125 SX USA 2013 SPARE PARTS MANUAL: CHASSIS ENGLISH ART.NO.: 3CFF6175M0EN

Transcription

1 125 SX USA 2013 SPARE PARTS MANUAL: CHASSIS ART.NO.: 3CFF6175M0EN ENGLISH

2

3 INDEX 125 SX USA 2013 FRONT FORK DISASSEMBLED FRONT FORK, TRIPLE CLAMP HANDLEBAR, CONTROLS FRAME 3x 5x 6x 7x SHOCK ABSORBER DISASSEMBLED SHOCK ABSORBER PRO LEVER LINKING SWING ARM 9x 11x 12x 13x EXHAUST SYSTEM AIR FILTER TANK, SEAT, COVER DECAL 14x 15x 16x 17x 1

4 INDEX 125 SX USA 2013 MASK, FENDERS FRONT WHEEL REAR WHEEL BRAKE CALIPER FRONT 18x 19x 20x 22x HAND BRAKE CYLINDER REAR BRAKE CONTROL BRAKE CALIPER REAR ACCESSORIES KIT 23x 24x 25x 26x All information contained is without obligation. KTM-Sportmotorcycle AG particularly reserves the right to modify any equipment, technical specifications, prices, colors, shapes, materials, services, service work, constructions, equipment and the like so as to adapt them to local conditions or to cancel any of the above items, all without previous announcement and without giving reasons. KTM may stop manufacturing certain models without previous notice. KTM shall not be held liable for any deviations of availability and/or ability to deliver, illustrations, descriptions, printing and/or other errors. The illustrated models partly contain extra equipment, which is not applied to standard models. by KTM-SPORTMOTORCYCLE AG, Mattighofen AUSTRIA; All rights reserved; Reprint, also in extracts, with written allowance of KTM- SPORTMOTORCYCLE AG, Mattighofen only. x 2

5 FRONT FORK DISASSEMBLED 125 SX USA S ADJUSTING KNOB + SCREW OUTER TUBE L577 D54/60MM 2L FORK PROTECTION RING GUIDING BUSH 48X52X12 R SUPPORT RING 50 X 57,6 X 1, OIL SEAL RING D48 SKF LOCK WASHER SB DUST SEAL DL D48 SKF GUIDING BUSH 47X49X20 R MEMBRANE O-RING NBR 9,5X1, O-RING NBR 17X2 PA S SCREW BUSH M20X1 L=33 CPL COPPER WASHER 20,5X26X ADJUSTING TUBE L= PISTON ROD SXS COUNTERNUT M12X1 WS REBOUND NEEDLE SX O-RING 2X1,5 NBR REBOUND SPRING C=4N/MM S SPRING D43.2 L N/MM x S SPRING 4,4 N/MM SET D=5,1MM x S SPRING 4,6 N/MM SET D=5,1MM x S %POLISHED SPRING 4,8 N/MM x S SPRING 5,0 N/MM x S SPRING 4,0 N/MM SET x S SPRING 4,2 N/MM SET D=5,0MM x SPACER 43X35X2,5 x SPACER 43X35X5 x SPACER 43X35X1,5 x GUIDING BUSH REBOUND SPRING SPRING SUPPORT O-RING 6X1,2 NBR SPRING REB. L=32 C=37 DI=13, PISTON ROD REBOUND / C * NEW PART X AS REQUIRED 3

6 FRONT FORK DISASSEMBLED 125 SX USA SHUTTLE VALVE SPRING C=0, S3 MEMBRANE HOLDER INKL. PIN SET LOCK WASHER D=25, AH SCREW M4X O-RING NBR 21X PISTON COMPRESSION D=27, O-RING NBR 4X1, S PIN KIT NUT M6X0,5 REBOUND GUIDE RING 44 X RING SPRING-SUPPORT WASHER 32X42X2, SA AXLE CLAMP LEFT + TUBE CPL SA AXLE CLAMP RIGHT + TUBE CPL HH COLLAR SCREW M8X25 TX * NUT VALVE M6X0, SPRING CHECK VALVE D=0, PISTON ROD COMPRESSION PISTON REBOUND SX PISTON RING 5X1X RING 23,45X8, SHAFT SEAL RING 12MM S SCREW SLEEVE M24,5X1 CPL DU BUSH FOR PISTON ROD CHECK VALVE STOP LOCK WASHER D= SILICON CAP RUBBER CAP D=26,4 2 83* S1 FORK OIL SAE4 5L O-RING NBR 43X S1 SCREW CAP CPL. L= SCREW M4X MEMBRANE SLEEVE 2 98 T511 SILICONE GREASE F. DUST STRI 1 99 R14020 SXS SERVICE KIT / C * NEW PART X AS REQUIRED 4

7 FRONT FORK, TRIPLE CLAMP 125 SX USA * 14187M5101 FORK WP 125/150 SX US HH COLLAR SCREW M8X50 TX HH COLLAR SCREW M8X25 TX HH COLLAR SCREW M8X40 TX S HH COLLAR SCREW M8X25 WS= S AH-COLLAR SCREW M10X35 ISA O-RING 25X3,55 NBR EJOT PT SCREW K60X20 ALU WS=6 2 32* TRIPLE CL. BOTT. CPL. X=22 BL. 1 34* TRIPLE CLAMP TOP X=22 BLACK STEER.HEAD SCREW M20X1,5 WS= HANDLEBAR CLAMP 28MM HANDLEB.SUPP. D=28MM H=32MM 05 x HANDLEB.SUPP. D=28MM H=37MM HANDLEB.SUPP. D=28MM H=42MM 05 x TAPERED ROLLER BEARING CPL O-RING SUPPORT W. SEALING LIP STEARING HEAD GASKET TOP CLAMP F. SPEED. CABLE D=6MM STEERING HEAD COVER SPECIAL SCREW M6X12,5 WS= FORK PROTECT. L/S+R/S WHITE HANDLEBAR SUPPORT KIT D28/H37 x STEARING HEAD REP. KIT x / C * NEW PART X AS REQUIRED 5

8 HANDLEBAR, CONTROLS 125 SX USA * HANDLEBAR RENTHAL BLACK BAR PAD 1 10* THROTTLE GRIP CPL PROTECTION COVER ' * O-RING 40,94X2,62 NBR * THROTTLE CABLE 2T.DOM/KEIH SHORT CIRCUIT BUTTON * GRIP SET CABLE TIE 200/3,6MM BLACK MASTER CYLINDER CPL. 9,5MM CLUTCH LEVER CPL REP.KIT PISTON 9,5MM COVER HYDR. CLUTCH CPL RUBBER FOR RESERVOIR OIL FOR HYD. CLUTCH 75ML MUD CAP LEVER SCREW SHORT CPL CLAMP, CYL. PIN, O-RING PUSH ROD CPL HH COLLAR SCREW M6X16 TX CLUTCH PIPE L=970MM / C * NEW PART X AS REQUIRED 6

9 FRAME 125 SX USA * BE FRAME ANTHRACITE "515L3" SUB FRAME SX SUB FRAME APPLICATION LEFT SUB FRAME APPLICATION RIGHT ENGINE BRACE 125 SX TANK REST RUBBER SPECIAL SCREW M8X26 WS= HEXAGON NUT DIN0934-M ENGINE BRAC.SCR. M10X105 WS= S FLAT HEAD SCREW M. ISA45 M8X HH COLLAR SCREW M 8X44 WS BLIND PLUG-IN NUT M5 WN 22A CABLE TIE 140/2,5MM BLACK CABLE TIE 300/4,8MM BLACK COU.SUNK SCR. AH ISO7380 M5X BUSH F. FRAME PROTECTION SELF LOCKING NUT M SELF LOCKING NUT M10 CU WS= HH COLLAR SCREW M8X30 TX HH COLLAR SCREW M6X40 TX WASHER DIN0125-A 6, FOOT PEG L/S SILVER FOOT PEG R/S SILVER BOLT FOR FOOT PED FOOTREST SPRING L/S & R/S WASHER DIN0125-A10, PIN DIN0094-3,2X25 STEEL FOOTPEG L.+R. CPL ANGLE PIECE ' PVC-HOSE 7X10 PER METER x SPROCKET COVER 250 SX CHAIN SLIDING PIECE BELOW BLIND RIVET NUT EM6-60LF/HX PLASTIC FRAME PROTECTION SET CHAIN SLIDING KIT BELOW CPL / C * NEW PART X AS REQUIRED 7

10 FRAME 125 SX USA SPROCKET COVER KIT / C * NEW PART X AS REQUIRED 8

11 SHOCK ABSORBER DISASSEMBLED 125 SX USA S1 MONOSHOCK UPPER PART CPL. 1 2* S17 DCC COMPR.DAMP.CON. SX 13 USA BUSH KGW 10X R12012 REP. KIT BEAR./SEAL UP BLEED PLUG R 1/ STICKER WP MONOSHOCK O-RING NBR 5,28X1, SCREW PLUG M5X RUBBER CAP "DO NOT OPEN" ADJUSTING NUT PLASTIC TENSIONING RING D64 H ALLENHEAD SCREW M5 L=20 STAINL SPACER RING SPRING 61,3X78X SPACER RING ADJUSTING NUT S SPRING N/MM ORANGE x S SPRING N/MM D11,25 OR. x S SPRING N/MM D11,5 OR. x S SPRING N/MM D11,75 OR. x S SPRING N/MM ORANGE x S SPRING N/MM ORANGE x CIRCLIP 58,2X VALVE SPRING D80 CLOSED PISTON ROD NUT M16X REBOUND DISC 16X34 T2 H S PISTON D REBOUND DISC D16X43 H * SA ADAPTER D50 H28 CPL SPRING RING REBOUND RUBBER SHIM D29,75 X D19 X T0, S SEAL D18X30X REBOUND SPRING O-RING 41X5 1 80* DU-BUSHING 18X20X DUST SEAL / C * NEW PART X AS REQUIRED 9

12 SHOCK ABSORBER DISASSEMBLED 125 SX USA CIRCLIP 53X1, RESERVOIR CAP D=50 H= BUMP RUBBER SA1 MONOSHOCK BOTTOM PART CPL ADAPTOR-BUSH M10x1,50, D= S1 SHOCK ABSORBER FLUID 5 LT 1 99* R12020 REPAIR KIT / C * NEW PART X AS REQUIRED 10

13 SHOCK ABSORBER 125 SX USA HH COLLAR SCREW M10X52 SW * 18187M5101 MONOSH. LINK 125/150 SX US / C * NEW PART X AS REQUIRED 11

14 PRO LEVER LINKING 125 SX USA * TRIANGLE LEVER CPL. SX PULL ROD CPL PULL ROD ANCHOR BOLT NEEDLE BUSH HK SHIM 20X32X SHAFT SEAL RING 25X32X7 4 7* BUCKET SHAFT SEAL RING 25X BUSHING SLEEVE 15 X 20 X SHIM D29,75 X D19 X T0, SHAFT SEAL RING 24X30X BUCKET FOR SHAFT SEAL RING 2 12* BOLT FOR CANTILEVER M * HEX NUT M14X1.5 SW BEARING SLEEVE 10X18X25, NEEDLE BUSH HN1816 RS 18/24/ BEARING SLEEVE NEEDLE BEARING HK X28X SHAFT SEAL RING G22x28x STEEL WASHER 15,2X19X0,1 x STEEL WASHER 15,2X19X0,2 x STEEL WASHER 15,2X19X0,3 x TRIANGLE LEVER REP. KIT FRONT x PULL ROD REP. KIT SX/SX-F x / C * NEW PART X AS REQUIRED 12

15 SWING ARM 125 SX USA * SWINGARM CPL CHAIN SLIDING PROTECTION BUSHING F. CHAIN SLIDING PR EJOT SPIRAL SCREW SF M5X10-K BRAKE LINE GUIDE SPECIAL SCREW M6X13 WS= BUCKET F. SHAFT SEAL RING SHAFT SEAL RING 25X32X BUSHING SLEEVE F. SWING ARM NEEDLE BEARING HK STOP DISK 22,2X31,7X CHAIN GUIDE REAR CPL SPECIAL SCREW M6X19 WS= HH COLLAR SCREW M6X45 TX BUSH. F. CHAIN FAIL. PROT SWINGARM BOLT M16X1, SELF LOCK.NUT M16X1,5 WS= CLOSING COVER CHAIN GUARD CPL PRESS IN NUT M6 STEEL ZINC CHAIN GUIDE KIT REAR SWINGARM REPAIR KIT x / C * NEW PART X AS REQUIRED 13

16 EXHAUST SYSTEM 125 SX USA * EXHAUST PIPE CPL. SX O-RING 44,00X3,00 VITON TEN.SPRING L=62MM EY.MOVEABLE RUBBER SLEEVE D=21MM/23MM ' SWINGELEMENT FOR EXHAUST PIPE HH COLLAR SCREW M6X15 TX HH COLLAR SCREW M6X10 TX RANGE CHANGE METAL NUT M O-RING 74,00X1,50 FKM 75SH SILENCER SX SPRING WASHER DIN0137-B SCREW TORX M5X SILENCER CASING CPL.W.MOUNTING DUMMY RIVET 4,8X 8 NIRO END CAP CPL HH COLLAR SCREW M6X30 TX ROCK WOOL 235G EXHAUST HARDWARE KIT x / C * NEW PART X AS REQUIRED 14

17 AIR FILTER 125 SX USA * A AIR BOX COVER R/S SX/XC COLLAR BUSH. F.REAR FENDER * A AIR BOX COVER L/S SX/XC * FILTER BOX CPL. WHITE HH COLLAR SCREW M6X20 TX QUICK RELEASE-NIPPLE BLIND RIVET 3,3X9,7 GROOVED QUICK RELEASE-SPRING HANGER FENDER FOR FILTER BOX AIR FILTER FILTER CARRIER FILTER SUPPORT CPL FILTER SUPPORT BUSH FASTEN. DEVICE FILTER S. SX CABURETOR CONNECT. BOOT HOSE CLAMP 50-70MM EJOT PT SCREW K60X20 ALU WS= BUSHING F. CHAIN SLIDING PR SPLASH PROTECTOR KIT SX/EXC x / C * NEW PART X AS REQUIRED 15

18 TANK, SEAT, COVER 125 SX USA * FUEL TANK CPL. 7,5L SX CAB GAS COCK MIKUNI ON/OFF O-RING 13,00X2, PVC-HOSE 5,6X10X270MM 1 8* X4 TANK PLUG CPL. BLACK SX SCREW SEAT FASTENING D=6X23/ TANK ROLLER 12X26X12 ' FUEL HOSE 6X2, CLAMP YDNAC MM EJOT PT SCREW K60X20 WS= EJOT PT SCREW K60X20 ALU WS= ANGLE PIECE 90 DEGREE M10X SEAT CPL SEAT COVER 1 50* A SPOILER KIT SX/XC WITH DECAL BUSH FOR SPOILER 6X11X16X5 MM HH COLLAR SCREW M6X20 TX HH COLLAR SCREW M6X12 TX / C * NEW PART X AS REQUIRED 16

19 DECAL 125 SX USA * DECAL NUMBER PLATE SX/XC * DECAL REAR PART 125 SX / C * NEW PART X AS REQUIRED 17

20 MASK, FENDERS 125 SX USA * START NUMBER PLATE WHITE SX * BRAKE HOSE GUIDE BLACK EJOT PT SCREW K60X20 ALU WS= HH COLLAR SCREW M6X10 TX HH COLLAR SCREW M5X16 TX30 2 7* FRONT FENDER ORANGE * HH COLLAR SCREW M6X16 TX COLLAR BUSH. F.REAR FENDER * REARPART ORANGE SX COLLAR NUT M12X1/WS17 H=5MM BUSHING FOR SEAT FASTENING HH COLLAR SCREW M6X25 TX / C * NEW PART X AS REQUIRED 18

21 FRONT WHEEL 125 SX USA * FRONTWHEEL CPL.1,6X21EXCEL FRONT WHEEL HUB CPL BEA.SPACERTUBE 35X2 L=79, GR.BALL BEAR.6906 DDU2CG23S6NM FRONT WHEEL REP. KIT SHAFT SEAL RING 35X47X7 TC SPACER BUSHING F. FR. WHEEL * SPOKE M4,5X226-21" BLACK SPOKE NIPPLE M4,5 AL RIM 1,6"X21" EXCEL RIM BAND 21" 1 15* SPOKE KIT FRONT "21" BLACK x 16* RIM LOCK 1,60" NUT FOR WHEEL HOLDER BRAKE DISC FRONT SPECIAL SCREW M6X13 WS= WHEEL SPIN.FR. D=26 M24x1, SPINDLE SCREW M24X1,5 WS= PLUG BUSHING WS= PLUG FOR RIM x AUXILIARY SCREW FRONT / C * NEW PART X AS REQUIRED 19

22 REAR WHEEL 125 SX USA * REAR WHEEL CPL.2,15X19"EXC * REAR WHEEL HUB CPL * BEARING DISTANCE TUBE 121,5MM GR.BALL BEAR.6005 DDU2CG23S6NM CIRCLIP DIN X1, SHAFT SEAL RING 32X47X7 BSL 2 7* DISTANCE BUSHING REAR WHEEL 2 8* SPOKE M4,5x205-19" BLACK SPOKE NIPPLE M4,5 AL RIM 2,15"X19" EXCEL BRAKE DISC REAR SPECIAL SCREW M6X13 WS= RIM BAND 18" AND 19" DISTANCE RING REAR SPROCKET 38-T x REAR SPROCKET 42-T x REAR SPROCKET 40-T x REAR SPROCKET 45-T x REAR SPROCKET 48-T x REAR SPROCKET 49-T x REAR SPROCKET 50-T REAR SPROCKET 51-T x REAR SPROCKET 52-T x S COUNTER-SUNK SCREW ISA45 M8X HEXAGON NUT DIN EN1661 M8 SW CHAIN 5/8X1/4" MX CONNECTING LINK F * RIM LOCK 2,15" NUT FOR WHEEL HOLDER PLUG FOR RIM x COVERING CAP SFL16 x 40* WHEEL SPINDLE CPL. ' * CHAIN TENSIONER R/S SCREW M10X1,25X50 WS= HH COLLAR NUT M10X1,25 WS= / C * NEW PART X AS REQUIRED 20

23 REAR WHEEL 125 SX USA * COLLAR NUT M25X1,5 WS= DRIVETRAIN KIT 125 SX 13T/50T x / C * NEW PART X AS REQUIRED 21

24 BRAKE CALIPER FRONT 125 SX USA CALIPER NAT. WITHOUT PADS BRAKE CALIPER SUPPORT FRONT REP. KIT SEALS 24MM REP. KIT PISTON 24MM BOLT CPL RETAINING PLATE SET BREMBO BRAKE PADS TOYO B BLEEDER SCREW WITH CAP CUP SET SHORT S HH COLLAR SCREW M8X35 TX BRAKEHO. FRONT 1235MM COPPER GASKET DIN X14X HOLLOW SCREW M10X1X / C * NEW PART X AS REQUIRED 22

25 HAND BRAKE CYLINDER 125 SX USA HAND BRAKE CYLINDER CPL. SX HANDBRAKE CYL.COVER CPL.NATURE REP.SET PISTON D=9MM CLAMP CPL. NATURE HH COLLAR SCREW M6X25 TX LEVER SCREW CPL HAND BRAKE LEVER + SPRING ADJUSTING SCREW CPL. SX PROTECTION CAP HAND BRAKE CYL BRAKEHO. FRONT 1235MM HOLLOW SCREW BLACK M10X1X COPPER GASKET DIN X14X VALVE BRAKE FLUID DOT5.1 0,25L / C * NEW PART X AS REQUIRED 23

26 REAR BRAKE CONTROL 125 SX USA REAR BRAKE CYLINDER CPL.SX REAR BRAKE CYL. COVER CPL FOOT-BRAKE CYL. GASKET SX HOLLOW SCREW BLACK M10X1X BRAKE HOSE REAR XXXMM COPPER GASKET DIN X14X FOOT BRAKE LEVER CPL STEP PLATE FOR BRAKE LEVER HH COLLAR SCREW M5X12 TX RETURN SPRING FOR BRAKE LEVER S HH COLLAR SCREW M6X20 TX PUSH ROD L=28MM SELF LOCK. NUT DIN0985-M SWIVEL HEAD KA S AH-COLLAR SCREW M10X40 ISA SPECIAL SCREW M8X26 WS= COLLAR NUT M8 WS= BALL BEARING SKF RS COLLAR NUT M10 WS= HH COLLAR SCREW M6X12 TX BRAKE FLUID DOT5.1 0,25L / C * NEW PART X AS REQUIRED 24

27 BRAKE CALIPER REAR 125 SX USA * BRAKE CAL. REAR - WITHOUT PADS REPAIR KIT SEALING RINGS 26MM BOLT SET FOR BRAKE CALIPER BRAKE PAD SET REAR TOYO 1 5* BRAKE PISTON 26MM * RETAINING SPRING * BRAKE CALIPER BRACKET REAR CUP SET SHORT BRAKE HOSE REAR XXXMM BLEEDER SCREW CPL COPPER GASKET DIN X14X / C * NEW PART X AS REQUIRED 25

28 ACCESSORIES KIT 125 SX USA AIR FILTER OIL 100ML PRINT LABEL 60X51 MM DOCUMENTS BAG KTM BALLPOINT PEN ORANGE * CUSTOMER WELCOME LETTER DE/GB PP OFFROAD FOLDER GB POWER WEAR TEASER FOOTPEG L.+R. CPL COVER FOR RADIATOR FULL COVER FOR RADIATOR HALF PLASTIC FRAME PROTECTION SET BAR PAD PLUG-IN STAND 1 1* EN O.M SX/ XC TOOL KIT GRIP ORANGE B&F WRENCH SW=17/21/27/32 B&F T-WRENCH WS=6/8/10/TX45/SK4X SPOKE-SPANNER WS 7/ / C * NEW PART X AS REQUIRED 26

29 NOTICE 125 SX USA 2013

30 NOTICE 125 SX USA 2013

31

32 KTM Group Partner KTM-Sportmotorcycle AG A-5230 Mattighofen *3CFF6175M0EN* 3CFF6175M0EN Art.Nr.: 3CFF6175M0EN 5/2012

33 125 SX 2013 SPARE PARTS MANUAL: ENGINE ART.NO.: 3CM081521MEN ENGLISH

34

35 INDEX 125 SX 2013 CLUTCH COVER REED VALVE CASE CYLINDER, CYLINDER HEAD CRANKSHAFT, PISTON 3x 4x 5x 6x ENGINE CASE CARBURETOR CLUTCH TRANSMISSION I - MAIN SHAFT 7x 8x 10x 11x KICK STARTER TRANSMISSION II - COUNTERSHAFT SHIFTING MECHANISM COOLING SYSTEM 12x 13x 14x 16x 1

36 INDEX 125 SX 2013 EXHAUST CONTROL IGNITION SYSTEM 17x 19x x x x x x x All information contained is without obligation. KTM-Sportmotorcycle AG particularly reserves the right to modify any equipment, technical specifications, prices, colors, shapes, materials, services, service work, constructions, equipment and the like so as to adapt them to local conditions or to cancel any of the above items, all without previous announcement and without giving reasons. KTM may stop manufacturing certain models without previous notice. KTM shall not be held liable for any deviations of availability and/or ability to deliver, illustrations, descriptions, printing and/or other errors. The illustrated models partly contain extra equipment, which is not applied to standard models. by KTM-SPORTMOTORCYCLE AG, Mattighofen AUSTRIA; All rights reserved; Reprint, also in extracts, with written allowance of KTM- SPORTMOTORCYCLE AG, Mattighofen only. x 2

37 CLUTCH COVER 125 SX CLUTCH COVER CPL. 125/ PLUG DIN0910-M 10X COPPER GASKET DIN X14X HH COLLAR SCREW M6X50 TX HH COLLAR SCREW M6X12 TX CU-SEAL RING DIN7603-6X10X O-RING 19,00X3,00 NBR OIL FILLER CAP M24x3 WITH O-R O-RING 16,00X3,00 NBR CLUTCH COVER GASKET 0,5MM CLUTCH OUTSIDE COVER CLUTCH OUTS.COVER GASKET 1MM HH COLLAR SCREW M6X40 TX HH COLLAR SCREW M6X35 TX HH COLLAR SCREW M6X30 TX WATER PUMP COVER 125/200 ' DOWEL 9,8 X 7 X / C * NEW PART X AS REQUIRED 3

38 REED VALVE CASE 125 SX REED VALVE ASSY V-FORCE RED VALVE-SET V-FORCE GASKET REED V.PLATE V-FORCE SPRING WASHER DIN0137-B HH COLLAR SCREW M6X25 TX CLAMP 52/12 GEMI INTAKE FLANGE / C * NEW PART X AS REQUIRED 4

39 CYLINDER, CYLINDER HEAD 125 SX INTERMEDIATE FLANGE CYLINDER+PISTON CPL CYLINDERHEAD 125 SX/EXC STUD DIN0835-M 8X O-RING 62,00X2,00 VITON CU-SEAL RING DIN7603-7,3X12X O-RING 12X2 VITON GREEN CYLINDER BASE GASKET 0,20MM x CYLINDER BASE GASKET 0,25MM x CYLINDER BASE GASKET 0,40MM x CYLINDER BASE GASKET 0,50MM x CYLINDER BASE GASKET 0,75MM x O-RING 86X2 VITON75SHORE GREEN HH COLLAR SCREW M 5X20 WS= HH COLLAR NUT M 8 WS= INTERMED. GASKET RETAINING PLATE HH COLLAR SCREW M6X10 TX CU-SEAL RING DIN7603-6X10X CYL. HEAD BOLT M 7X30 WS= CYLINDER GASKET SET 125/ x / C * NEW PART X AS REQUIRED 5

40 CRANKSHAFT, PISTON 125 SX I PISTON I CPL II PISTON II CPL x SPACER BUSHING 12MM CON.ROD REPAIR KIT 125' CRANKSHAFT CPL. 125 SX LOCKING RING VSK COLLAR NUT M12X1 R/S WOODRUFF KEY DIN6888-3X5X WOODRUFF KEY 5X6,5 HARDED 1 25* PRIM. PINION 23-T 125/200' LOCKING RING VSK HEXAGON NUT M 16 X 1,5 - L/S TRAPEZOID RING x PISTON PIN 15X45, NEEDLE BEARING KBK 15X19X SHAFT SEAL RING 25X35X7 BTSL SHAFT SEAL RING 32X45X6,5 BT WIRE LOCK RING 15X O-RING 25,00X2,00 NBR BALL BEARING 6305 JR2 CS CYL.ROLLER BEAR.NJ206 ET2XCS CRANKSHAFT REP. KIT x / C * NEW PART X AS REQUIRED 6

41 ENGINE CASE 125 SX * ENGINE CASE KPL * IGNITION COVER KICKSTART DOWEL BUSHING 13,8X11X12 2 6* DOWEL 9,8X7X OILDRAIN PLUG W.MAG. M 12X1, CU-SEAL RING DIN X18X1, ENGINE CASE GASKET 0,5MM ' HH COLLAR SCREW M6X50 TX HH COLLAR SCREW M6X55 TX * HH COLLAR SCREW M6X20 TX HH COLLAR SCREW M6X60 TX * HH COLLAR SCREW M6X25 TX OIL GUARD GROMMET 25X31 ' GASKET KIT / C * NEW PART X AS REQUIRED 7

42 CARBURETOR 125 SX CARBUR. KEIHIN PWK 38S AG IDLE JET 38 KEIHIN x IDLE JET 40 KEIHIN x IDLE JET 42 KEIHIN x IDLE JET 45 KEIHIN x IDLE JET 48 KEIHIN x IDLE JET 50 KEIHIN x IDLE JET 52 KEIHIN x IDLE JET 55 KEIHIN x ARM PIN FLOAT FLOAT CPL GASKET FLOAT CHAMBER FLOAT CHAMBER PWK38-S AG RETAINING PLATE FOR BLEEDER STARTER JET 85 KEIHIN HH COLLAR SCREW M 4X16 WS= SPRING FOR ADJUSTMENT SCREW ADJUSTMENT SCREW SPRING ADJUSTMENT SCREW M FLOAT NEEDLE CLAMP MAIN JET 170 KEIHIN x MAIN JET 172 KEIHIN x MAIN JET 175 KEIHIN x MAIN JET 178 KEIHIN x MAIN JET 180 KEIHIN x MAIN JET 182 KEIHIN x MAIN JET 185 KEIHIN x MAIN JET 188 KEIHIN x MAIN JET 190 KEIHIN x MAIN JET 192 KEIHIN x MAIN JET 195 KEIHIN x MAIN JET 198 KEIHIN x MAIN JET 200 KEIHIN x / C * NEW PART X AS REQUIRED 8

43 CARBURETOR 125 SX MAIN JET GR. 202 KEIHIN x MAIN JET 205 KEIHIN x MAIN JET 208 KEIHIN x MAIN JET 210 KEIHIN x MAIN JET 212 KEIHIN x MAIN JET 215 KEIHIN x SPECIAL-AH-SCREW M 4X THROTTLE CALBE HOLDER M6X0, CARBURETOR COVER PWK 38S AG GASKET FOR CARBURETOR COVER CLIP FOR JET NEEDLE SLIDING SPRING SPRING CAP NIPPLE JET NEEDLE NOZ F KEIHIN x JET NEEDLE NOZ G KEIHIN x JET NEEDLE NOZ H KEIHIN x JET NEEDLE NOZ I KEIHIN x JET NEEDLE NOZ J KEIHIN x JET NEEDLE NOZ K KEIHIN x THROTTLE VALVE 7 FOR 38 PJ ' STARTER PISTON CPL CLAMP 6 MM PVC-HOSE 4X6MM x PVC-HOSE 3X5MM x PLUG M 18X O-RING 18,00X2,30 NBR WASHER ADJUSTING SCREW O-RING ADJUSTING SCREW / C * NEW PART X AS REQUIRED 9

44 CLUTCH 125 SX OUTER CLUTCH HUB '98 1 WITHOUT PRIMARY PINION INNER CLUTCH HUB 125/200' PRESSURE PLATE 125/200' INTERMEDI. DISC STEEL 1,5MM' INTERMEDIATE DISC 1,5MM LINING DISC 3,0MM INNER RING 20X26X25,9 ' SHEET METAL LOCK 1,5MM ' HEXAGON NUT DIN0936-M18X1,5 R STOP DISK 20X39,6X3 ' PRIM. PINION 23-T 125/200' CLUTCH KIT 125 SX/EXC WASHER 6,2X18X PUSH ROD L= / PRESSURE PIECE ' CYLINDER CPL. 125/200' HOLLOW SCREW CPL. M 10X1 ' CLUTCH RELEASE GASKET 0,3MM x CLUTCH RELEASE GASKET 0,5MM x CLUTCH RELEASE GASKET 0,75MM x BALL DIN CU-SEAL RING DIN X16X PISTON W. O-RING 125/ HH COLLAR SCREW M6X40 TX HH COLLAR SCREW M6X20 TX HH COLLAR SCREW M6X25 TX VENT INJEKTION HYDR. CLUTCH CLUTCH SPRING 2,3X39,5 125' NEEDLE BEARING K26X30X22ZW.KSE AXIAL NEEDLE BEARING AXK AXIAL WASHER AS X26X AXIAL WASHER 12,5X25,8X1,5 x CIRCLIP DIN7993-RW / C * NEW PART X AS REQUIRED 10

45 TRANSMISSION I - MAIN SHAFT 125 SX MAIN SHAFT CPL. 13-T ' IDLE GEAR 5.G. 5S19H SX SLIDING GEAR 3./4. G. SX 06 1 "3S17H"-"4S20H" IDLE GEAR 6TH G. 6S22H SX SOLID GEAR 2ND G.15-T"2S15" IDLER GEAR BUSH. 22X25X11,1 A GROOVED BALL B C4 J BALL BEARING 6004 TN9 C STOP DISC 22,2X27,8X1 A STOP DISC 17,2X26X1 B STOP DISK 22,2X27,8X LOCK RING 22X1, / C * NEW PART X AS REQUIRED 11

46 KICK STARTER 125 SX STOP DISK 17,2X24X CIRCLIP DIN X THRUST WASHER DIN X22X SPACER BUSHING 16X23X26X6, HH COLLAR SCREW M8X20 TX HH COLLAR SCREW M6X16 TX STOP DISC 17,2X26X1 B KICKSTARTER SHAFT 125/200' KICKSTART.GEAR 26-T 125/200' KICKSTARTER RATCHET INTERMEDIATE GEAR 27-T KICKSTARTER SPRING 2,6MM ' DRIVING HUB 125/200' SPRING 1,4MM ' STOP MET.SHEET 4MM 125/200' KICK STARTER CPL SHAFT SEAL RING 17X28X7 B WASHER 8,2X22X4,5 ' / C * NEW PART X AS REQUIRED 12

47 TRANSMISSION II - COUNTERSHAFT 125 SX COUNTER SHAFT 125/200 ' IDLE G.3RD G.28-T "3S28H" IDLE GEAR 4TH G. 4S28 SX SLIDING GEAR 6TH G. 6S24 SX IDLER G. 2ND G. 30-T "2S30"' IDLER GEAR 1.G 32-T SLIDING GEAR 5TH G.5S23H SX IDLER GEAR BUSHING 17X20X9,7 B IDLER GEAR BUSHING 22X25X8,1 C IDLER GEAR BUSHING 25X28X9,7 D LOCK RING DIN X1,64SD FRONT SPROCKET 13-T FRONT SPROCKET 14-T x BALL BEARING 6003 TN9 C4 1 31* BALL BEARING 6205 C3 NTN STOP RING SHAFT SEAL RING 32X45X7 BSLNBR SPACER BUSHING 12MM O-RING 23,00X2,00 NBR STOP DISC 22,2X27,8X1 A STOP DISC 17,2X26X1 B STOP DISK 22,2X28X1 C STOP DISC 25,2X32X STOP DISC 22,2X30X2, LOCK RING 22X1, LOCK RING 25X1, COUNTER SHAFT REP.KIT x / C * NEW PART X AS REQUIRED 13

48 SHIFTING MECHANISM 125 SX SHIFTING FORK 5TH/6TH GEAR SHIFTING FORK 2ND/4TH GEAR SHIFTING FORK 1ST/3RD GEAR SHIFTING SHAFT 125/200' SPRING FOR RATCHET 0,5X11, RATCHET SUPPORT 125/200' STOP DISK 8,2X26X0, BUSHING 6X8X12X4, SHIFTING RATCHET 125/200' PRESSURE END PAD 4,1X5,6X8, SHIFTING DRUM LOCATING DRUM 125/200' RETURN SPRING 3MM SPECIAL SCREW M8X21,5 WS= SHIFTING GATE 3MM 125/200' NEEDLE ROLLER ZRB 6X SHIFTING ROD DRIVE 11,8X67, SHIFT. ROD DRIVE END 11,8X94, LOCATING LEVER SPRING 2,5MM' LOCATING LEVER CPL BALL BEARING 6000 RS1 C BALL BEARING C FLAT H.SCEW DIN7991-M5X LOCK RING DIN X1, SPRING WASHER 12,2X25X0, NEEDLE ROL.DIN5402 NRB 4X9, NEEDLE BEAR.HK X20X STOP DISK 14,3X20X LOCK WASHER DIN X STOP DISK 14,2X22X1, SHAFT SEAL RING 14X24X6 B SPECIAL SCREW M6X16 WS= PAIR OF WASHERS M 6 NORDLOCK HH COLLAR SCREW M6X16 TX WASHER DIN0125-A 8, / C * NEW PART X AS REQUIRED 14

49 SHIFTING MECHANISM 125 SX WASHER DIN7349-5X15X HH COLLAR SCREW M5X20 TX STEEL WASHER 6,4X17X SLEEVE FOR LOCKING LEVER SHIFT LEVER CPL. 2-STROKE SHIFTING LEVER SPRING BOLT 6X25 FOR SHIFT LEVER STEP PLATE FOR SHIFT LEVER / C * NEW PART X AS REQUIRED 15

50 COOLING SYSTEM 125 SX * RADIATOR L/S "55562" * RADIATOR R/S "55620" RADIATOR CAP SMALL 1,8 BAR Y-CONNECOTOR CPL HOSE CLAMP GEMI HOSE CLAMP NORMA 12/ * CLAMP YDNAC 10096F (9,6MM) ANGLE PIECE ' PVC-HOSE 6X9 x RADIATOR HOSE 18X25 PER METRE x RADIATOR HOSE 18X25 125/200' PREFORMED HOSE RADIATOR PROTECTION BLACK HOSE CONNECTOR L=172, RUBBER SLEEVE D=12MM WASHER FOR RADIATOR COLLAR SCREW M6X12 TX / C * NEW PART X AS REQUIRED 16

51 EXHAUST CONTROL 125 SX STOP DISK 14,2X22X1, SIDE COVER R/S GASKET SIDE COVER R/S SIDE COVER LEFT GASKET SIDE COVER L/S ANGLE PIEC 90 DEGREE M10X O-RING 8,00X2,00 NBR HH COLLAR SCREW M 5X12 WS= NEEDLE ROL. DIN5402 NRB 5X15, TUBE RUBBER 6X9 DVOH 200MM CU-SEAL RING DIN X32X WASHER 5,2 X 12 X HH COLLAR SCREW M6X10 TX ECCENTRIC FOR CRANKBOLT CRANK BOLT F.CONTROL FL.125' CONTROL FLAP 125 CPL AXLE FOR CONTRIL FLAP CU-SEAL RING DIN7603-6X10X GROOVED BALL BEAR RS C CIRCLIP DIN X WASHER DIN2093-8,2X16X0, SPACER BUSHING 8X12X2, BALL BEARING 608 RS C O-RINGSTRING 4MM NBR 70 PER/M x O-RING 16,00X3,00 NBR SHEET METAL GUIDE 3MM 125' CLOSING COVER ' CLOSING COVER GASKET 1MM CENTRIFUGAL TIMER CPL. 125' BUSHING HOLDER M 26X1 ' CLOSING NUT M 26X1 WS= CONTROL LEVER 125/200' CONTROL SHAFT M 6 WS=10 ' CONTROL SHAFT CPL.L/S CONTROL SHAFT CPL.R/S / C * NEW PART X AS REQUIRED 17

52 EXHAUST CONTROL 125 SX HH COLLAR SCREW M6X12 TX HH COLLAR SCREW M5X12 TX LEVER F. CONTROL SEGMENT ' CONTROL SHAFT SEGMENT 125' DRIVE WHEEL 26-T 125/200' BUSHING SUPPORT WATER PUMP ' ROLLER GUIDE 5X6,1X8X4 ' SHAFT SEAL RING 8X24X7 A DUO BALL BEARING 6000/C O-RING 49,00X2,50 NBR WATER PUMP SHAFT WATER PUMP WHEEL LOCK METAL SHEET 2MM ' WATER PUMP REP. KIT EXC x / C * NEW PART X AS REQUIRED 18

53 IGNITION SYSTEM 125 SX FLYWHEEL KOKUSAN 2K-1/2K-4 ' STATOR KOKUSAN 2K SPARK PLUG CAP NGK REINFORC SEALING CUP FOR SPARK PLUG SPARK PLUG BR9ECMVX IGNITIONCOIL "IG5128" CDI UNIT 125 SX WIRING HARNESS FOR CDI 2-ST RUBBER GROMMET 16X10,8X * EJOT DELTA PT SCREW 45X12-Z 2 39* ELECTRIC CASE HH COLLAR SCREW M5X16 TX HH COLLAR SCREW M6X16 TX / C * NEW PART X AS REQUIRED 19

54 NOTICE 125 SX 2013

55

56 KTM Group Partner KTM-Sportmotorcycle AG A-5230 Mattighofen *3CM081521MEN* 3CM081521MEN Art.Nr.: 3CM081521MEN 5/2012