Ktm duke 200 руководство по ремонту

Руководства по эксплуатации, обслуживанию и ремонту мотоциклов и квадроциклов KTM

Сборник руководств (92 штуки) на английском языке по эксплуатации и техническому обслуживанию мотоциклов KTM 2000-2014 годов выпуска.

• Издательство: KTM-Sportmotocycle AG
• Год издания: 1999-2013
• Страниц: —
• Формат: PDF
• Размер: 341,5 Mb

Owner`s Manual 2008 KTM 450 XC ATV/525 XC ATV.

Руководство на английском языке по эксплуатации и техническому обслуживанию квадроциклов KTM 450 XC/525 XC 2008 года выпуска.

• Издательство: KTM-Sportmotocycle AG
• Год издания: 2007
• Страниц: 103
• Формат: PDF
• Размер: 6,6 Mb

Owner`s Manual 2012 KTM 525 XC ATV.

Руководство на английском языке по эксплуатации и техническому обслуживанию квадроциклов KTM 525 XC 2012 года выпуска.

• Издательство: KTM-Sportmotocycle AG
• Год издания: 2011
• Страниц: 207
• Формат: PDF
• Размер: 3,9 Mb

Owner`s Repair Manual KTM 250 MX/250 MXC/250 GS.

Руководство на английском и немецком языках по техническому обслуживанию и ремонту мотоциклов KTM 250 GS/250 MX/250 MXC.

• Издательство: KTM-Motor-Fahrzeugbau KG
• Год издания: 1983
• Страниц: 63
• Формат: PDF
• Размер: 178,0 Mb

Repair Manual Engine KTM 60 SX/65 SX.

Руководство на английском языке по ремонту двигателей мотоциклов KTM 60 SX/65 SX.

• Издательство: KTM Sportmotocycle AG
• Год издания: —
• Страниц: 92
• Формат: PDF
• Размер: 3,2 Mb

Repair Manual Engine KTM 85 SX.

Руководство на английском языке по ремонту двигателя мотоциклов KTM 85 SX.

• Издательство: KTM Sportmotocycle AG
• Год издания: —
• Страниц: 89
• Формат: PDF
• Размер: 3,1 Mb

Repair Manual Engine KTM 125/200.

Руководство на английском языке по ремонту двигателей KTM 125/200.

• Издательство: KTM Sportmotocycle AG
• Год издания: —
• Страниц: 92
• Формат: PDF
• Размер: 158,0 Mb

Repair Manual Engine KTM 250 SX.

Руководство на английском языке по ремонту двигателя мотоциклов KTM 250 SX.

• Издательство: KTM Sportmotocycle AG
• Год издания: —
• Страниц: 80
• Формат: PDF
• Размер: 2,7 Mb

Repair Manual Engine 2005-2006 KTM 250 SX-F.

Руководство на английском языке по ремонту двигателя мотоциклов KTM 250 SX-F 2005-2006 годов выпуска.

• Издательство: KTM Sportmotocycle AG
• Год издания: —
• Страниц: 125
• Формат: PDF
• Размер: 7,3 Mb

Repair Manual Engine 2004-2006 KTM 250/300.

Руководство на английском языке по ремонту двигателей мотоциклов KTM 250/300 SX/SXS/MXC/EXC/EXC Six Days/XC/XC-W 2004-2006 годов выпуска.

• Издательство: KTM Sportmotocycle AG
• Год издания: —
• Страниц: 159
• Формат: PDF
• Размер: 11,3 Mb

Repair Manual Engine KTM 250/300/380 SX, MXC, EXC.

Руководство на английском языке по ремонту двигателей мотоциклов KTM 250/300/380 EXC, MXC, SX.

• Издательство: KTM Sportmotocycle AG
• Год издания: —
• Страниц: 153
• Формат: PDF
• Размер: 5,3 Mb

Repair Manual Engine KTM 250-525 SX, MXC, EXC Racing.

Руководство на английском языке по ремонту двигателей мотоциклов KTM 250-525 SX, MXC, EXC Racing.

• Издательство: KTM Sportmotocycle AG
• Год издания: —
• Страниц: 167
• Формат: PDF
• Размер: 26,3 Mb

Repair Manual Engine 2000-2006 KTM 250-610.

Руководство на английском языке по ремонту двигателей мотоциклов KTM 250 EXC Racing, 400/450 SX, MXC, XC, EXC, SMR, SXS Racing, 520/525 SX, MXC, XC, EXC, SMR Racing, 540 SXS, 560 SMR, 640 Crate 2000-2006 годов выпуска.

• Издательство: KTM Sportmotocycle AG
• Год издания: —
• Страниц: 125
• Формат: PDF
• Размер: 12,2 Mb

Repair Manual Engine KTM 400/620 LC4/LC4e `97.

Руководство на немецком языке по ремонту двигателей KTM 400/620 LC4/LC4e 1997 года выпуска.

• Издательство: KTM Sportmotocycle AG
• Год издания: —
• Страниц: 76
• Формат: PDF
• Размер: 10,2 Mb

Repair Manual Engine KTM 400-660 LC4 2003.

Руководство на английском языке по ремонту двигателей KTM 400-660 LC4 2003 года выпуска.

• Издательство: KTM Sportmotocycle AG
• Год издания: —
• Страниц: 387
• Формат: PDF
• Размер: 18,4 Mb

Repair Manual Engine KTM 950 Adventure 2003.

Руководство на английском языке по ремонту двигателей мотоциклов KTM 950 Adventure 2003 года выпуска.

• Издательство: KTM Sportmotocycle AG
• Год издания: —
• Страниц: 185
• Формат: PDF
• Размер: 9,1 Mb

Repair Manual Engine KTM 950 Adventure/990 Super Duke 2003-2005.

Руководство на английском языке по ремонту двигателей мотоциклов KTM 950 Adventure и 990 Super Duke 2003-2005 годов выпуска.

• Издательство: KTM Sportmotocycle AG
• Год издания: —
• Страниц: 273
• Формат: PDF
• Размер: 18,0 Mb

Repair Manual Engine KTM 950/990 2003-2006.

Руководство на английском языке по ремонту двигателей мотоциклов KTM 950/990 Adventure, 950 Super Enduro, 950 Supermoto, 990 Super Duke 2003-2006 годов выпуска.

• Издательство: KTM Sportmotocycle AG
• Год издания: —
• Страниц: 394
• Формат: PDF
• Размер: 24,4 Mb

Repair Manual Engine KTM 950/990 2003-2007.

Руководство на английском языке по ремонту двигателей мотоциклов KTM 950/990 Adventure, 950 Super Enduro, 950 Supermoto, 990 Super Duke 2003-2007 годов выпуска.

• Издательство: KTM Sportmotocycle AG
• Год издания: —
• Страниц: 394
• Формат: PDF
• Размер: 25,8 Mb

Repair Manual WP Shok absorber 2005-2006.

Руководство на английском языке по ремонту амортизаторов WP Suspension моделей 5018 DCC/5018 SXS/5018 SMR 2005-2006 годов выпуска.

• Издательство: KTM Sportmotocycle AG
• Год издания: —
• Страниц: 103
• Формат: PDF
• Размер: 5,1 Mb

Repair Manual WP Fork SXS/SMR 4860 MXMA 2005-2006.

Руководство на английском языке по ремонту амортизаторов WP Suspension Fork SXS/SMR 4860 MXMA 2005-2006 годов выпуска.

• Издательство: KTM Sportmotocycle AG
• Год издания: —
• Страниц: 123
• Формат: PDF
• Размер: 6,8 Mb

Workshop Manual WP 4860 MXMA.

Руководство на английском языке по ремонту амортизаторов WP Suspension модели 4860 MXMA.

• Издательство: —
• Год издания: —
• Страниц: 51
• Формат: PDF
• Размер: 1,5 Mb

Workshop Manual WP 5018 PDS 2003.

Руководство на английском языке по ремонту амортизаторов WP Suspension модели 5018 PDS 2003 года выпуска.

• Издательство: —
• Год издания: —
• Страниц: 99
• Формат: PDF
• Размер: 4,9 Mb

Мотоциклы. Устройство и принцип действия.

В руководстве представлена информация об устройстве и работе всех узлов и агрегатов мотоцикла.

• Издательство: Алфамер
• Год издания: —
• Страниц: 220
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Источник

KTM 125 200 sx exc, 1999-2003 125-200 Duke Service Manual

Art No 320588 -E

Repair manual KTM 125 / 200

KTM SPORTMOTORCYCLE AG

5230 Mattighofen Austria www.ktm.at

REPAIR MANUAL ENGINE

2 GENERAL INFORMATION

3 REMOVING AND REFITTING ENGINE

4 DISASSEMBLING THE ENGINE

5 SERVICING INDIVIDUAL COMPONENTS

6 ASSEMBLING THE ENGINE

8 TROUBLE SHOOTING

9 TECHNICAL SPECIFICATIONS

10 PERIODIC MAINTENANCE SCHEDULE

11 WIRING DIAGRAMS

I MPORTANT I NFORMATION /U PDATING INSTRUCTIONS

To be able to continue using the existing loose-leaf repair instructions, simply print the following pages and insert them in the existing repair instructions:

Replace by page (s)

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 (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.

E XP LA NATION — U PD ATING

3.205.74-E Repair Manual 125/200 SX, MXC, EXC

Basicversion Modelyear 1999 (Engine number with first digit “9“)

3.205.88-E Updating of Rep.Manual 3.205.74-E

(2000: Engine number with first digit “0“) (2001: Engine number with first digit “1“)

3.210.27-E Updating of Rep.Manual 3.205.74-E

(Engine number with first digit “2“)

3.206.005-E Updating of Rep.Manual 3.205.74-E

(Engine number with first digit “3“)

Technical Details, Technical Specifications,

Periodic Maintenance Schedule, Wiring Diagrams

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.

STRICT COMPLIANCE WITH THESE INSTRUCTIONS IS

ESSENTIAL TO AVOID DANGER TO LIFE AND LIMB.

NON-COMPLIANCE WITH THESE INSTRUCTIONS CAN LEAD

TO DAMAGE OF MOTORCYCLE COMPONENTS OR RENDER

MOTORCYCLES UNFIT FOR TRAFFIC !

„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.

KTM Sportmotorcycle AG

5230 Mattighofen, Austria

All design and assembly modification rights reserved.

C by KTM SPORTMOTORCYCLE AG, AUSTRIA

All rights reserved

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 – whether these are technical errors, incorrect or unclear repair procedures, tool problems, missing technical data or torques, inaccurate or incorrect translations or wording, etc. – please enter the error(s) in the table below and fax the completed form to us at 0043/7742/6000/5349.

– Enter the complete item no. for the repair manual in column 1 ( e.g.: 3.206.005-E ).

You will find the number on the cover page or in the left margin on each right page of the manual.

– Enter the corresponding page number in the repair manual ( e.g.: 5-7c ) in column 2.

– Enter the current text (inaccurate or incomplete) in column 3 by quoting or describing the respective passage of the text. If your text deviates from the text contained in the repair manual, please write your text in German or English if possible.

– Enter the correct text in column 4.

Your corrections will be reviewed and incorporated in the next issue of our repair manual.

Item no. of repair manual

Additional suggestions, requests or comments on our Repair Manuals (in German or English):

Name mechanic/shop foreman

GENERAL INFORMATION

OPERATING RANGES OF THE CARBURETOR . . . . . . . . . . . . . . . . . . . . . . .

BLEEDING OF THE HYDRAULIC CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . .

OIL PUMP ADJUSTING —

MODELS WITH SEPARATE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . .

Art No 3.206.005-E

Repair manual 125 / 200

Art No 3.206.005 -E

Repair manual KTM 125 / 200

main jet 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

1

Operation with closed throttle valve. This range is influenced by the position of the air control screw 1 and the idle adjusting screw 2 . Only make adjustments when the engine is hot.

To this end, slightly decrease the idling speed of the engine by means of the idle adjusting screw. Turning it clockwise produces a higher idling speed and turning the screw counterclockwise produces a lower idling speed. Create a round and stable engine speed using the air control screw (basic position of the air control screw = open by 1.5 turns and 1,25 on EXE and Supermoto). Then adjust to the normal idling speed by means of the idle adjusting screw.

Engine behavior when the throttle opens. The idle jet and the shape of the throttle valve influences this range. If, despite good idling-speed and part-throttle setting, the engine sputters and smokes when the throttle is fully opened and develops its full power not smoothly but suddenly at high engine speeds, the mixture to the carburetor will be too rich, the fuel level too high or the float needle is leaking.

Part-throttle range C

Operation with partly open throttle valve. This range is only influenced by the jet needle (shape and position). The optimum part-throttle setting is controlled by the idling setting in the lower range and by the main jet in the upper range. If the engine runs on a four-stroke cycle or with reduced power when it is accelerated with the throttle partly open, the jet needle must be lowered by one notch. If then the engine pings, especially when accelerating under full power at maximum engine revs, the jet needle should be raised.

If these faults should occur at the lower end of the part throttle range at a four-stroke running, make the idling range leaner; if the engine pings, adjust the idling range richer.

Full throttle range D

Operation with the throttle fully open (flat out). This range is influenced by the main jet and the jet needle. If the porcelain of the new spark plug is found to have a very bright or white coating or if the engine rings, after a short distance of riding flat out, a larger main jet is required. If the porcelain is dark brown or black with soot the main jet must be replaced by a smaller one.

Carburetor adjustment

Basic information on the original carburetor setting

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).

Mixing ratio 2-stroke motor oil : super fuel 1:40.

Basic information on a change of the carburetor setting

Always start out from the original carburetor setting. Essential requirements are a clean air filter system, air-tight exhaust system and an intact carburetor. Experience has shown that adjusting the main jet, the idling jet and the jet needle is sufficient and that changes of other parts of the carburetor will not greatly affect engine performance.

high altitude or high temperatures low altitude or low temperatures

choose leaner carburetor adjustment

choose richer carburetor adjustment

– O NLY USE PREMIUM — GRADE GASOLINE (125: ROZ 98 / 200: ROZ 95) MIXED WITH HIGH — GRADE TWO — STROKE ENGINE OIL . O THER TYPES OF GASOLINE CAN CAUSE ENGINE FAILURE , AND USE OF SAME WILL VOID YOUR WARRANTY .

– O NLY USE HIGH — GRADE 2- STROKE ENGINE OIL OF KNOWN BRANDS .

– N OT ENOUGH OIL OR LOW — GRADE OIL CAN CAUSE EROSION OF THE PISTON . U SING TOO MUCH OIL , THE ENGINE CAN START SMOKING AND FOUL

– I N THE CASE OF A LEANER ADJUSTMENT OF THE CARBURETOR PROCEED CAUTIOUSLY . A LWAYS REDUCE THE JET SIZE IN STEPS OF ONE NUMBER TO AVOID OVERHEATING AND PISTON SEIZURE .

NOTE: If despite a changed adjustment the engine does not run properly, look for mechanical faults and check the ignition system.

Basic information on carburetor wear

As a result of engine vibrations, throttle valve, jet needle, and needle jet are subjected to increased wear. This wear may cause carburetor malfunction (e.g., overly rich mixture). Therefore, these parts should be replaced after 10 000 kilometers (6 000 miles).

throttle valve open

throttle valve open

Compared to the needle NOZ D, the jet needle NOZ F is two steps leaner in the range from the closed position of the throttle to 1/4 throttle. Otherwise, there are not differences.

Compared to the needle R 1467D, the jet needle R 1469D is two steps leaner in the range from the closed position of the throttle to 1/4 throttle. Otherwise, there are not differences.

Art No 3.206.005 -E

Repair manual KTM 125 / 200

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 1 . Instead of mount the bleeder syringe 2 which is filled with SAE 10 biodegradable hydraulic oil (ex. Shell Naturelle HF-E15).

– Refill oil, until oil is discharged from the bore 3 of the master cylinder in a bubble-free state. Make sure that the oil does not overflow.

H AVING COMPLETED THE BLEEDING PROCEDURE , YOU HAVE TO VERIFY THAT THE OIL LEVEL IN THE MASTER CYLINDER IS CORRECT . FOR FILLING OF THE MASTER CYLINDER ,

USE SAE 10 BIODEGRADABLE HYDRAULIC OIL ONLY ( EX . S HELL N ATURELLE

HF-E15); NEVER USE BRAKE FLUID NOR MIX BIODEGRADABLE HYDRAULIC OILS WITH MINERAL OILS .

Adjusting oil pump (only with separate lubrication)

NOTE: Prior to adjusting the oil pump, you have to check and, if necessary, adjust the clearance of the throttle cable.

– Loosen the 3 bolts 1 of the oil pump housing and remove the oil pump cover 2 . To make adjustment and control easier, loosen the bolts of the intake flange 3 , remove 4 of them and move the flange sidewards.

– If the oil pump has been adjusted correctly, the mark A must coincide with the notch B on the cable pulley (except 125 EXE and 125 Supermoto).

– On 125 EXEand 125 Supermoto-models the notch B must coincide with the edge C .

I F THE ADJUSTMENT OF THE OIL PUMP IS NOT CORRECT , THE ENGINE IS NOT SUPLIED WITH THE CORRECT AMOUNT OF OIL AND THIS CAN RESULT IN ENGINE DAMAGE .

– If necessary, loosen the lock nut 4 , and correct the adjustment by turning the adjusting screw 5 as required.

– Following the adjustment procedure, the lock nut has to be tightened again.

– Mount cover 2 and flange 3 , tighten the 2 bolts.

Check of the exhaust control (engine running)

– Remove the left side cover from the cylinder.

– Mark 1 of the control segment is near by mark 2 of the guide plate.

B ASE POSITION MUST BE ADJUSTED WITH A DEPTH GAUGE — SHOWN IN CHAPTER

6-10 — DIMENSION „Z“.

– Open throttle flap, with increasing the revolutions mark 1 moves downwards to the bore in the housing 3 .

M ARK 4 IS NOT USED .

I F MARK 1 DOES NOT REACH BORE 3 OR DOES NOT MOVE , THE EXHAUST

CONTROL MECHANISM IS TO BE OVERHAULED .

– Mount cover and tighten the bolts.

Art No 3.206.005 -E

Repair manual KTM 125 / 200

REMOVING AND REFITTING ENGINE 3

REMOVING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

REFITTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

Art No 3.206.005-E

Repair manual 125 / 200

Art No 3.206.005 -E

Repair manual KTM 125 / 200

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.

– Thoroughly clean the motorcycle.

– Use a suitable supporting device to jack up the motorcycle.

– Remove the seat and the tank with the spoilers.

– Drain the cooling liquid.

– Remove the exhaust system and the engine brace.

– Disconnect the radiator hoses at the engine.

– Remove the carburetor.

– Dismount the brake cylinder cover.

– Remove the engine sprocket cover and the chain.

– Disconnect the electrical wires.

– Unscrew the clutch master cylinder and reposition the clutch line such that it will not get entangled when the engine is lifted out.

– Unhook the return spring of the foot brake pedal from the clutch cover.

– Undo the engine mounting bolts.

– Remove the swingarm pivot and pull the swingarm backwards.

– Lift the engine out of the frame on the left side.

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.

– Connect the electrical wires.

– Position clutch line correctly, and mount clutch master cylinder at handlebar.

– Mount the chain and the engine sprocket cover.

– Mount brake cylinder cover.

– Mount the carburetor.

Art No 3.206.005 -E

Repair manual KTM 125 / 200

– 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. Retighten the screws as soon as the cooling liquid that emerges is free of air bubbles.

– Mount the exhaust system.

– Mount the tank with the spoilers and the seat.

– Fix the breather tube to the frame.

– Check the electrical system for faultless operation.

– Adjust the carburetor.

– After the test ride, check the engine, the cooling system and the exhaust system for leaks.

Fixing the cables to the frame — Models with separate lubrication

T O PREVENT DISENGAGEMENT OF THE THROTTLE CABLE AND THE OIL PUMP CABLE IT IS NECESSARY TO FIX 1 THE CABLES ABOVE THE CARBURATOR TO THE FRAME .

Art No 3.206.005-E

Repair manual 125 / 200

DISMANTLING THE ENGINE

DISMOUNTING THE CLUTCH SLAVE CYLINDER . . . . . . . . . . . . . . . . . . . .

REED VALVE HOUSING, INTAKE FLANGE AND CLUTCH COVER . . . . . . . . .

REED VALVE HOUSING, INTAKE FLANGE AND OIL PUMP

MODELS WITH SEPARATE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . .

REMOVING CLUTCH AND PRIMARY DRIVE . . . . . . . . . . . . . . . . . . . . . . . .

REMOVING SHIFT MECHANISM AND TRANSMISSION . . . . . . . . . . . . . . . .

SPECIAL TOOLS – ENGINE

WOODEN FORK PLATE

Repair manual KTM 125 / 200

Universal engine work stand

Clutch holder 125 / 200

Holding spanner for primary gear wheel

Magneto extractor M27x1 Kokusan

Holding spanner for flywheel Kokusan 2K-1/2/3/4

Dial gauge 1-10 mm

Dial gauge support

Loctite 243 blue 6 ccm

Mounting tool inner ring NJ206

Adjusting plate for control flap

Holding plate for locating drum

– 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.

4

Cylinder head, cylinder, piston

– Undo the 6 bolts 5 and remove the cylinder head together with the

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.

Art No 3.206.005 -E

Repair manual KTM 125 / 200

– 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.

– Remove the piston and take the piston pin bearing out of the conrod eye.

– Remove the cylinder base gaskets.

Ignition

– Remove 4 bolts and take off the ignition cover together with the gasket.

– Hold the rotor with the special tool and undo the hexagon nut.

– Take the hexagon nut and the detent edged ring off the crankshaft.

– Twist the rotor extractor into the thread of the rotor (LH thread) and remove the rotor.

– Remove the 3 collar bolts 1 and take the stator out of the housing.

– Take the woodruff key out of the crankshaft.

1

Engine sprocket

– Use a pair of circlip pliers to take the circlip 2 off the countershaft.

– Take the engine sprocket, the distance bushing and the O-ring off the countershaft.

Reed valve housing, intake flange and clutch cover

– Remove 5 bolts 1 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.

– Remove the cover 3 of the centrifugal timer together with the seal ring and undo screw 2 .

– Remove all bolts of clutch cover and the 2 front-end bolts 4 of the water-pump cover, and dismount clutch cover.

– Remove the clutch cover gasket and pull the dowels out of the housing.

– Take O-ring 8 out of water bore.

NOTE: The water pump cover 5 , the exterior cap 6 and the hexagon cap nut 3 need not be removed. The water pump and the centrifugal timer are left in the clutch cover.

W HEN REMOVING THE CLUTCH COVER MAKE SURE THAT THE ROCKER ARM 7 OF THE EXHAUST CONTROL DOES NOT JAM IN THE HOUSING AND IS NOT DAMAGED .

Reed valve housing, intake flange and oil pump (separate

– When dismounting the clutch cover 2 additionally remove the bolt

– Pull the oil pump wheel A off the oil pump

– Remove the cover D from the oil pump housing.

Remove the 4 bolts of the intake flange and then, move the intake

flange sideways as shown.

– Pull the 2 dowel bushings B out of the housing.

NOTE: The bolt 3 at the intake flange can be unscrewed completely

only as soon as the oil pump housing E has been dismantled.

– Pull the oil pump housing off the engine case and swing it

sideways (see picture).

– Remove the 2 bolts C , and withdraw oil pump together with gasket

from the engine case.

– Remove the bolt 3 at the intake flange, and dismount intake flange

together with reed valve housing.

Removing clutch and primary drive

– Undo the 5 bolts 4 in diagonal order so as to prevent jamming of the

clutch discs when the springs relax.

– Remove bolts, spring retainers and springs.

Take the pressure cap and the disc package out of the outer clutch

– Pull the thrust bearings out of the main shaft.

– 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.

– Take the supporting disc 1 and the outer clutch hub together with the bearing off the main shaft.

– Remove the intermediate starter gear and the stop disc 2 below.

– Mount the primary gear holder and undo the hexagon nut (LH thread).

– Remove the primary gear holder.

– Take the hexagon nut, the detent edged ring and the primary gear off the crankshaft.

– Take the woodruff key out of the crankshaft.

Shift drum locating, kickstarter

– Simply pull the shift shaft out of the housing. Keep in mind the stop disc 3 (It can be left in the housing).

Art No 3.206.005 -E

Repair manual KTM 125 / 200

– Carefully unhook the kickstarter spring from bore 1 (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 2 together with the ratchet carrier 3 . Procede with care by watching out for the collar bushing 4 on the ratchet carrier.

– The locking lever 5 need not be removed unless the engine housing is exchanged.

– For this purpose, undo bolt 6 , then remove the locking lever together with the spring.

– Take the washer 7 out of the locking drum.

– Hold the locking drum 9 with the special tool, undo bolt 8 and remove the bolt together with the washer.

– Pull the locking drum off the shift roller.

T HE LOCKING DRUM MUST BE HELD WITH THE SPECIAL TOOL TO PREVENT DAMAGING OF THE BUSHINGS ON THE DRIVING PINS OF THE SHIFT FORKS .

Dividing the engine housing

– Swing the ignition side upwards and remove all 12 housing bolts.

– Undo the engine mounting device at the mounting rack.

– Lift the left housing half by the lifting points of the housing, using appropriate tools, or separate it from the right housing half by lightly tapping the countershaft with a plastic hammer.

T O PREVENT DAMAGING OF THE SEALING SURFACES , DO NOT USE A SCREWDRIVER OR SIMILAR TOOL TO LEVER THE HOUSING HALVES APART !

– Remove the housing half and the gasket.

– Keep in mind the stop disc of the main shaft (can stick to the inside of the housing).

Removing shift mechanism and transmission

– Pull out the shift rails 1 and swing the shift forks 2 including rollers

– Pull the shift roller 4 out of the grooved ball bearing.

– Take the shift forks 2 out of the housing.

NOTE: When dismounting the shift forks, make sure that you do not

lose the rollers 3 on the shift forks.

– Pull the complete main shaft and the countershaft together out of the bearing seats.

Removing crankshaft

– Pull the crankshaft out of the bearing seat (if necessary lightly tap it with a plastic hammer).

– Take the distance bushing 5 and the O-ring 6 out of the right crankshaft seal ring.

– Clean all parts. Check for wear and exchange worn components.

NOTE: All gaskets, shaft seal rings, O-rings and bearings should be exchanged on the occasion of each complete engine overhaul.

Art No 3.206.005-E

Repair manual 125 / 200

SERVICING INDIVIDUAL COMPONENTS 5

RIGHT HOUSING HALF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2 LEFT HOUSING HALF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3 CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4 CRANKSHAFT WEBS – MEASURE OUTER DIMENSION . . . . . . . . . . . . . . . .5-4 PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4 PISTON RING END GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4 CHECKING CYLINDER FOR WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5 NIKASIL COATING OF CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5 DISMOUNTING AND CHECKING THE EXHAUST CONTROL

SYSTEM IN THE CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6 PREASSEMBLING THE CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7 CLUTCH COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10 PREASSEMBLING THE CLUTCH COVER . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10 WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11 PREASSEMBLING THE WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11 CHECKING CLUTCH FOR WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12 REED VALVE HOUSING, INTAKE FLANGE . . . . . . . . . . . . . . . . . . . . . . . . . .5-13 KICKSTARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14 PREASSEMBLING THE KICKSTARTER SHAFT . . . . . . . . . . . . . . . . . . . . . . .5-14 SHIFT MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16 PREASSEMBLING THE SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16 TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-17 ASSEMBLING THE MAIN SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-17 ASSEMBLING THE COUNTERSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18 IGNITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-19 CHECK STATOR AND PULSE GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . .5-19

NOTE: Read through the following section before commencing work. Then determine the assembly sequence so that the engine housing halves only need to be heated up once before replacing the bearings.

Having first removed the dowels, in order to expel the bearings or remove them with light mallet blows, the housing halves must be placed on a suitably large plane surface, supporting the whole of the sealing surface without damaging it. A wooden panel is best used as a base.

Bearings or shaft seal rings should not be hammered into their seats. If no suitable press is available, use a suitable mandrel and hammer them in with great care. Cold bearings will practically drop into their seats at an engine housing temperature of approx. 150° C.

After cooling, should the bearings fail to lock in the bore, they are bound to rotate after warming. In that event the housing must be replaced.

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