TECHNICAL DATA ENGINE 125 / 200 SX, EXC 2004

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TECHNICAL DATA ENGINE 125 / 200 SX, EXC 2004 Engine 125 SX 125 EXC 200 SX 200 EXC Design Liquid-cooled, single-cylinder, two-stroke engine with intake and exhaust control Piston displacement 128 ccm 193 ccm Bore / stroke 54 / 55 mm (126 / 145 in) 64 / 60 mm (52 / 362 in) Fuel unleaded fuel with at least RON 95 (USA = Premium RON 91), mixed with high grade two stroke oil Oil / gasoline ratio 1:40-1:60 when using high grade, two- stroke oil (Motorex Cross Power 2T). When in doupt, please contact your importer Crankshaft bearing 1 deep-groove ball bearing / 1 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 one plain compression ring two plain compression rings (upper edge pistonupper edge cylinder) Dimension X 0,0 mm Ignition timing 4 mm (0.055 in) (16.5 ) BTDC 6 mm (0.063 in) (17 ) BTDC Spark plug NGK BR9 EVX NGK BR 8 EG Electrode gap 0,60 mm Dimension Z (height of control flap) the 43 mm (67 in) 46 mm (1,81 in) 47 mm ( in) Primary drive straight cut spur gears, primary ratio 23:73 Clutch multiple disc clutch in oil bath, hydraulically operated (Motorex Kupplungs-Fluid 75) Transmission 5 speed, claw actuated 6 speed, claw actuated Gear ratio 1st gear 13 : 32 1S32 12 : 33 1G33 13 : 32 1S32 13 : 33 1G33 2nd gear 2S15 15 : 30 2S30 2S15 15 : 31 2G31 2S15 15 : 30 2S30 2S15 15 : 31 2G31 3rd gear 3S17 17 : 28 3S28 3S17 17 : 28 3S28 3S17 17 : 28 3S28 3S17 17 : 28 3S28 4th gear 4S19 19 : 26 4S26 4S19 19 : 26 4S26 4S19 19 : 26 4S26 4S19 19 : 26 4S26 5th gear 5S21 21 : 25 5S25 5S21 21 : 25 5S25 5S21 21 : 25 5S25 5G17 21 : 25 5G19 6th gear 6G20 20 : 20 6G20 6S22 20 : 23 6S23 6G22 20 : 20 6G20 Gear lubrication 0.7 l engine oil (Motorex Top Speed 4T 15W50) Available chain sprockets 13Z / 14Z / 15Z for chain 5 /8 x 1 /4" Coolant 2 litres, 40% anti freeze, 60% water, at least -25 C (-13 F) Ignition system KOKUSAN 2K-1 KOKUSAN 2K-3 KOKUSAN 2K-3 KOKUSAN 2K-3 Generator output no genaerator 12V / 110 W 12V / 110 W 12V 110 W Ignition system USA KOKUSAN 2K-1 KOKUSAN 2K-2 KOKUSAN 2K-3 KOKUSAN 2K-2 Generator output no genaerator 12V 40 W 12V / 110 W 12V 40 W Carburetor flat-slide carburetor, carburetor setting see table Air-filter wet foam type air filter insert

TIGHTENING TORQUES - ENGINE Flange bolts - cylinder-head M 7 18 Nm Nuts-cylinder base M 8 30 Nm Flywheel collar nut M 12x1 60 Nm Nut for primary sprocket (LH thread) M 16x5 180 Nm Nut for inner clutch hub M 18x5 120 Nm Crankcase and clutch cover bolts M 6 8 Nm Spark plug M 14x25 20 Nm Swingarm pivot M 16x5 100 Nm Other screws M 6 10 Nm M 8 25 Nm M 10 45 Nm BASIC CARBURETOR SETTING 125 SX 200 EXC USA 200 SX 200 EXC AUS 200 EXC EU 125 EXC EU 125 EXC AUS Carburetor Carburetor setting number Main jet Idling jet Starting jet Jet needle Needle position from top Throttle valve Air adjustment screw open Performance restrictor Keihin PWK 39 141102 188 (1/190) 45 (48) R 1469 D (R 1468 D) II 5 Keihin PWK 38 AG 080202 178(180/1) 45 (48) NOZ E (NOZ F) III 6.5 Keihin PWK 39 151102 188 (1/190) 45 (48) R 1468G (R1469G) III 5 Keihin PWK 38 AG 100202 180 (178) 35 (45/48) R 1475J (NOZ E/NOZ F) III 6.5 slide stop36mm Keihin PWK 38 AG 070202 148 (180/1) 35 (45/48) R 1472 N (NOZ E/NOZ F) V 6.5

CARBURETOR SETTING KTM 125 SX EUROPA / USA 2004 KEIHIN PWK 39 MEERESHÖHE TEMPERATUR -20 C bis -7 C -6 C bis 5 C 6 C bis 15 C 16 C bis 24 C 25 C bis 38 C 37 C bis 49 C 2 LSCHR AS 1 1/2 1 3/4 2 2 1/4 2 1/2 LD IJ 45 42 40 38 38 NADEL NEEDLE R1469D R1470D R1470D R1470D R1471D POS POS 2 3 2 2 1 HD MJ 1 182 180 178 175 LSCHR AS 1 1/4 1 1/2 1 3/4 2 2 1/4 2 1/2 LD IJ 48 45 42 40 38 38 NADEL NEEDLE R1469D R1469D R1470D R1470D R1470D R1471D POS POS 3 2 3 2 2 1 HD MJ 188 1 182 180 178 175 LSCHR AS 1 1 1/4 1 1/2 1 3/4 2 2 1/4 LD IJ 50 48 45 42 40 38 NADEL NEEDLE R1468D R1469D R1469D R1470D R1470D R1470D POS POS 3 3 2 2 2 2 HD MJ 190 188 1 182 180 178 LSCHR AS 3/4 1 1 1/4 1 1/2 1 3/4 2 LD IJ 52 50 48 45 42 40 NADEL NEEDLE R1468D R1468D R1469D R1469D R1470D R1470D POS POS 4 3 3 3 2 2 HD MJ 192 190 188 1 182 180 LSCHR AS 1/2 3/4 1 1 1/4 1 1/2 1 3/4 LD IJ 55 52 50 48 45 42 NADEL NEEDLE R1468D R1468D R1469D R1469D R141469D R1470D POS POS 5 4 3 3 2 2 HD MJ 195 192 190 188 1 182 Schieber= 5,5 Zerstäuber= 6 mm Slide = 5,5 Atomizer = 6 mm

CARBURETOR SETTING KTM 125 EXC EUR 2004 KEIHIN PWK 38 AG MEERESHÖHE TEMPERATUR -20 C bis -7 C -6 C bis 5 C 6 C bis 15 C 16 C bis 24 C 25 C bis 38 C 37 C bis 49 C 2 Schieber= 6,5 Zerstäuber= 5 mm LSCHR AS 1 1/2 1 3/4 2 2 1/4 2 1/2 LD IJ 45 42 40 38 35 NADEL NEEDLE NOZE NOZE NOZE NOZF NOZF POS POS 3 3 2 1 1 HD MJ 180 178 175 172 170 LSCHR AS 1 1/4 1 1/2 1 3/4 2 2 1/4 2 1/2 LD IJ 48 45 42 40 38 35 NADEL NEEDLE NOZD NOZE NOZE NOZF NOZF NOZF POS POS 4 3 3 2 1 1 HD MJ 182 180 178 175 172 170 LSCHR AS 1 1 1/4 1 1/2 1 3/4 2 2 1/4 LD IJ 50 48 45 42 40 38 NADEL NEEDLE NOZD NOZD NOZE NOZE NOZE NOZF POS POS 4 4 3 2 2 1 HD MJ 1 182 180 178 175 172 LSCHR AS 3/4 1 1 1/4 1 1/2 1 3/4 2 LD IJ 52 50 48 45 42 40 NADEL NEEDLE NOZD NOZD NOZE NOZE NOZE NOZF POS POS 4 4 3 3 2 2 HD MJ 188 1 182 180 178 175 LSCHR AS 1/2 3/4 1 1 1/4 1 1/2 1 3/4 LD IJ 55 52 50 48 45 42 NADEL NEEDLE NOZC NOZD NOZD NOZE NOZE NOZF POS POS 5 4 4 3 3 2 HD MJ 190 188 1 182 180 178 Slide = 6,5 Atomizer= 5 mm

CARBURETOR SETTING KTM 200 SX EUROPA / USA 2004 KEIHIN PWK 39 MEERESHÖHE TEMPERATUR -20 C bis -7 C -6 C bis 5 C 6 C bis 15 C 16 C bis 24 C 25 C bis 38 C 37 C bis 49 C 2 Schieber= 5,5 Zerstäuber= 6 mm LSCHR AS 1 1/2 1 3/4 2 2 1/4 2 1/2 LD IJ 48 45 42 40 40 NADEL NEEDLE R1468G R1469G R1469G R1469G R1470G POS POS 2 3 2 2 1 HD MJ 190 188 1 182 180 LSCHR AS 1 1/4 1 1/2 1 3/4 2 2 1/4 2 1/2 LD IJ 50 48 45 42 40 38 NADEL NEEDLE R1468G R1468G R1469G R1469G R1469G R1470G POS POS 3 2 3 2 2 1 HD MJ 192 190 188 1 182 180 LSCHR AS 1 1 1/4 1 1/2 1 3/4 2 2 1/4 LD IJ 52 50 48 45 42 4 NADEL NEEDLE R1467G R1468G R1468G R1469G R1469G 1469G POS POS 3 3 2 2 2 2 HD MJ 195 192 190 188 1 182 LSCHR AS 3/4 1 1 1/4 1 1/2 1 3/4 2 LD IJ 55 52 50 48 45 42 NADEL NEEDLE R1467G R1467G R1468G R1468G R1469G R1469G POS POS 4 3 3 3 2 2 HD MJ 198 195 192 190 188 1 LSCHR AS 1/2 3/4 1 1 1/4 1 1/2 1 3/4 LD IJ 58 55 52 50 48 45 NADEL NEEDLE R1466G R1467G R1468G R1468G R1468G R1469G POS POS 5 4 3 3 2 2 HD MJ 200 198 195 192 190 188 Slide = 5,5 Atomizer= 6 mm

CARBURETOR SETTING KTM 200 MXC/EXC EUR/USA 2004 KEIHIN PWK 38 AG MEERESHÖHE TEMPERATUR -20 C bis -7 C -6 C bis 5 C 6 C bis 15 C 16 C bis 24 C 25 C bis 38 C 37 C bis 49 C 2 LSCHR AS 1 3/4 1 3/4 1 3/4 2 2 LD IJ 45 45 42 42 42 NADEL NEEDLE NOZE NOZF N0ZG NOZG NOZH POS POS 2 2 2 1 1 HD MJ 178 175 172 170 168 LSCHR AS 1 1/4 1 3/4 1 3/4 1 3/4 2 2 LD IJ 45 45 45 42 42 42 NADEL NEEDLE NOZE NOZE NOZF NOZG NOZG NOZH POS POS 3 2 2 2 1 1 HD MJ 180 178 175 172 170 168 LSCHR AS 1 1/2 1 1/4 1 1/2 1 3/4 1 3/4 2 LD IJ 48 45 45 45 42 42 NADEL NEEDLE NOZD NOZE NOZE NOZF NOZG NOZG POS POS 3 3 2 2 2 1 HD MJ 182 180 178 175 172 170 LSCHR AS 1 1/4 1 1 1/4 1 1/2 1 3/4 1 3/4 LD IJ 48 48 45 45 45 42 NADEL NEEDLE NOZD NOZD NOZE NOZE NOZF NOZG POS POS 4 4 3 3 2 2 HD MJ 1 182 180 178 175 172 LSCHR AS 1 1 1/4 1 1/2 1 1/4 1 1/2 1 3/4 LD IJ 50 48 48 45 45 45 NADEL NEEDLE NOZC NOZD NOZD NOZE NOZE NOZG POS POS 5 4 3 3 2 2 HD MJ 188 1 182 180 178 175 Schieber= 6,5 Zerstäuber= 5 mm Slide = 6,5 Atomizer= 5 mm

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