KTM 125 200 Engine Repair Manual – PDF DOWNLOAD
DESCRIPTION:
KTM 125 200 Engine Repair Manual – PDF DOWNLOAD
INTRODUCTION :
- This repair manual offers extensiv repair-instructions and is an up-to-date version that describes the
latest models of the series. However, the right to modifications in the interest of technical
improvement is reserved without updating the current issue of this manual. - A description of general working modes common in work shops has not been included. Safety rules
common in the work shop have also not been listed. We take it for granted that the repairs are
made by qualified profesionally trained mechanics. - Read through the repair manual before beginning with the repair work.
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
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VIDEO PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
S.V