User Manuals: KTM 125 Motorcycle

Manuals and User Guides for KTM 125 Motorcycle. We have 2 KTM 125 Motorcycle manuals available for free PDF download: Repair Manual, Owner's Handbook Manual

KTM 125 Repair Manual (160 pages)

Brand: KTM | Category: Engine | Size: 16 MB

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

KTM 125 Owner's Handbook Manual (67 pages)

KTM-Sportmotorcycle AG Motorcycle User Manual

Brand: KTM | Category: Motorcycle | Size: 3 MB

Important Warranty and Guarantee Information
4
Table of Contents
5
Serial Number Locations
6
Chassis Number
6
Engine Number, Engine Type (125/200)
6
Engine Number, Engine Type (250/300)
6
Operation Instruments
6
Clutch Lever
6
Hand Brake Lever
6
Electronic Speedometer, Indicator Lamp (EXC)
7
Electronic Speedometer
7
Tripmaster Switch
8
Overview of Tripmaster Functions
11
Short Circuit Button (SX)
12
Combination Switch (EXC)
12
Headlamp Switch (EXC USA)
12
Flasher Switch
12
Emergency off Switch (Australia)
12
Filler Cap
13
Fuel Tap
13
Choke Knob
13
Shift Lever
13
Kickstarter
14
Foot Brake Pedal
14
Side Stand
14
Steering Lock
14
Compression Damping of Fork
15
Rebound Damping of Fork
15
Compression Damping of Shock Absorber (SX)
15
Compression Damping of Shock Absorber (MXC, EXC)
16
Rebound Damping of Shock Absorber (SX, MXC, EXC)
16
General Tips and Warnings for Starting the Motorcycle
17
Instructions for Your First Ride
17
Running in
17
Driving Instructions
18
What You Should Check before each Start
18
Starting When the Engine Is Cold
19
Starting When the Engine Is Warm
19
What to Do When the Engine Is "Flooded
19
Starting off
19
Shifting/Riding
19
Braking
20
Stopping, Parking
20
Refueling, Fuel
20
Periodic Lubrication - and Maintenance-Schedule
21
Maintenance Work on Chassis and Engine
25
Checking and Adjusting the Steering Head Bearing
25
How to Change the Handlebar Position
26
Breather Plug Front Fork
26
Cleaning the Dust Sleeves of the Telescopic Fork
26
Basic Suspension Setup for the Weight of the Driver
27
Checking the Shock Absorber and Spring
27
Determining the Static Sag of the Shock Absorber
27
Determining the Riding Sag of the Shock Absorber
27
Checking the Basic Setup of the Telescopic Fork
28
Changing the Spring Preload on the Telescopic Fork (SX Models)27
28
Changing the Spring Preload on the Telescopic Fork (MXC/EXC Models).27
28
Replacing Fork Springs
28
Adjusting the Spring Preload on the Fork (SX)
29
Changing the Spring Preloading of the Shock Absorber
29
Pivot Bearing
29
Checking the Chain Tension
30
Correct the Chain Tension
30
Chain Maintenance
31
Chain Wear
31
General Information about KTM Disc Brakes
32
Adjusting the Free Travel at the Hand Brake Lever
33
Checking the Brake Fluid Level - Front Brake
33
Refilling the Front Brake Fluid Reservoir
33
Checking the Front Brake Pads
33
Replacing the Front Brake Pads
34
Changing the Basic Position of the Foot Brake Pedal
34
Checking the Rear Brake Fluid Level
34
Refilling the Rear Brake Fluid Reservoir
34
Checking the Rear Brake Pads
35
Replacing the Rear Brake Pads
35
Dismounting and Mounting the Front Wheel
35
Dismounting and Mounting the Rear Wheel
36
Tires-Air Pressure
37
Checking the Spoke Tension
37
Replacing the Battery of the Electronic Speedometer
37
Activating/Deactivating the Display Modes
38
Kilometers or Miles
38
Setting the Clock of the Electronic Speedometer
38
Checking/Setting the Distance of the Magnetic Sensor
39
Replacing the Headlight Lamp
39
Cooling System
40
Radiator Cover for the Cold Season
40
Checking the Coolant Level
40
Refilling/Bleeding the Cooling System
41
Cleaning the Air Filter
41
Changing the Original Position of the Clutch Lever
42
Checking the Oil Level of the Hydraulic Clutch
42
Bleeding of the Hydraulic Clutch
42
Exhaust System
42
Cleaning the Spark Arrestor (EXC USA)
43
Carburetor Adjustment
43
Draining the Float Chamber of the Carburetor
44
Checking the Float Level
44
Checking the Transmission Oil Level (125/200)
45
Changing the Transmission Oil (125/200)
45
Checking the Transmission Oil Level (250/300)
45
Changing the Transmission Oil (250/300)
45
Cleaning
46
Conservation for Winter Operation
46
Storage
46
Using RE Iniation
46
Use after a Period of Storage
46
Technical Specifications - Chassis (125/200)
47
Technical Specifications - Engine (125/200)
49
Technical Specifications - Chassis (250/300)
51
Technical Specifications - Engine (250/300)
53
Tightening Torques
54
Periodic Lubrication - and Maintenance-Schedule
55
Index
55

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