 143 11-4C...
  • Page 144 11-5C...
  • Page 145 11-6C...
  • Page 147 11-8C...
  • Page 148 11-9C S P O R T M O T O R C Y C L E S...
  • Page 149 11-10C...
  • Page 150 11-11C Land: Kabelstrangnummer: Datum, Name: 125 EXE 2000/2001 Modell SERVICE vorne:512.11.075.000 Europa 125 Super Moto 2000/2001 22.11.99 Hasl. hinten:503.14.040.100 S P O R T M O T O R C Y C L E S ge-bl ge-bl s-ge s-ge ge-s...
  • Page 151 11-12C Deutsch Englisch Italienisch Französisch 1 Scheinwerfer 1 headlight 1 faro 1 phare 2 Standlicht 2 parking light 2 luce di posizione 2 feu de position 3 Blinker li vo 3 turn indic.left fr. 3 lampegg.ant.sn. 3 clignoteur av gauche 4 Blinker re vo 4 turn indic.right fr.
  • Page 152 11-13C 125-200 EXC 2001/2002...
  • Page 153 11-14C KTM 125-200 EXC 2001/2002 KTM 125-200 EXC 2001/2002...
  • Page 155 11-15C...
  • Page 156 11-16C 125-200 EXC 2003...
  • Page 157 11-17C KTM 125-200 EXC 2003...
  • Page 158 11-18C...
  • Page 159 Click below to find more Mipaper at www.lcis.com.tw Mipaper at www.lcis.com.tw...

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