KTM 125 200 EGS EXC SIX DAYS Engine 1999-2006 Service Repair Manual

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Tipo: Motorcycle

Proveedor:

SKU: 94472

Etiquetas: 125 1999 200 EGS 2000 2001 2002 2003 2004 2005 2006 EXC SIX DAYS KTM Misc Motorcycle Motorcycles

Variantes de producto

Descripción

This manual covers the 125 EGS, 200 EGS, and EXC models, including Six Days editions, produced between 1999 and 2006. These off-road motorcycles are renowned for their high-performance two-stroke engines, capable WP suspension, and robust construction, reflecting a strong legacy in motorsports. Designed for competitive riding and trail use, these models offer a potent combination of power and agility, making them popular choices in the enduro segment. The 125cc variants produce approximately 30-35 HP, while the 200cc models deliver around 38-42 HP, both featuring liquid-cooled, single-cylinder configurations and a 6-speed transmission. This comprehensive service repair manual provides detailed guidance for owners, mechanics, and technicians. It covers all essential aspects of maintenance, diagnostics, and repair for both the 125cc and 200cc engine variants, including complete engine overhauls, carburetor service, and tuning. The manual also details procedures for the chassis, suspension, brakes, fuel, cooling, exhaust, and electrical systems, along with specific instructions for the Six Days models. With in-depth troubleshooting guides and technical specifications, this manual is an indispensable resource for ensuring the optimal performance and longevity of your motorcycle.

🏷️ Basic Information

Identification

Make:

Model:

125 EGS, 200 EGS, EXC, Six Days

Engine Variant:

125cc, 200cc

Production Years Covered:

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

Codes

Chassis Codes:

Refer to specific model year within manual

👋 Introduction

Market Position

Segment:

Off-road/Enduro motorcycles, popular for competitive riding and trail use.

Competitive Analysis

Competitors 1999 2006:

Yamaha YZ125, YZ250, Honda CR125R, CR250R, Suzuki RM125, RM250, Kawasaki KX125, KX250, Husqvarna WR125/250.

Key Features

Ktm Legacy:

KTM's reputation for high-performance, durable off-road motorcycles.

Model Strengths:

Strong engines, capable WP suspension, competitive pricing for performance.

📋 Manual Details

Coverage Areas

Engine Coverage:

Complete engine overhaul, diagnostics, tuning, and repair for 125cc and 200cc engines.

Chassis Coverage:

Suspension, brakes, wheels, fuel system, cooling system, exhaust system, electrical system, frame, and bodywork.

Special Editions Covered:

KTM Six Days models for applicable years.

Page Count

Estimated Pages:

High (typical for comprehensive service manuals, exact number not specified but expected to be substantial)

Manual Type

Type:

Service Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Cylinder, piston, crankshaft, connecting rod, balancing shaft, camshaft (if applicable), valve train, timing, lubrication system.

Fuel System:

Carburetor (Mikuni VM/TM series typical), fuel pump, fuel lines, fuel tank, petcock operation and service.

Ignition System:

CDI unit, ignition coil, spark plug, stator, rotor, wiring diagrams.

Cooling System:

Radiator, hoses, thermostat, water pump, coolant specifications, bleeding procedures.

Exhaust System:

Exhaust pipe, silencer, mounting, repacking procedures for silencer.

Transmission And Clutch:

Gearbox operation, clutch assembly (perch, cable, plates, springs), shift mechanism, lubrication.

Chassis And Suspension:

Front fork (WP USD typical), rear shock absorber (WP PDS typical), linkages, bearings, steering head bearings.

Brakes:

Hydraulic brake system (front and rear), calipers, master cylinders, brake lines, brake pads, rotor specifications, fluid types.

Electrical System:

Wiring diagrams, lighting, battery, charging system (stator, regulator/rectifier), fuses, switches, horn, indicators.

Wheels And Tires:

Rim specifications, spoke tensioning, wheel bearings, tire size recommendations, inflation pressures.

Procedures Included

Routine Maintenance:

Oil change intervals and specifications, filter replacement, spark plug inspection, chain adjustment and lubrication, air filter cleaning/replacement.

Engine Rebuild:

Complete engine disassembly, inspection, measurement of wear limits, reassembly procedures, torque specifications.

Carburetor Service:

Disassembly, cleaning, jetting specifications, float height adjustment, idle speed setting.

Suspension Service:

Fork oil change and level setting, fork seal replacement, rear shock service, linkage bearing maintenance.

Brake System Service:

Brake fluid flush and replacement, caliper piston service, pad replacement, bleeding procedures.

Electrical Troubleshooting:

Diagnostic procedures for common electrical faults, component testing, wiring harness repair.

Troubleshooting Guides:

Step-by-step diagnosis for starting issues, performance problems, cooling system faults, and electrical gremlins.

Technical Depth

Depth:

Comprehensive from basic maintenance to complete engine and chassis overhauls.

Diagnostic Capabilities:

Detailed diagnostic procedures and specifications for identifying and resolving mechanical and electrical issues.

Special Tools:

Lists recommended special tools for specific repair procedures.

📊 Manual Specifications

File Format

File Type:

Searchability:

Likely text-searchable, facilitating quick information retrieval.

Print Quality:

Assumed to be printable for workshop use, resolution dependent on original scan/creation.

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Type 125:

2-stroke, single-cylinder, liquid-cooled

Bore Stroke 125:

Approx. 54mm x 54.5mm (check manual for exact spec)

Displacement 125:

124.8 cc

Type 200:

2-stroke, single-cylinder, liquid-cooled

Bore Stroke 200:

Approx. 64mm x 62.2mm (check manual for exact spec)

Displacement 200:

193.2 cc

Performance

Horsepower 125:

Approx. 30-35 HP (varies by year and tuning)

Horsepower 200:

Approx. 38-42 HP (varies by year and tuning)

Fuel System

Carburetor Type:

Mikuni VM series (e.g., VM28/2 for 125, VM30/1 for 200 typical)

Fuel Type:

Premium Unleaded Gasoline (91 octane or higher recommended)

2 Stroke Oil Mix:

Pre-mix (manual will specify ratio, typically 1:40 or 1:50 for Motorex or similar quality oil)

🔧 Transmission

Standard

Type:

6-speed constant mesh

Optional

Options:

Features

Clutch Type:

Hydraulic wet multi-disc clutch

Gear Ratios:

Detailed in manual for each model year and variant.

Transmission Oil Spec:

KTM recommends Motorex Gear Oil SAE 80 or equivalent API GL-4.

📐 Dimensions

Exterior

Wheelbase:

Varies by model year, typically around 1450-1470 mm.

Seat Height:

Varies by model year, typically around 900-920 mm.

Weights

Dry Weight 125:

Approx. 94-96 kg

Dry Weight 200:

Approx. 96-98 kg

Fuel Tank Capacity:

Approx. 8-10 liters (check manual for specific model)

🛡️ Safety Features

Ratings

Safety Certifications:

N/A (Off-road vehicles are not subject to the same road safety certifications as street bikes).

Active Features

Braking System:

Powerful hydraulic disc brakes front and rear (Brembo typically).

Passive Features

Frame Construction:

Chromium-molybdenum steel trellis frame for strength and rigidity.

💡 Technology Features

Infotainment

Features:

Minimal; focus on function over comfort. Typically features a basic odometer/trip meter and hour meter.

Driver Assistance

Features:

Connectivity

Features:

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 15-20 hours of riding, or annually. Refer to manual for specific guidance.

Air Filter Cleaning:

After every few rides, or more frequently in dusty conditions.

Spark Plug Inspection:

Every 20-30 hours of riding.

Piston Ring Replacement:

Typically every 50-100 hours, depending on usage and maintenance.

Fluid Specifications

Engine Oil Type:

Fully synthetic 2-stroke engine oil (e.g., Motorex Cross Power 2T or similar).

Coolant Type:

Ethylene glycol based coolant with anti-corrosion additives (e.g., Motul Motocool Expert or equivalent).

Brake Fluid Type:

DOT 4 Hydraulic Brake Fluid (e.g., Brembo DOT 4 or equivalent).

Known Issues

Common Wear Items:

Clutch plates, piston rings, wheel bearings, steering head bearings, swingarm bearings, exhaust packing.

Potential Faults:

Carburetor jetting sensitivity to altitude/temperature, occasional electrical connector issues, water pump seal leaks if maintenance is neglected.

📚 Vehicle History

Brand Heritage

Ktm Offroad Focus:

KTM has a long and successful history in off-road motorsports, including motocross, enduro, and rally raid.

Model Evolution

Development Philosophy:

Continuous refinement of their two-stroke engines and advanced WP suspension for competitive performance.

Production

Manufacturing Location:

Austria (KTM AG)

🏆 Awards & Recognition

Recognitions

Motorsport Success:

KTM 125/200 EXC models and their derivatives have seen significant success in amateur and professional enduro and cross-country racing.

Ratings

User Reviews:

Generally highly regarded for performance, handling, and durability when properly maintained.