KTM 125 144 150 200 1999-2010 Service Repair Workshop Manual Download PDF

Precio habitual: $16.99
Precio de venta: $16.99
Precio habitual
Precio unitario: por

This manual covers 125 SX, 125 EXC, 144 SX, 144 EXC, 150 SX, 150 EXC, 200 SX, and 200 EXC models produced between 1999 and 2010. Originating from Austria, the...

23 people are viewing this right now

Tipo: Motorcycle

Proveedor:

SKU: 77925

Etiquetas: 125 144 150 1999 200 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 KTM Motorcycle Motorcycles

Variantes de producto

Descripción

This manual covers 125 SX, 125 EXC, 144 SX, 144 EXC, 150 SX, 150 EXC, 200 SX, and 200 EXC models produced between 1999 and 2010. Originating from Austria, the brand is renowned for its high-performance off-road motorcycles, and these models are celebrated for their lightweight chassis, potent two-stroke engines, and exceptional handling. They represent a significant part of the brand's legacy in motocross and enduro racing, often favored for their premium components and robust Austrian engineering. These motorcycles are designed for demanding off-road use, offering a thrilling riding experience and a competitive edge in their respective classes. This comprehensive service repair workshop manual provides detailed information essential for maintaining and repairing your motorcycle. It covers all critical systems, including the two-stroke engine, transmission, clutch, ignition, and exhaust, as well as the chassis, suspension, brakes, and electrical components. You will find step-by-step instructions for routine maintenance, such as oil changes and filter replacements, along with in-depth guidance for complex repairs, engine rebuilds, and troubleshooting common issues. This manual is an invaluable resource for owners, mechanics, and technicians, ensuring your vehicle operates at its peak performance and longevity.

🏷️ Basic Information

Identification

Make:

Model:

125 SX, 125 EXC, 144 SX, 144 EXC, 150 SX, 150 EXC, 200 SX, 200 EXC

Year Range:

1999-2010

Codes

Chassis Codes:

Varies by model and year (e.g., SX models typically use SX chassis codes, EXC models use EXC chassis codes)

Engine Codes:

Varies by model and displacement (e.g., 125cc, 144cc, 150cc, 200cc)

👋 Introduction

Market Position

Segment:

Off-road motorcycles (Motocross and Enduro) known for their performance-oriented nature and Austrian engineering.

Competitive Analysis

Key Competitors:

Yamaha YZ125, YZ250, YZ250F; Honda CR125R, CR250R, CRF250X; Suzuki RM125, RM250, RM-Z250; Kawasaki KX125, KX250, KX250F

Key Features

Manual Value Proposition:

Provides comprehensive, factory-level repair and maintenance information, empowering owners and independent workshops to perform all necessary tasks with confidence.

Vehicle Strengths:

Lightweight chassis, potent two-stroke engines (for their displacement), excellent handling characteristics, premium components typical of KTM.

📋 Manual Details

Coverage Areas

Primary Regions:

Global (covering specifications and procedures applicable across most international markets for these models)

Specific Models Covered:

KTM 125 SX, KTM 125 EXC, KTM 144 SX, KTM 144 EXC, KTM 150 SX, KTM 150 EXC, KTM 200 SX, KTM 200 EXC

Page Count

Estimated Page Count:

Hundreds (exact count not specified, but described as 'hundreds of pages' with detailed photos & diagrams)

Manual Type

Type:

Service Repair Workshop Manual

Language

Language:

English (implied by product description and common practice for such manuals)

Format

Format:

Downloadable PDF

📖 Manual Coverage

Systems Covered

Powertrain:

Engine (two-stroke), clutch, gearbox, ignition system, exhaust system

Chassis:

Frame, suspension (front forks, rear shock absorber), steering, wheels, brakes (front and rear), fuel tank, seat, bodywork, electrical system (lighting, wiring harness)

Procedures Included

Maintenance:

Routine servicing, oil changes, filter replacements, chain adjustment, spark plug service, decarbonization

Repair:

Engine rebuilds (top-end and bottom-end), transmission overhauls, suspension component replacement, brake caliper servicing, carburetor tuning, electrical fault diagnosis and repair

Troubleshooting:

Diagnostic procedures for common issues, performance problems, starting difficulties, electrical faults

Technical Depth

Depth:

Comprehensive; covers everything from basic maintenance to complete engine and chassis overhauls, including detailed exploded diagrams and step-by-step instructions.

📊 Manual Specifications

File Format

File Type:

Searchable:

Likely searchable if OCR processed, though not explicitly stated. Typical for professional PDFs.

Print Quality

Printable:

Yes, single pages or the entire manual can be printed.

Binding Type

Binding:

N/A (Digital download)

Paper Type

Paper Quality:

N/A (Digital download)

Usage Rights

Device Compatibility:

Compatible with unlimited computers (Windows & MAC), tablets, and smartphones.

Licensing:

Full, unlimited use for life; no expiry dates or renewal fees.

⚙️ Engine Specifications

Primary Engine

Type:

Two-stroke, single-cylinder, liquid-cooled

Displacements:

125cc, 144cc, 150cc, 200cc (specific to models)

Bore X Stroke:

Varies by displacement (e.g., 125cc models often around 54mm x 54.5mm, 200cc models around 64mm x 62.4mm)

Performance

Horsepower:

Estimated 30-40+ HP depending on model and year (typical for this class)

Torque:

Estimated 20-25+ Nm depending on model and year

Fuel System

Carburetor:

Typically Keihin PWK or similar, sized appropriately for displacement (e.g., 36-38mm).

Fuel Type:

Unleaded gasoline with appropriate two-stroke oil pre-mix (ratio typically 1:30 or 1:40, check manual for specifics)

Ignition System

Type:

Digital CDI (Capacitor Discharge Ignition) with variable ignition timing.

Lubrication

System:

Premix fuel/oil system, gearbox oil.

🔧 Transmission

Standard

Type:

6-speed manual transmission

Optional

Options:

N/A (Standard configuration)

Features

Clutch:

Hydraulically operated multi-plate wet clutch

Gear Ratios:

Specific ratios vary by model year and variant; detailed in the manual.

Fluid Specifications

Gearbox Oil:

Typically SAE 10W/40 or 15W/50 API SG or higher, manual specific.

📐 Dimensions

Exterior

Wheelbase:

Varies by model and year, typically around 1440-1470 mm.

Weights

Dry Weight:

Approximately 95-105 kg (depending on model and equipment).

Fuel Tank Capacity:

Typically 7-9 liters (depending on model and year).

🛡️ Safety Features

Ratings

Crash Safety:

N/A (Off-road motorcycles not subjected to road vehicle crash safety standards like NCAP.)

Active Features

Braking System:

Hydraulic disc brakes front and rear, typically with Brembo components.

Suspension Design:

Telescopic front forks (e.g., WP USD) and single-shock rear suspension (e.g., WP Monoshock) with adjustable preload, compression, and rebound damping.

Passive Features

Frame Material:

Chromoly steel trellis frame

💡 Technology Features

Infotainment

Features:

N/A (Basic off-road motorcycles, typically no complex infotainment systems beyond basic instrumentation.)

Driver Assistance

Features:

N/A (No electronic rider aids common on modern street bikes).

Connectivity

Features:

Instrumentation

Features:

Digital or analog tachometer, speedometer (on some models), hour meter, indicator lights.

🔧 Maintenance

Service Intervals

Oil Change Gearbox:

Typically every 10-15 hours of riding, or annually. Check manual for exact recommendation.

Air Filter Cleaning:

Frequent cleaning recommended, especially in dusty conditions (every few hours of use).

Spark Plug Replacement:

Varies, but recommended every 20-40 hours of riding or as per manual.

Top End Rebuild:

Typically 40-100 hours depending on riding style and engine condition; manual will provide specific guidance.

Fluid Specifications

Coolant:

Mixture of distilled water and antifreeze (ethylene glycol based), typically 50/50.

Brake Fluid:

DOT 4 or DOT 5.1 hydraulic brake fluid.

Known Issues

Common Wear Items:

Piston rings, piston, clutch plates, spokes, wheel bearings, fork seals.

Two Stroke Specific:

Need for regular decarbonization of exhaust port and power valve, proper premixing, and potential for carbon buildup if ridden gently.

Suspension Maintenance:

Regular fork oil changes and seal replacement are crucial for optimal performance and longevity.

📚 Vehicle History

Brand Heritage

Founder:

Hanns Trukenpolz

Origin:

Austria

Specialty:

Performance off-road motorcycles, particularly in motocross and enduro racing.

Model Evolution

Key Changes 1999-2010:

Significant updates to chassis geometry, engine tuning, suspension components (WP), and styling across the SX and EXC lines. Introduction and refinement of the 144cc and 150cc displacements.

Production

Manufacturing Location:

Austria

🏆 Awards & Recognition

Recognitions

Racing Success:

KTM models in this era have a strong history of success in amateur and professional motocross and enduro racing, underscoring their performance capabilities.

Ratings

Industry Perception:

Consistently rated highly by riders and media for their power-to-weight ratio, handling, and durability in demanding off-road conditions.