TECHNICAL SPECIFICATIONS ENGINE 125 SX, EXC, 200 EXC 2005»

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1 Repair manual KTM / 00 Art.-Nr E TECHNICAL SPECIFICATIONS ENGINE SX, EXC, 00 EXC 00» ENGINE SX EXC 00 EXC Design Liquid-cooled, single-cylinder, two-stroke engine with intake and exhaust control Piston displacement.8 ccm.8 ccm 9 ccm Bore / stroke Fuel Oil / gasoline ratio /. mm (.6 /. in) /. mm (.6 /. in) 6 / 60 mm (. /.6 in) unleaded fuel with at least RON 9 (USA = Premium RON 9), mixed with high grade two stroke oil :0-:60 when using high grade, two- stroke oil (Motorex Cross Power T). When in doubt, please contact your importer 0-6E Crankshaft bearing deep-groove ball bearing / cylinder roller bearing Connecting rod bearing needle bearing Piston pin bearing needle bearing Piston cast piston Piston ring one plain compression ring two plain compression rings two plain compression rings (upper edge pistonupper edge cylinder) Dimension X 0,0 mm Ignition timing. mm (0.0 in) (6. ) BTDC. mm (0.0 in) (6. ) BTDC.6 mm (0.06 in) (7 ) BTDC Spark plug NGK BR9 EVX NGK BR9 EVX NGK BR 8 EG Electrode gap 0,60 mm Dimension Z (height of the control flap) mm (.67 in) mm (.67 in) 7 mm (.8 in) Primary drive straight cut spur gears, primary ratio :7 Clutch multiple disc clutch in oil bath, hydraulically operated (Motorex Kupplungs-Fluid 7) Transmission speed, claw actuated 6 speed, claw actuated 6 speed, claw actuated Gear ratio st gear : S : G : G nd gear S : 0 S0 S : G S : G rd gear S7H 7 : 8 S8H S7H 7 : 8 S8H S7H 7 : 8 S8H th gear S9H 9 : 6 S6 S9H 9 : 6 S6 S9H 9 : 6 S6 th gear S : S S : S G7H 7 : 9 G9H 6th gear 6G0 0 : 0 6G0 6GH : 0 6E0H Gear lubrication 0,7 liter Motorex Top Speed T W0 Available chain sprockets t / t for chain /8 x /" Coolant. litres, 0% anti freeze, 0% water, at least - C (- F) Ignition system KOKUSAN K- KOKUSAN K- KOKUSAN K- Generator output no generator V / 0 W V / 0 W Ignition system USA KOKUSAN K- KOKUSAN K- KOKUSAN K- Generator output no generator V 0 W V 0 W Carburetor flat-slide carburetor, carburetor setting see table Air-filter wet foam type air filter insert

2 0-7E TIGHTENING TORQUES SX, EXC, 00 EXC 00» TIGHTENING TORQUES CHASSIS Collar screw, front wheel spindle Mx, 0 Nm Brake caliper, front M8 Loctite + Nm Brake disks M6 Loctite + 0 Nm Clamping screws, upper fork bridge (EXC) M8 0 Nm Clamping screws, lower fork bridge (EXC) M8 Nm Clamping screws, upper fork bridge (SX) M8 Nm Clamping screws, lower fork bridge (SX) M8 0 Nm Clamping screws, fork stubs M8 0 Nm Collar nut, rear wheel spindle M0x, 80 Nm Hexagon nut, swing arm bolt M6x, 00 Nm Hexagon collar screw, handlebar clamp M8 Loctite + 0 Nm Allan head screw, handlebar support M0 Loctite + 0 Nm Shock absorber, top M 80 Nm Shock absorber, bottom M 80 Nm Sprocket screws M8 Loctite + Nm Ball joint for push rod M6 Loctite + 0 Nm Engine mounting bolt M0 60 Nm Engine brace M8 Nm Screw adjusting ring spring preload shock abs. M6 8 Nm Spoke nipple M, / M Nm Other screws on chassis M6 0 Nm M8 Nm M0 Nm Other collar nuts on chassis M6 Nm M8 0 Nm M0 0 Nm TIGHTENING TORQUES - ENGINE Flange bolts - cylinder-head M7 8 Nm Nuts-cylinder base M8 0 Nm Flywheel collar nut Mx 60 Nm Nut for primary sprocket (LH thread) M6x, 0 Nm Nut for inner clutch hub M8x, 0 Nm Crankcase and clutch cover bolts M6 0 Nm Spark plug M X, Nm Swingarm pivot M6x, 00 Nm Carburetor nipple (throttle slide) M0x0,7 Nm Carburetor plug M8x Nm Other screws M 6 0 Nm M 8 Nm M 0 Nm

3 0-8E BASIC CARBURETOR SETTING 00» BASIC CARBURETOR SETTING SX EXC EU (, KW) EXC SIX-DAYS 00 EXC USA 00 EXC AUS 00 EXC EU (7 KW) Carburetor Keihin PWK 9 Keihin PWK 8 AG Keihin PWK 8 AG Keihin PWK 8 AG Keihin PWK 8 AG Carburetor setting mark 98SA0 8KTPB 8SA 8SA0 8KTUB Carburetor setting number Main jet 88 (8/90) 8 (80/8) 80 (8) 78 (80) 80 (78) Idling jet (8) (/8) (8) (8) (/8) Starting jet Jet needle R69D (R68D) R7N (/) () () R7J (/) Needle position from top II V IV III III Throttle valve Air adjustment screw open,,,,, Performance restrictor slide stop 6 Repair manual KTM / 00 Art.-Nr E TOLERANCES AND FITTING CLEARANCES» GASKET THICKNESSES 00» TOLERANCES AND FITTING CLEARANCES Piston fitting clearance = 0.06 mm 00 = 0.0 mm Piston ring end cap max. 0.0 mm Connecting rod bearing - radial clearance mm Piston pin radial clearance 0,00 mm Transmission shafts end float mm Clutch springs - length new = 9 mm, minimum length = 8 mm Clutch discs min.,9 mm (new, mm) Crank stud - run out 0,0 mm Crankshaft webs outer dimension mm GASKET THICKNESSES Crankcase Clutch cover Clutch driving cylinder Cylinder bottom gasket Available bottom gasket 0, mm 0, mm 0.0 / 0.0 / 0.7 mm as required 0.07 / 0. / 0.0 / 0. / 0.0 / 0.0 / 0.7 mm

4 VERGASERTABELLE» CARBURETOR TABLE VERGASERREGULIERUNG CARBURETOR SETTING KEIHIN PWK 9 MEERESHÖHE ALTIDUDE 000 m 0000 ft 0 m 70 ft TEMPERATUR TEMPERATURE - 0 C bis -7 C - F to 0 F, R69D 8-6 C bis C 9 F to F R70D 8 SX 00 6 C bis C F to 60 F 0 R70D 80 6 C bis C 6 F to 78 F, 8 R70D 78 C bis 8 C 79 F to 98 F, 8 R7D 7 7 C bis 9 C 99 F to 0 F ANHANG APPENDICE APPENDIX APÉNDICE 7 00 m 700 ft 0 m 00 ft, 8 R69D 88, R69D 8 R70D 8 0 R70D 80, 8 R70D 78, 8 R7D 7 00 m 000 ft 7 m 0 ft 0 R68D 90, 8 R69D 88, R69D 8 R70D 8 0 R70D 80, 8 R70D m 00 ft 0 m 00 ft 0,7 R68D 9 0 R68D 90, 8 R69D 88, R69D 88 R70D 8 0 R70D m 000 ft Meeresniveau Sea level 0, R68D 9 0,7 R68D 9 0 R69D 90, 8 R69D 88, R69D 8 R70D 8 LSO = Luftregulierschraube offen LD = Leerlaufdüse POS = Nadel Clip Position von oben HD = Hauptdüse ASO = Air screw open from fully-seated IJ = Idling jet POS = Needle clip position from top MJ = Main jet NICHT FÜR STRASSENBETRIEB Kraftstoff: Super Bleifrei ROZ 9 NOT FOR HIGHWAY USE Fuel: unleaded fuel with at least RON 9 USA = Premium RON 9 EXC Modelle: Die oben angeführten Vergaserregulierungen gelten nur für entdrosselte Motorräder. Um die volle Motorleistung zu erhalten, sind neben der Vergaserregulierung auch noch andere Maßnahmen erforderlich, Ihr KTM Händler hilft Ihnen gerne. WENN SIE ÄNDERUNGEN AM MOTORRAD VORNEHMEN, GEHT DIE STRASSENZULASSUNG VERLOREN, DER BETRIEB AUF ÖFFENTLICHEN STRAS- SEN IST DANN VERBOTEN UND STRAFBAR! AUSSERDEM ERLISCHT DER VERSICHERUNGSSCHUTZ! EXC models: The carburetor adjustments described above only apply to dethrottled motorcycles. Other measures will be required in addition to the carburetor adjustment for full engine performance. Your KTM dealer will be pleased to assist you. CHANGES TO YOUR MOTORCYCLE WILL CAUSE YOU TO LOSE YOUR ROAD APPROVAL. IT WILL BE ILLEGAL TO OPERATE THE MOTORCYCLE ON PUBLIC ROADS! YOUR INSURANCE COVERAGE WILL ALSO BE CANCELLED! Modelli EXC: Le tarature suindicate del carburatore valgono solo per motociclette potenziate. Per ottenere la piena potenza del motore sono richieste, oltre alla taratura del carburatore, anche altre misure. Il vostro concessionario KTM sarà sempre disposto ad aiutarvi. MODIFICHE APPORTATE ALLA MOTOCICLETTA DETERMINANO LA PERDITA DELL'OMOLOGAZIONE STRADALE, L'IMPIEGO SU STRADE PUBBLI- CHE DI CONSEGUENZA È VIETATO E PASSIBILE DI PENA! INOLTRE DECADE LA COPERTURA ASSICURATIVA! Modèles EXC : Les réglages de carburateur décrits ci-dessus valent seulement pour des machines débridées. Pour obtenir la pleine puissance, d'autres mesures sont nécessaires en plus de ces réglages. Les agents KTM connaissent ces mesures. QUAND ON EFFECTUE DES TRANSFORMATIONS SUR UNE MOTO, L'HOMOLOGATION N'EST PLUS VALABLE, L'UTILISATION SUR LA VOIE PUBLI- QUE EST INTERDITE ET TOMBE SOUS LE COUP DE LA LOI. DE PLUS LA COUVERTURE D'ASSURANCE DISPARAÎT. Modelos EXC: Los reglajes del carburador arriba indicados son válidos solamente para motocicletas sin reducción. Para alcanzar la potencia plena del motor, además de la regulación del carburador son necesarias también otras medidas. Su distribuidor KTM le ayudará con todo gusto. SI EFECTÚA CAMBIOS EN LA MOTOCICLETA, SE PIERDE EL PERMISO DE CIRCULACIÓN EN CARRETERAS; LA CIRCULACIÓN EN VÍAS PÚBLICAS QUEDA ENTONCES PROHIBIDA Y ES PUNIBLE. ADEMÁS CADUCA LA PROTECCIÓN DEL SEGURO!

5 VERGASERTABELLE» CARBURETOR TABLE ANHANG APPENDICE APPENDIX APÉNDICE 8 VERGASERREGULIERUNG CARBURETOR SETTING KEIHIN PWK 8 AG MEERESHÖHE ALTIDUDE 000 m 0000 ft 0 m 70 ft TEMPERATUR TEMPERATURE - 0 C bis -7 C - F to 0 F, 80-6 C bis C 9 F to F 78 EXC 00 6 C bis C F to 60 F C bis C 6 F to 78 F, 8 7 C bis 8 C 79 F to 98 F, 70 7 C bis 9 C 99 F to 0 F 00 m 700 ft 0 m 00 ft, 8 8, , 8 7, m 000 ft 7 m 0 ft 0 8, 8 8, , m 00 ft 0 m 00 ft 0, , 8 8, m 000 ft Meeresniveau Sea level 0, NOZC 90 0, , 8 8, LSO = Luftregulierschraube offen LD = Leerlaufdüse POS = Nadel Clip Position von oben HD = Hauptdüse ASO = Air screw open from fully-seated IJ = Idling jet POS = Needle clip position from top MJ = Main jet NICHT FÜR STRASSENBETRIEB Kraftstoff: Super Bleifrei ROZ 9 NOT FOR HIGHWAY USE Fuel: unleaded fuel with at least RON 9 USA = Premium RON 9 EXC Modelle: Die oben angeführten Vergaserregulierungen gelten nur für entdrosselte Motorräder. Um die volle Motorleistung zu erhalten, sind neben der Vergaserregulierung auch noch andere Maßnahmen erforderlich, Ihr KTM Händler hilft Ihnen gerne. WENN SIE ÄNDERUNGEN AM MOTORRAD VORNEHMEN, GEHT DIE STRASSENZULASSUNG VERLOREN, DER BETRIEB AUF ÖFFENTLICHEN STRAS- SEN IST DANN VERBOTEN UND STRAFBAR! AUSSERDEM ERLISCHT DER VERSICHERUNGSSCHUTZ! EXC models: The carburetor adjustments described above only apply to dethrottled motorcycles. Other measures will be required in addition to the carburetor adjustment for full engine performance. Your KTM dealer will be pleased to assist you. CHANGES TO YOUR MOTORCYCLE WILL CAUSE YOU TO LOSE YOUR ROAD APPROVAL. IT WILL BE ILLEGAL TO OPERATE THE MOTORCYCLE ON PUBLIC ROADS! YOUR INSURANCE COVERAGE WILL ALSO BE CANCELLED! Modelli EXC: Le tarature suindicate del carburatore valgono solo per motociclette potenziate. Per ottenere la piena potenza del motore sono richieste, oltre alla taratura del carburatore, anche altre misure. Il vostro concessionario KTM sarà sempre disposto ad aiutarvi. MODIFICHE APPORTATE ALLA MOTOCICLETTA DETERMINANO LA PERDITA DELL'OMOLOGAZIONE STRADALE, L'IMPIEGO SU STRADE PUBBLI- CHE DI CONSEGUENZA È VIETATO E PASSIBILE DI PENA! INOLTRE DECADE LA COPERTURA ASSICURATIVA! Modèles EXC : Les réglages de carburateur décrits ci-dessus valent seulement pour des machines débridées. Pour obtenir la pleine puissance, d'autres mesures sont nécessaires en plus de ces réglages. Les agents KTM connaissent ces mesures. QUAND ON EFFECTUE DES TRANSFORMATIONS SUR UNE MOTO, L'HOMOLOGATION N'EST PLUS VALABLE, L'UTILISATION SUR LA VOIE PUBLI- QUE EST INTERDITE ET TOMBE SOUS LE COUP DE LA LOI. DE PLUS LA COUVERTURE D'ASSURANCE DISPARAÎT. Modelos EXC: Los reglajes del carburador arriba indicados son válidos solamente para motocicletas sin reducción. Para alcanzar la potencia plena del motor, además de la regulación del carburador son necesarias también otras medidas. Su distribuidor KTM le ayudará con todo gusto. SI EFECTÚA CAMBIOS EN LA MOTOCICLETA, SE PIERDE EL PERMISO DE CIRCULACIÓN EN CARRETERAS; LA CIRCULACIÓN EN VÍAS PÚBLICAS QUEDA ENTONCES PROHIBIDA Y ES PUNIBLE. ADEMÁS CADUCA LA PROTECCIÓN DEL SEGURO!

6 VERGASERTABELLE» CARBURETOR TABLE VERGASERREGULIERUNG CARBURETOR SETTING KEIHIN PWK 8 AG MEERESHÖHE ALTIDUDE 000 m 0000 ft 0 m 70 ft TEMPERATUR TEMPERATURE - 0 C bis -7 C - F to 0 F 78-6 C bis C 9 F to F 7 00 EXC 00 6 C bis C F to 60 F 7 6 C bis C 6 F to 78 F 70 C bis 8 C 79 F to 98 F NOZH 68 7 C bis 9 C 99 F to 0 F ANHANG APPENDICE APPENDIX APÉNDICE 9 00 m 700 ft 0 m 00 ft, NOZH m 000 ft 7 m 0 ft, 8 8, 80, m 00 ft 0 m 00 ft, , 80, m 000 ft Meeresniveau Sea level 0 NOZC 88, 8 8, 8 8, 80, 78 7 LSO = Luftregulierschraube offen LD = Leerlaufdüse POS = Nadel Clip Position von oben HD = Hauptdüse ASO = Air screw open from fully-seated IJ = Idling jet POS = Needle clip position from top MJ = Main jet NICHT FÜR STRASSENBETRIEB Kraftstoff: Super Bleifrei ROZ 9 NOT FOR HIGHWAY USE Fuel: unleaded fuel with at least RON 9 USA = Premium RON 9 EXC Modelle: Die oben angeführten Vergaserregulierungen gelten nur für entdrosselte Motorräder. Um die volle Motorleistung zu erhalten, sind neben der Vergaserregulierung auch noch andere Maßnahmen erforderlich, Ihr KTM Händler hilft Ihnen gerne. WENN SIE ÄNDERUNGEN AM MOTORRAD VORNEHMEN, GEHT DIE STRASSENZULASSUNG VERLOREN, DER BETRIEB AUF ÖFFENTLICHEN STRAS- SEN IST DANN VERBOTEN UND STRAFBAR! AUSSERDEM ERLISCHT DER VERSICHERUNGSSCHUTZ! EXC models: The carburetor adjustments described above only apply to dethrottled motorcycles. Other measures will be required in addition to the carburetor adjustment for full engine performance. Your KTM dealer will be pleased to assist you. CHANGES TO YOUR MOTORCYCLE WILL CAUSE YOU TO LOSE YOUR ROAD APPROVAL. IT WILL BE ILLEGAL TO OPERATE THE MOTORCYCLE ON PUBLIC ROADS! YOUR INSURANCE COVERAGE WILL ALSO BE CANCELLED! Modelli EXC: Le tarature suindicate del carburatore valgono solo per motociclette potenziate. Per ottenere la piena potenza del motore sono richieste, oltre alla taratura del carburatore, anche altre misure. Il vostro concessionario KTM sarà sempre disposto ad aiutarvi. MODIFICHE APPORTATE ALLA MOTOCICLETTA DETERMINANO LA PERDITA DELL'OMOLOGAZIONE STRADALE, L'IMPIEGO SU STRADE PUBBLI- CHE DI CONSEGUENZA È VIETATO E PASSIBILE DI PENA! INOLTRE DECADE LA COPERTURA ASSICURATIVA! Modèles EXC : Les réglages de carburateur décrits ci-dessus valent seulement pour des machines débridées. Pour obtenir la pleine puissance, d'autres mesures sont nécessaires en plus de ces réglages. Les agents KTM connaissent ces mesures. QUAND ON EFFECTUE DES TRANSFORMATIONS SUR UNE MOTO, L'HOMOLOGATION N'EST PLUS VALABLE, L'UTILISATION SUR LA VOIE PUBLI- QUE EST INTERDITE ET TOMBE SOUS LE COUP DE LA LOI. DE PLUS LA COUVERTURE D'ASSURANCE DISPARAÎT. Modelos EXC: Los reglajes del carburador arriba indicados son válidos solamente para motocicletas sin reducción. Para alcanzar la potencia plena del motor, además de la regulación del carburador son necesarias también otras medidas. Su distribuidor KTM le ayudará con todo gusto. SI EFECTÚA CAMBIOS EN LA MOTOCICLETA, SE PIERDE EL PERMISO DE CIRCULACIÓN EN CARRETERAS; LA CIRCULACIÓN EN VÍAS PÚBLICAS QUEDA ENTONCES PROHIBIDA Y ES PUNIBLE. ADEMÁS CADUCA LA PROTECCIÓN DEL SEGURO!

TECHNICAL SPECIFICATIONS ENGINE 250 SX, EXC, 300 MXC, EXC 2005

0- Repair manual KTM 0-00 SX/MXC/EXC Art.- Nr..06.0-E TECHNICAL SPECIFICATIONS ENGINE 0 SX, EXC, 00 MXC, EXC 00 MOTOR 0 SX 0 EXC 00 MXC/EXC Design Liquid-cooled single-cylinder two-stroke engine with KTM