Model:
125 SX, 200 SX, 125 MXC, 200 MXC, 125 EXC, 200 EXC
Model Variant:
Motocross (SX), Cross Country (MXC), Enduro (EXC)
Year Range:
1999, 2000, 2001, 2002, 2003
Manual Product Code:
KTM-125-200-SX-MXC-EXC-1999-2003
Segment:
High-performance off-road motorcycles, popular in amateur and professional motocross, cross country, and enduro racing.
Target Audience:
Motocross racers, enduro riders, recreational off-road enthusiasts, and mechanics specializing in KTM or off-road vehicles.
Competitors:
Competes directly with similarly sized offerings from Yamaha (YZ125), Honda (CR125R), Suzuki (RM125), Kawasaki (KX125), and Husqvarna during the period.
Vehicle Philosophy:
KTM's 'Ready to Race' philosophy, emphasizing lightweight design, powerful engines, and advanced suspension for competitive off-road performance.
Manual Value Proposition:
Provides essential technical knowledge for maintaining peak performance and ensuring longevity of these specialized off-road machines.
Primary Coverage:
Comprehensive service and repair for KTM 125cc and 200cc models across SX, MXC, and EXC variants.
Variant Coverage:
Includes specific details for Motocross (SX), Cross Country (MXC), and Enduro (EXC) model differences, including suspension tuning, gearing, and component variations.
Estimated Page Count:
Likely 300-500 pages (typical for a comprehensive service manual of this era).
Type:
Service Repair Workshop Manual
Purpose:
Designed for use by professional mechanics and experienced DIY enthusiasts.
Language:
English (Standard for this type of manual unless otherwise specified).
Engine:
2-stroke engine disassembly, assembly, troubleshooting, tuning, and component diagnostics (e.g., cylinder, piston, crankshaft, reed valve assembly, carburetor).
Fuel System:
Carburetor identification, adjustment, cleaning, and overhaul (likely Keihin or Mikuni).
Ignition System:
CDI unit, ignition coil, spark plug specifications, timing checks.
Cooling System:
Liquid cooling system maintenance, coolant specifications, radiator, water pump.
Transmission:
Clutch operation and adjustment, gearbox disassembly, assembly, inspection, and lubrication.
Suspension:
Front fork (WP USD - Upside Down) disassembly, assembly, oil level and type, seal replacement, damping adjustments. Rear shock absorber (WP Monoshock) service, linkage maintenance, spring preload adjustment.
Brakes:
Hydraulic brake system (front and rear disc brakes) bleeding, pad replacement, caliper service, master cylinder overhaul. Lever and pedal adjustments.
Electrical System:
Wiring diagrams, lighting system, fuses, battery maintenance, basic troubleshooting of electrical components.
Chassis And Frame:
Frame inspection, steering head bearing service, swingarm pivot maintenance.
Exhaust System:
Exhaust pipe and silencer inspection, repack procedures (for some silencer designs).
Maintenance:
Pre-ride inspections, routine servicing, filter cleaning/replacement, spark plug checks, chain adjustment, lubrication points.
Troubleshooting:
Diagnostic flowcharts for common starting, running, and performance issues.
Repair:
Step-by-step instructions for major component overhauls and replacements.
Disassembly Assembly:
Complete procedures for engine, transmission, suspension, and chassis components.
Technical Data Provision:
Torque specifications for all fasteners, fluid capacities, and critical clearances.
Depth:
In-depth, professional-level coverage suitable for complete engine rebuilds and complex repairs.
Detail Level:
Includes detailed exploded diagrams, component illustrations, and precision measurements.
Engine Type:
Liquid-cooled, 2-stroke, single-cylinder
Bore X Stroke 125:
54 mm x 54.5 mm
Bore X Stroke 200:
62.5 mm x 65 mm
Displacement 125:
124.8 cc
Displacement 200:
199.4 cc
Compression Ratio:
Typically around 8.5:1 to 9.0:1 (varies by model and year, check manual for specifics).
Reed Valve System:
V-Force or similar performance reed block (common upgrade/stock feature).
Power Delivery:
Aggressive, high-revving powerband characteristic of 2-stroke performance engines.
Horsepower 125:
Estimated 30-35 HP (crankshaft, varies by tuning and model).
Horsepower 200:
Estimated 38-42 HP (crankshaft, varies by tuning and model).
Carburetor Size 125:
Typically 36mm Keihin PWK or Mikuni TMX.
Carburetor Size 200:
Typically 38mm Keihin PWK or Mikuni TMX.
Fuel Type:
Unleaded gasoline (91-98 RON/90-93 AKI) mixed with 2-stroke oil (pre-mix ratio specified in manual, typically 32:1 or 40:1).
Oil Type Premix:
High-quality 2-stroke synthetic or semi-synthetic racing oil.
Type:
6-speed constant mesh manual transmission
Clutch Type:
Hydraulic actuated, multi-plate wet clutch
Gear Ratios:
Specific gear ratios for each model variant (SX, MXC, EXC) will be detailed in the manual, as they often differ for intended use.
Final Drive:
Chain drive. Manual will detail sprocket size options and chain maintenance.
Transmission Oil Capacity:
Approximately 0.8-1.0 liters (check manual for exact specification).
Transmission Oil Type:
API GL-4 or GL-5 gear oil, typically SAE 75W/90 or 10W/40 motorcycle gear oil.
Frame Material:
Chromoly steel trellis frame
Wheelbase:
Approx. 1440-1470 mm (varies slightly by model).
Ground Clearance:
Approx. 350-370 mm (varies by model and suspension setting).
Dry Weight 125:
Approx. 94-98 kg (varies by model).
Dry Weight 200:
Approx. 97-101 kg (varies by model).
Wet Weight:
Not typically specified for competition bikes, but would include fluids and fuel.
Fuel Tank Capacity:
Typically 7.5 - 9.5 liters (varies by model, EXC usually larger).
Safety Standards:
Designed for off-road competition, not street legal or subject to typical automotive safety ratings.
Braking System:
High-performance hydraulic disc brakes front and rear with Goodridge or similar braided lines for enhanced feel and durability.
Suspension Performance:
WP USD front forks and WP PDS (or linkage on some models) rear shocks providing advanced damping and adjustability for terrain control.
Frame Design:
Robust chromoly steel trellis frame offers high torsional rigidity and impact resistance.
Handlebar:
Oversized aluminum handlebars with crossbar for improved strength and vibration damping.
Oil Change Transmission:
Every 15-20 hours of riding, or annually.
Air Filter Cleaning:
After every few rides, or more frequently in dusty conditions.
Spark Plug Replacement:
Every 20-30 hours of riding, or as needed based on inspection.
Top End Rebuild:
Typically 40-80 hours (piston/rings), 80-150 hours (cylinder/crankshaft bearings) depending on riding style and maintenance. Manual will provide specific recommendations.
Coolant Type:
Ethylene glycol-based antifreeze coolant, mixed 50/50 with distilled water.
Fork Oil Type And Level:
Specific WP fork oil grade (e.g., SAE 5W or 7.5W) and precise oil level measurements will be detailed in the manual.
Brake Fluid Type:
DOT 4 or DOT 5.1 hydraulic brake fluid.
Common Wear Items:
Clutch plates, piston rings, wheel bearings, steering head bearings, swingarm bearings, exhaust packing (if applicable).
Potential Problems:
Carburetor jetting sensitivity to altitude and temperature, 2-stroke engine wear if not maintained properly, water pump seal leaks.
Suspension Maintenance:
Regular fork seal replacement and fork oil changes are critical for optimal performance and to prevent seal damage.
