KTM 125, 200 Engines - Repair, Service and Maintenance Manual

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KTM 125, 200 ENGINE - WORKSHOP, SERVICE, REPAIR MANUAL

- English Service Manual / Repair Manual, for KTM 125, 200 Engines.
 

CONTENTS:

Service-Informations
- Derestriction
- Intermediate Flange
- Shift Spring
- Chain Tension
- Control Flap Axle
- Oilpump Adjustment
- Crankshaft Main Bearing
- Master Cylinder
General Information
- Operating Ranges Of The Carburetor
- Carburetor Adjustment
- Bleeding Of The Hydraulic Clutch
- Oil Pump Adjusting -Models With Separate Lubrication
- Check Of Exhaust Control
Removing And Refitting Engine
- Removing The Engine
- Refitting The Engine
Disassembling The Engine
- Special Tools – Engine 125/200
- Draining The Gear Oil
- Dismounting The Clutch Slave Cylinder
- Cylinder Head, Cylinder, Piston
- Ignition
- Engine Sprocket
- Reed Valve Housing, Intake Flange And Clutch Cover
- Reed Valve Housing, Intake Flange And Oil Pumpmodels With Separate Lubrication
- Removing Clutch And Primary Drive
- Shift Drum Locating, Kickstarter
- Dividing The Engine Housing
- Removing Shift Mechanism And Transmission
- Removing Crankshaft
Servicing Individual Components
- Right Housing Half
- Left Housing Half
- Crankshaft
- Crankshaft Webs – Measure Outer Dimension
- Piston
- Piston Ring End Gap
- Checking Cylinder For Wear
- Nikasil Coating Of Cylinder
- Dismounting And Checking The Exhaust Controlsystem In The Cylinder
- Preassembling The Cylinder
- Clutch Cover
- Preassembling The Clutch Cover
- Water Pump
- Preassembling The Water Pump
- Checking Clutch For Wear
- Reed Valve Housing, Intake Flange
- Kickstarter
- Preassembling The Kickstarter Shaft
- Shift Mechanism
- Preassembling The Shift Shaft
- Transmission
- Assembling The Main Shaft
- Assembling The Countershaft
- Ignition
- Check Stator And Pulse Generator
Assembling The Engine
- Mounting The Crankshaft
- Transmission Shaft, Shift Mechanism
- Assembling The Engine Housing
- Engine Sprocket
- Ignition System
- Shift Drum Locating Device
- Kickstarter
- Primary Drive, Clutch
- Clutch Discs, Pressure Cap
- Oil Pump, Reed Valve Housing, Intake Flange(Separate Lubrication)
- Reed Valve Housing, Intake Flange
- Clutch Cover
- Piston, Cylinder
- Adjusting Dimension „X“
- Adjusting The Control Flap (Dimension „Z“)
- Cylinder Head
- Ignition Cover
- Measuring Dimension „Y“
- Mounting The Clutch Slave Cylinder
- Filling In The Gear Oil
Electrical
- Checking The Voltage Regulator-Rectifier (Shindengen)
- Checking The Voltage Regulator (Kokusan)
- Checking The Capacitor
- Ignition Coil (Kokusan)
- Cdi Unit
- Measurements With Peak Voltage Adapter
- Static Ignition Values 125-200 Sx, Mxc, Exc
- Static Generator Values 125-200 Exc
- Static Ignition Values/Generator Values 125-200 Mxc, Exc Usa
- Static Ignition Values 125 Exe, Supermoto
- Static Generator Values 125 Exe, Supermoto
Trouble Shooting
Technical Specifications
- Model 1999
- Technical Specifications – Engine 125/200
- Technical Specifications – Chassis 125/200
- Technical Specifications – Engine 200 Only Singapore
- Basic Carburetor Setting – 200 Only Singapore
- Model 2000
- Technical Specifications – Engine 125 Exe, Supermoto
- Technical Specifications – Chassis 125 Exe, Supermoto
- Technical Specifications – Engine 125/200 Sx, Mxc, Exc
- Technical Specifications – Chassis 125/200 Sx, Mxc, Exc
- Model 2001
- Technical Specifications – Engine 125 Exe, Supermoto
- Technical Specifications – Chassis 125 Exe, Supermoto
- Technical Specifications – Engine 125/200
- Technical Specifications – Chassis 125/200
- Model 2002
- Technical Specifications – Engine 125/200
- Technical Specifications – Chassis 125/200
- Model 2003
- Technical Specifications – Engine 125/200
- Technical Specifications – Chassis 125/200
- Carburator Specification
- Model 1999
- Model 2000
- Model 2001
- Model 2002
- Model 2003
Periodic Maintenance Schedule
- 125 / 200 Up To 2000
- 125 / 200 Sx, Mxc, Exc 2001 / 2002
- 125 Exe, Supermoto
- 125 / 200 Sx, Mxc, Exc 2003
Wiring Diagrams
- Wiring Diagrams 1999
- 125/200 Exc (Europe)
- 125/200 Egs
- 125 Exc (Usa)
- 200 Exc (Usa)
- Wiring Diagrams 2000
- 125/200 Exc (Usa)
- 125/200 Exc (Europa)
- 125 Exe, Supermoto
- Wiring Diagrams 2001
- 125/200 Exc (Europa)
- 125/200 Exc (Usa)
- 125 Exe, Supermoto
- Wiring Diagrams 2002
- 125/200 Exc (Europa)
- 125/200 Exc (Usa)
- Wiring Diagrams 2003
- 125/200 Exc (Europa)
- 125/200 Exc (Usa)