KTM 125 200 SX SXS MXC 1999-2006 Repair Service Manual

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Tipo: Motorcycle

Proveedor:

SKU: 60234

Etiquetas: 125 1999 200 2000 2001 2002 2003 2004 2005 2006 Agriculture Case KTM Motorcycle MXC MXC Series SX SXS Tractors

Variantes de producto

Descripción

This manual covers 125 SX, 200 SX, SXS, and MXC models manufactured between 1999 and 2006. These competition off-road motorcycles are powered by 125cc and 200cc two-stroke, liquid-cooled engines, known for their performance in motocross and enduro racing. Built with a heritage of off-road prowess and manufactured in Austria, models from this era feature robust chromoly steel frames, WP suspension components, and reliable Brembo braking systems, emphasizing durability and handling for demanding riding conditions. This comprehensive workshop repair service manual provides detailed, factory-level information for owners, independent repair shops, and DIY enthusiasts. It covers all aspects of maintenance, from regular service and fluid changes to intricate engine rebuilds and suspension servicing. The manual includes step-by-step repair procedures, troubleshooting guides for common issues, and essential technical specifications such as torque values and clearances. The English-language manual is presented in a user-friendly format, complete with illustrations and diagrams, enabling accurate and efficient upkeep of your motorcycle.

🏷️ Basic Information

Identification

Make:

Model:

125 SX, 200 SX, SXS, MXC

Applicable Model Years:

1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006

👋 Introduction

Market Position

Target Audience:

KTM owners, independent repair shops, and DIY enthusiasts seeking professional-level service information.

Competitive Analysis

Advantage:

Provides factory-level information, equivalent to what professionals use, enabling cost savings on repairs and maintenance.

Key Features

Content Quality:

COMPLETE and INTACT, hundreds of pages, diagrams, detailed information, written by manufacturers.

Delivery:

Instant Download, no shipping or waiting.

Ease Of Use:

Easy-to-follow directions, pictures, numbered instructions, numbered table of contents.

📋 Manual Details

Coverage Areas

Covered Models:

KTM 125 SX, 200 SX, SXS, MXC (all variants and trim levels)

Covered Engines:

125cc and 200cc two-stroke engines

Covered Transmissions:

All transmission types used within the specified model years.

Page Count

Estimated Pages:

Hundreds of pages (as stated in product description, specific count not provided)

Manual Type

Type:

Workshop Repair Service Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

General Information, Fuel System, Cooling System, Top End, Lubrication System, Engine Removal/Installation, Crankshaft, Transmission

Drivetrain:

Clutch, Final Drive

Chassis:

Wheels/Tires, Brakes, Suspension, Steering, Frame

Electrical:

Electrical System, Wiring Diagrams

Procedures Included

Maintenance:

Regular service, fluid changes, filter replacements, general upkeep.

Repair:

Detailed step-by-step repair procedures for all covered systems, disassembly and reassembly.

Troubleshooting:

Diagnostic procedures and common issue resolution.

Technical Data:

Critical specifications, torque values, clearances, fluid capacities.

Engine Rebuild:

Complete engine disassembly, inspection, repair, and reassembly procedures.

Suspension Servicing:

Detailed procedures for fork and shock absorber maintenance, seal replacement, and fluid changes.

Electrical Diagnostics:

Troubleshooting of lighting, ignition, and charging systems with detailed wiring diagrams.

Technical Depth

Depth:

Comprehensive, professional-level diagnostics, repair, and maintenance.

Illustrations:

Includes detailed illustrations, drawings, and photos for each procedure.

Precision:

Contains critical specifications and precise measurements required for accurate repairs.

Troubleshooting Guides:

Specific troubleshooting sections to help diagnose and resolve common and uncommon issues.

Appendices

Included Sections:

Covers an Appendix section, which typically includes additional technical data, conversion charts, or special tools.

📊 Manual Specifications

File Format

Format:

Searchability:

Likely searchable text within the PDF (standard for professional manuals).

Print Quality

Printability:

Full Printable

Zoom Capability:

YES (Zoom IN/OUT)

Binding Type

Type:

Digital (No physical binding)

Paper Type

Type:

N/A (Digital format)

Compatibility

Operating Systems:

All Versions of Windows & Mac

Requirements

Software:

Adobe PDF Reader & WinZip

⚙️ Engine Specifications

Primary Engine

Engine Type:

Two-Stroke, Liquid-Cooled (typical for these models)

Displacement:

125cc and 200cc variants

Performance

Horsepower 125Cc:

Approximately 35-40 HP (varies by specific model variant and tuning)

Horsepower 200Cc:

Approximately 40-45 HP (varies by specific model variant and tuning)

Fuel System

Carburetion:

Mikuni or Keihin Carburetors (specific models vary, e.g., VM28 for 125)

Fuel Type:

High-octane unleaded gasoline mixed with two-stroke oil.

Lubrication

Oil Type:

High-quality two-stroke synthetic oil (specific recommendations in manual).

🔧 Transmission

Standard

Type:

6-speed manual transmission

Optional

Type:

N/A (standard for this class of competition bikes)

Features

Clutch Type:

Hydraulic clutch actuation (typical for KTM).

📐 Dimensions

Exterior

Frame Type:

Chromoly Steel, central double-cradle type (typical for KTM).

Weights

Dry Weight 125:

Approx. 93-96 kg (205-212 lbs) depending on variant.

Dry Weight 200:

Approx. 96-99 kg (212-218 lbs) depending on variant.

🛡️ Safety Features

Ratings

Classification:

Competition off-road motorcycles (not street legal in most configurations).

Active Features

Braking System Front:

Hydraulic disc brake, Brembo calipers (typical).

Braking System Rear:

Hydraulic disc brake, Brembo calipers (typical).

Passive Features

Suspension Front:

Upside-down telescopic forks (e.g., WP).

Suspension Rear:

Monoshock WP rear suspension with PDS (Power Dispersion System) or similar linkage-less design.

💡 Technology Features

Infotainment

Features:

N/A (These are competition off-road motorcycles; focus is on performance and durability, not infotainment).

Driver Assistance

Features:

N/A (No electronic rider aids typically found on these models).

Connectivity

Features:

Ignition

System:

Digital CDI ignition system.

🔧 Maintenance

Service Intervals

Oil Change Recommendation:

Refer to manual for specific hours/miles. Frequent checks and top-offs of premix are crucial.

Air Filter Cleaning:

Frequent cleaning/replacement recommended, especially after dusty rides.

Spark Plug Replacement:

Refer to manual for specific hours/miles or as needed based on performance.

Fluid Specifications

Fork Oil:

Specific viscosity and quantity detailed in the manual (e.g., WP suspension fluid). Common types include 5W or 7.5W.

Coolant:

Ethylene glycol-based antifreeze mixed with distilled water (50/50 ratio typical).

Brake Fluid:

DOT 4 or DOT 5.1 hydraulic brake fluid (check specific recommendations for Brembo systems).

Clutch Fluid:

DOT 4 or DOT 5.1 hydraulic fluid (typically the same as brake fluid for KTM).

Known Issues

Common Wear Items:

Clutch plates, piston rings, crank bearings, suspension seals, wheel bearings are common wear items on high-performance off-road bikes of this era.

Carburetor Tuning:

Can be sensitive to altitude, temperature, and jetting changes. Manual provides detailed tuning guides.

Cooling System Maintenance:

Regular flushing and proper coolant mixture are essential to prevent overheating.

📚 Vehicle History

Brand Heritage

Heritage:

KTM is renowned for its off-road racing pedigree, particularly in motocross and enduro.

Model Evolution

Evolution Context:

These models represent a significant period in KTM's development of competitive motocross and cross-country bikes, building on earlier designs and introducing advancements in suspension and chassis.

Production

Manufacturing Region:

Austria (KTM headquarters and primary manufacturing).

🏆 Awards & Recognition

Recognitions

Racing Success:

KTM models of this era were highly successful in various national and international motocross and enduro championships.

Ratings

User Satisfaction:

Generally high user satisfaction among experienced riders and mechanics for performance and handling.