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

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Taper: Motorcycle

Distributeur:

UGS: 60233

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

Variantes de produits

Description

This manual covers the 125 EGS, 200 EGS, EXC, and SIX DAYS models manufactured between 1999 and 2006. These performance-oriented off-road motorcycles embody a "Ready to Race" philosophy, characterized by lightweight construction, potent two-stroke engines, and advanced suspension systems designed for competitive enduro and trail riding. Known for their robust build quality and exceptional handling, these models are engineered to deliver superior performance in demanding off-road conditions, making them a popular choice among enthusiasts and competitors alike. This comprehensive workshop service manual provides detailed procedures for maintenance, troubleshooting, and repair. It covers all essential systems, including engine disassembly and assembly, drivetrain components, chassis systems, and electrical systems, complete with wiring diagrams. Owners, mechanics, and technicians will find step-by-step instructions for routine maintenance tasks, diagnostics, component overhauls, and the identification of special tools required for optimal service. The manual is designed to ensure these high-performance motorcycles remain in peak operating condition.

🏷️ Basic Information

Identification

Make:

Model:

125 EGS, 200 EGS, EXC, SIX DAYS

Codes

Product Identifier:

KTM125200EGS_EXC_SIXDAYS_1999-2006_Repair_Service_Manual_PDF

👋 Introduction

Market Position

Segment:

Performance Off-Road Motorcycles (Enduro / Motocross variants)

Target Audience:

Enthusiast owners, amateur racers, mechanics, and service technicians working on KTM 125/200 EGS, EXC, and SIX DAYS models.

Competitive Analysis

Competitors:

Honda CR series, Yamaha YZ series, Suzuki RM series, Kawasaki KX series, Husqvarna models.

Key Features

Vehicle Philosophy:

KTM's 'Ready to Race' philosophy, focusing on lightweight construction, powerful engines, and advanced suspension for competitive off-road performance.

Manual Value Proposition:

Provides comprehensive, detailed, and accurate repair and maintenance procedures essential for keeping these high-performance off-road machines in optimal condition.

📋 Manual Details

Coverage Areas

Covered Years:

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

Covered Models:

125 EGS, 200 EGS, EXC (all variants), SIX DAYS (all variants)

Page Count

Estimated Page Count:

High (typical for comprehensive workshop manuals, often 300-600+ pages)

Manual Type

Manual Type:

Workshop Service Manual / Repair Manual

Language

Language:

English (standard for most KTM manuals)

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Systems:

Engine disassembly, assembly, tuning, troubleshooting, lubrication, cooling, fuel delivery (carburetor), exhaust, ignition system, starting system, engine management (if applicable to specific models/years).

Drivetrain Systems:

Transmission disassembly, assembly, maintenance, troubleshooting, clutch operation, final drive (chain/sprockets).

Chassis Systems:

Frame inspection and repair, suspension (forks, rear shock), steering system, wheel and tire servicing, brake system (hydraulic front and rear), electrical system (wiring diagrams, component testing, lighting, charging).

Bodywork And Ergonomics:

Fairing removal and installation, seat, fuel tank, fenders, handlebars, levers, controls.

Procedures Included

Maintenance Procedures:

Scheduled maintenance, oil changes, filter replacements (air, oil, fuel), chain adjustment, brake fluid flush, spark plug replacement, valve clearance checks/adjustment, coolant checks/replacement.

Troubleshooting Procedures:

Diagnostic flowcharts, common problem identification and solutions, electrical system diagnostics, engine performance issues, starting problems.

Repair Procedures:

Step-by-step instructions for component removal, overhaul, and installation of engine, transmission, suspension, brakes, electrical components, and body parts.

Special Tools And Techniques:

Identification of specific KTM special tools required for certain procedures, torque specifications, assembly sequences, and critical adjustments.

Technical Depth

Diagnostic Capabilities:

Advanced diagnostics including electrical component testing, ignition system analysis, and fuel system troubleshooting.

Rebuild Information:

Detailed procedures for complete engine and transmission rebuilds, including piston, ring, cylinder, crankshaft, and gearbox component overhauls.

Electrical Schematics:

Comprehensive wiring diagrams for all electrical systems, including lighting, ignition, charging, and instrumentation.

📊 Manual Specifications

File Format

File Type:

Searchability:

Likely text-searchable PDF (if professionally scanned/digitized)

Print Quality

Print Quality:

High (suitable for printing, with clear diagrams and text)

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

2-Stroke Single Cylinder

Bore X Stroke 125:

54 mm x 54.5 mm (typical for 125 EXC models of this era)

Bore X Stroke 200:

64 mm x 62.4 mm (typical for 200 EXC models of this era)

Displacement 125:

124.8 cc

Displacement 200:

199.6 cc

Cooling System:

Liquid-cooled

Ignition System:

Digital CDI (Capacitor Discharge Ignition)

Performance

Horsepower 125:

Approx. 30-35 HP (depending on specific model/tuning)

Horsepower 200:

Approx. 38-42 HP (depending on specific model/tuning)

Fuel System

Fuel Delivery:

Carburetor (e.g., Keihin PWK or similar)

Carburetor Size 125:

36 mm (typical)

Carburetor Size 200:

38 mm (typical)

Fuel Type:

Unleaded Gasoline (RON 95 or higher recommended, specific octane rating in manual)

Premix Ratio:

Typically 1:40 or 1:50 (synthetic 2-stroke oil) - refer to manual for exact specification

🔧 Transmission

Standard

Transmission Type:

6-Speed Manual

Features

Clutch Type:

Hydraulically operated, multi-plate wet clutch

Final Drive:

Chain Drive

Fluid Specifications

Transmission Oil Type:

Specific motorcycle transmission oil or SAE 10W/15W gear oil (refer to manual for exact specification and API rating)

Transmission Oil Capacity:

Approx. 0.6 - 0.8 Liters (refer to manual for exact capacity)

📐 Dimensions

Exterior

Frame Type:

Chromium-molybdenum steel trellis frame

Weights

Dry Weight 125:

Approx. 90-95 kg

Dry Weight 200:

Approx. 95-100 kg

🛡️ Safety Features

Ratings

Safety Standards:

Designed to meet off-road competition and general safety standards of the era.

Active Features

Braking System:

Hydraulic disc brakes, front and rear. Often Brembo calipers.

Suspension Design:

Upside-down telescopic front forks (e.g., WP), Monoshock rear suspension with PDS (Power শোষণ System) or similar linkage.

Passive Features

Frame Construction:

High-strength steel trellis provides rigidity and impact resistance.

💡 Technology Features

Infotainment

Instrumentation:

Digital tachometer, speedometer, odometer, trip meter, and basic indicator lights.

Driver Assistance

Electronic Aids:

Generally minimal electronic aids on these models, focusing on mechanical performance and rider control.

Connectivity

Diagnostic Ports:

May have basic diagnostic connectors for troubleshooting specific electrical components, but not OBD-II like cars.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 15-20 operating hours or annually (for transmission oil). Engine oil (premix) is constantly replenished.

Air Filter Cleaning:

Every 5-10 operating hours or as needed based on conditions.

Spark Plug Replacement:

Every 20-30 operating hours (refer to manual for specific plug type and gap)

Chain And Sprockets:

Inspect for wear and adjust tension regularly (every few rides). Replacement depends on usage and maintenance.

Fluid Specifications

Coolant Type:

Ethylene glycol-based coolant with corrosion inhibitors (e.g., Motorex M3.0 or equivalent). Refer to manual for specific type and mixture ratio.

Brake Fluid Type:

DOT 4 hydraulic brake fluid

Known Issues

Carburetor Tuning:

Sensitivity to jetting changes based on altitude and temperature; requires proper tuning for optimal performance.

Clutch Wear:

Clutch plates can wear with aggressive riding; regular inspection and adjustment are necessary.

Suspension Maintenance:

Regular fork seal inspections and rear shock servicing are critical for maintaining optimal handling.

Power Valve Cleaning:

The exhaust power valve mechanism requires periodic cleaning to prevent sticking and maintain performance.

📚 Vehicle History

Brand Heritage

Ktm Motorsport Focus:

KTM has a long and successful history in off-road motorsports, including motocross, enduro, and rally racing, which heavily influences their production models.

Model Evolution

Exc Lineage:

The EXC line represents KTM's enduro-focused off-road motorcycles, known for their versatility in various terrain types. The 125/200 variants offer accessible performance within this range.

Six Days Variants:

The 'Six Days' designation refers to special edition models commemorating the International Six Days Enduro (ISDE), often featuring enhanced components and special graphics.

Production

Manufacturing Location:

Primarily Austria (Mattighofen, Austria)

🏆 Awards & Recognition

Recognitions

Offroad Capability:

KTM EXC models are consistently praised in off-road publications for their performance, handling, and competitive edge in enduro and trail riding.

Ratings

Build Quality:

Generally regarded for robust build quality and durable components suitable for demanding off-road use.