KTM 125, Repair Manual

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Repair manual KTM 125 / 200
Art No 3.206.005 -E
– Mount the outer clutch hub and the supporting disc (20x39.6x3 mm)
on the main shaft.
– Mount the inner clutch hub, a new lock washer and the hexagon nut
on the main shaft.
– Mount the clutch holder 1 and tighten the hexagon nut with 120
Nm (88 ft.lb.).
– Remove the clutch holder and secure the hexagon nut by bending
the two brackets of the lock washer upwards.
– The bracket of the lock washer that meshes with the inner clutch hub
must be carefully hammered down after tightening the hexagon nut
to make sure that it rests properly against the inner clutch hub.
Clutch discs, pressure cap
– Oil the thrust bearing and insert it into the main shaft.
– Properly oil the lining discs before mounting them.
NOTE: These engines have 4 clutch discs of aluminum and 2 clutch discs
of steel. These must be mounted in the following order:
– One of the lining discs must be on top.
– Mount the pressure cap, then the clutch springs, the spring retainers
and the collar bolts.
– Tighten the collar bolts crosswise. Apply a maximum of 6 Nm
(4.5 ft.lb.) to prevent damaging of the threads in the inner clutch
hub.
6-6C
aluminium aluminium steel
1 lining disc
1 lining disc
1 lining disc
1 lining disc
1 lining disc
1 lining disc
1 lining disc
1 clutch disc (aluminium)
1 clutch disc (aluminium)
1 clutch disc (steel)
1 clutch disc (steel)
1 clutch disc (aluminium)
1 clutch disc (aluminium)
1