KTM 125 SX 2008 Guide

125 SX 2008
SPARE PARTS MANUAL: CHASSIS
ART.NO.: 3CF6101H0EN
ENGLISH

INDEX
125 SX 2008
FRONT FORK, TRIPLE CLAMP
3x
FRONT FORK DISASSEMBLED
4x
HANDLEBAR, CONTROLS
7x
FRAME
8x
MONOSHOCK
9x
SWING ARM
10x
MONOSHOCK DISASSEMBLED
11x
EXHAUST SYSTEM
13x
AIR FILTER
14x
TANK, SEAT, COVER
15x
MASK, FENDERS
16x
DECAL
17x
1

INDEX
125 SX 2008
FRONT WHEEL
18x
REAR WHEEL
19x
HAND BRAKE CYLINDER
21x
REAR BRAKE CONTROL
22x
BRAKE CALIPER FRONT
23x
BRAKE CALIPER REAR
24x
ACCESSORIES KIT
25x 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.
2

125 SX 2008
FIG PART NUMBER DESCRIPTION QTY
1* 14187D01 FRONT FORK WP D=48 CC 125 SX08 1
3* 0025080256 HH COLLAR SCREW M8X25 TX40 8
4* 0025080356 HH COLLAR SCREW M8X35 TX40 10
5* 0025080256S HH COLLAR SCREW M8X25 TX40 1
6 0912100356 AH SCREW DIN6912-M10X35 10.9 2
7 54801036100 STE.HEAD SCR. M20X1,5 WS=27 SL 1
SELF-LOCKING
8 0770025035 O-RING 25X3,55 NBR70 05 1
9 0017060204 EJOT PT SCREW K60X20 ALU WS=6 2
32 59401031019 BOTTOM TRIPLE CLAMP D=60MM 05 1
33 59401033000 FORK TUBE L=237MM 05 1
34 59401034019 TOP TRIPLE CLAMP D=54MM 05 1
36 54801036000 STEER.HEAD SCREW M20X1,5 WS=27 1
38 59401038000 HANDLEBAR CLAMP 28MM 05 2
39 59401039032 HANDLEB.SUPP. D=28MM H=32MM 05 x
39 59401039037 HANDLEB.SUPP. D=28MM H=37MM 05 x
39 59401039042 HANDLEB.SUPP. D=28MM H=42MM 05 x
81 54201081100 TAPERED ROLLER BEARING CPL. 06 2
82 54601084100 O-RING SUPPORT W. SEALING LIP 1
84 54601184000 STEARING HEAD GASKET TOP 1
85* 7800108500030 CLAMP F.SPEED.CABLE D=6MM 08 1
86 54201086000 STEERING HEAD COVER 1
91 59001092050 SPECIAL SCREW M6X12,5 WS=8 6
92* 7800109400030 FORK PROT. L/S+R/S BLACK 1
085030112 / C085030110
* NEW PART X AS REQUIRED
3
FRONT FORK
,
TRIPLE CLAMP

125 SX 2008
FIG PART NUMBER DESCRIPTION QTY
3 48600569 SETTING KNOB 2
12* 48600693 OUTER TUBE L577 D54/60MM 2L BL 2
13* 48600698 FORK PROTECTION RING 08 2
15 48600429 DU-BUSH D48XD52X12DDL02 2
16 48600013 SUPPORT RING 50 X 57,6 X 1,5 2
17 48600347 OIL SEAL RING 48X57,8X9,5 03 2
18 48600070 LOCK WASHER SB58 2
19 48600400 DUST CAP D=48 58,4X11,8 2
22 48600428 DU-BUSH D47XD49X20DDL02 2
24 48600281 MEMBRANE 2
26 48600301 O-RING NBR 9,5X1,5 2
27 46810811 O-RING NBR 17X2 PA 2
28 48600280S SCREW BUSH M20X1 L=33 CPL. 2
29 48600275 COPPER WASHER 20,5X26X1 2
30 48600269 ADJUSTING TUBE L=371 2
31 48600464 PISTON ROD SXS 2005 2
32 48600459 COUNTERNUT M12X1 WS17 2
33 48600277 ADJUSTER NEEDLE 07 2
34 48600298 O-RING 2X1,5 NBR 2
35 48600444 REBOUND SPRING C=4N/MM 2
38 91410027S SPRING 4,4 N/MM SET D=5,1MM x
38 91410028S SPRING 4,6 N/MM SET D=5,1MM x
38 91410029S POLISHED SPRING 4,8 N/MM x
38 91410030S SPRING 5,0 N/MM x
38 91410051S POLISHED SPRING 4,2 N/MM2 CC x
38 91410052S POLISHED SPRING 4,4 N/MM2 CC x
38* 91410059S SPRING 4,0 N/MM SET x
38 91410060S SPRING 4,2 N/MM SET D=5,0MM x
39 48600456 SPACER 43X35X2,5 x
39 48600457 SPACER 43X35X5 x
39 48600458 SPACER 43X35X1,5 x
40 48600525 GUIDING BUSH REBOUND SPRING 2
42 48600520 SPRING SUPPORT 2
43 48600299 O-RING 6X1,2 NBR 4
44 48600578 SPRING REB. L=32 C=37 DI=13,9 2
45 48600576 PISTON ROD REBOUND 2
087800132 / C087800132
* NEW PART X AS REQUIRED
4
FRONT FORK DISASSEMBLED

125 SX 2008
FIG PART NUMBER DESCRIPTION QTY
47 35480377 SPRING CHECK VALVE D=0,5 2
47 48600382 SHUTTLE VALVE SPRING C=0,4 2
48* 48600519S3 MEMBRANE HOLDER 2
49 48600512 LOCK WASHER D=25,5 2
50 48600542 AH SCREW M4X6 2
51 46811499 O-RING NBR 21X2 4
52 48600047 PISTON COMPRESSION D=27,9 2
53 50180222 O-RING NBR 4X1,5 8
54 48600518S PIN VALVE SET 2
55 40540486 NUT M6X0,5 REBOUND 2
56 48600294 GUIDE RING 44,2 X39,3 2
57 48600577 RING SPRING-SUPPORT 2
59 48600048 O-RING NBR 46 X 2 2
60* 48600690S1 AXLE CLAMP L/S + TUBE CPL. 08 1
61* 48600691S1 AXLE CLAMP R/S + TUBE CPL. 08 1
62 0015080253 HH COLLAR SCREW M 8X25 WS=10 4
63 48600163 CHECK VALVE NUT M6X0,5 D=2 2
64 48600202 SPRING CHECK VALVE D=0,7 2
69 48600509 PISTON ROD COMPRESSION 2
71 48600575 PISTON REBOUND SX 2007 2
72 48600455 PISTON RING 5X1X68 2
74 48600296 RING D=23,45X2,65 2
75 48600471 PISTON ROD SEALING 2
76 48600546S SCREW SLEEVE M24,5X1 CPL. 2
77 48600430 DU_BUS FOR PISTON ROD 2
78* 48600709 CHECK VALVE STOP 2
79 48600446 LOCK WASHER D=20 2
81 15080017 SILICON CAP 2
82* 48600692 RUBBER CAP D=26,4 2
83 48600401S1 FORK OIL SAE5 5L 2005 1
84 40140024 O-RING NBR 43X2 2
85 48600516S1 SCREW CAP CPL. L=125 2
86 48600527 AH SCREW M4X6 2
87 48600526 SCREW M4X10 4
88 48600514 MEMBRANE SLEEVE 2
98 T511 SILICONE GREASE F. DUST STRI 1
087800132 / C087800132
* NEW PART X AS REQUIRED
5
FRONT FORK DISASSEMBLED

125 SX 2008
FIG PART NUMBER DESCRIPTION QTY
99 R14014 REPAIR-KIT GASKET 48MM 0 1
087800132 / C087800132
* NEW PART X AS REQUIRED
6
FRONT FORK DISASSEMBLED

125 SX 2008
FIG PART NUMBER DESCRIPTION QTY
1* 7730200110017 HANDLEBAR RENTHAL SX 28MM 08 1
2 59002002000 HANDLEBAR PAD 05 1
4 57013072000 WIRING HOLDER 12MM 1
5* 60111094000 CLAMP 5/7 MM 06 2
10 54802010000 THR.TWIST CRIP CPL. W.O.CA. 04 1
11 54802013000 TWIST GRIP COVER RENTHAL 04 1
12 50302020000 PROTECTION COVER '97 1
14 50302091000 THROTTLE C. 125-380 DOM./KEIH. 1
15 50311089200 SHORT CIRCUIT BUTTON 02 1
17 54802039000 FIXED GRIP RENTHAL 04 1
18 44011076200 CABLE TIE 200/3,6MM BLACK 1
19 50301089000 SPACER BUSHING 6X10X5 1
30 50302030200 MASTER CYLINDER CPL. 9,5MM 04 1
31 54602031000 CLUTCH LEVER SHORT CPL. 2003 1
31 59002031000 CLUTCH LEVER LONG CPL. 2003 x
32 59002032000 REP.KIT PISTON 9,5MM RAC. 2000 1
33 50302033100 COVER HYD.CLUTCH 2T 2000 1
34 50302034000 RUBBER FOR RESERVOIR '98 1
35 59002035000 SPRING FOR CLUTCH LEVER 03 1
36 50302036200 OIL FOR HYD. CLUTCH 75ML 1
37 50302037000 PROTECT.CAP FOR LEVER PERCH'98 1
38 50302038000 LEVER SCREW CPL. 125-200 '98 1
39 50302030150 CLAMP WITH PIN 2000 1
41* 0025060166 HH COLLAR SCREW M6X16 TX30 1
44 0965040123 FLAT HEAD SCREW DIN0965-M 4X12 2
63 50332063200 CLUTCH PIPE L=970MM 04 1
085230211 / C085030210
* NEW PART X AS REQUIRED
7
HANDLEBAR
,
CONTROLS

125 SX 2008
FIG PART NUMBER DESCRIPTION QTY
1 5030340100030 FRAME 125 SX "BA07" 07 1
2 77303002000 SUB FRAME SX "Q7" 07 1
3* 78003002010 SUB FRAME APPLICATION LEFT 08 1
4* 78003002020 SUB FRAME APPLICATION RIGHT 08 1
5 50303413000 REINFORCING B. 125 SX 07 2
7 50307012000 ADH. FOIL TRANSP. 80X80 MM 04 2
8 59001037000 SPECIAL SCREW M8X26 WS=10 2
9 0934080003 HEXAGON NUT DIN0934-M 8 2
12 54603013000 ENGINE BRAC.SCR. M10X105 WS=13 2
14* 0019080206S FLAT HEAD SCREW M. ISA45 M8X20 4
15 56530079000 COLLAR SCREW M8X42 WS=13 10.9 3
25 54310086200 SELF LOCKING NUT M8 10.9 3
26 54310086100 SELF LOCKING NUT M10 CU WS=14 2
27* 0025080306 HH COLLAR SCREW M8X30 TX40 2
28* 0025060406 HH COLLAR SCREW M6X40 TX30 1
29* 0125060003 WASHER DIN0125-A 6,4 1
36 59003040250 FOOT PED L/S SILVER 02 1
40 59003041250 FOOT PED R/S SILVER 02 1
41 54803044000 BOLT FOR FOOT PED 03 2
42 54603041000 FOOTREST SPRING L/S & R/S 2
43 0125100003 WASHER DIN0125-A10,5 2
44 0094032253 PIN DIN0094-3,2X25 STEEL 2
45 5030314013390 FOOTREST L.+R. CPL. 03 1
46 50303089000 ANGEL PIECE '97 2
47 55007016001 PVC-HOSE 7X10 PER METER x
50 54803096000 SPROCKET COVER 250 SX 07 1
59 77303053000 CHAIN SLIDING PIECE BELOW 07 1
62 77303139000 BLIND RIVET NUT EM6-60LF/HX 4
63 77303094000 FRAME PROTECTION STICK. SET 07 1
64 77303053010 CHAIN SLIDING P. BELOW CPL. 07 1
085030310 / C085030310
* NEW PART X AS REQUIRED
8
FRAME