Market Segment:
Off-road motorcycles, specifically Enduro (EXC) and Cross-Country (XC-W) segments. Targeted at competitive riders and serious enthusiasts.
Competitors:
Primarily competes with similar displacement models from brands like Yamaha (YZ/WR series), Honda (CRF series), Kawasaki (KX/KLX series), and Husqvarna.
Model Philosophy:
KTM's 'Ready to Race' philosophy emphasizes performance, lightweight design, and premium components.
Manual Target Audience:
Professional motorcycle technicians and experienced DIY mechanics seeking in-depth service information.
Coverage Scope:
Comprehensive service, repair, maintenance, and diagnostics for 2016 KTM 125 EXC, 200 EXC, 125 XC-W, and 200 XC-W models.
Manual Type:
Service and Repair Manual
Engine:
Complete engine teardown, assembly, timing, lubrication, cooling, and fuel systems.
Transmission:
Gearbox, clutch operation, lubrication, and related components.
Chassis And Suspension:
Frame, swingarm, front fork (WP Suspension), rear shock absorber (WP Suspension), bearings, and related components.
Brakes:
Hydraulic brake systems (front and rear), caliper service, master cylinder, brake fluid specifications, and bleeding procedures.
Electrical System:
Wiring diagrams, ignition system, lighting, starting system, charging system, sensors, ECU diagnostics, and troubleshooting.
Fuel System:
Carburetor (Keihin for 125/200 EXC/XC-W variants) or Fuel Injection (depending on specific sub-model variant within the year, though often carbureted for these models), fuel pump, fuel lines.
Exhaust System:
Exhaust pipe, silencer, and related fittings.
Bodywork And Ergonomics:
Seat, fuel tank, fenders, plastics, handlebars, levers, and rider controls.
Scheduled Maintenance:
Oil changes, filter replacement, chain adjustment, spark plug replacement, air filter cleaning/replacement, valve clearance checks.
Troubleshooting:
Diagnostic charts and symptom-based troubleshooting for common mechanical and electrical issues.
Disassembly And Assembly:
Step-by-step instructions for component removal and installation, including major assemblies.
Component Rebuilding:
Detailed instructions for rebuilding engine components, suspension units, and brake systems.
Torque Specifications:
Precise torque values for critical fasteners throughout the motorcycle.
Technical Depth:
Advanced diagnostics, complete engine rebuilds, suspension tuning, and electrical system troubleshooting.
Engine Type 125:
Liquid-cooled, 2-stroke, single-cylinder (KTM 125 EXC/XC-W)
Engine Type 200:
Liquid-cooled, 2-stroke, single-cylinder (KTM 200 EXC/XC-W)
Bore Stroke 125:
Typically around 54 mm x 54.5 mm (specifics vary slightly by exact model variant within the year)
Bore Stroke 200:
Typically around 64 mm x 62.6 mm (specifics vary slightly by exact model variant within the year)
Horsepower 125:
Approx. 35-40 HP (variant dependent, subject to national regulations)
Horsepower 200:
Approx. 40-45 HP (variant dependent, subject to national regulations)
Torque:
Specific torque figures will be detailed in the manual, generally higher for the 200cc.
Carburetor Type:
Keihin PWK 36 (common for these displacements and year, check manual for exact spec)
Fuel Type:
Unleaded gasoline, typically 95 RON or higher recommended.
Premix Ratio:
Refer to manual for specific oil-to-fuel ratio for pre-mix if applicable (modern KTMs often have separate oil injection or are purely premix)
Engine Oil Type:
High-quality 2-stroke engine oil, specific grades (e.g., JASO FD, ISO-L-EGD) to be confirmed in manual.
Transmission Oil Type:
Specific motorcycle transmission oil (e.g., SAE 10W/50, API GL-4) as per manual recommendations.
Wheelbase:
Approximately 1480 mm +/- 10 mm (specific to model variant)
Seat Height:
Approximately 960 mm (specific to model variant)
Dry Weight 125:
Approx. 96 kg (specific to model variant)
Dry Weight 200:
Approx. 99 kg (specific to model variant)
Fuel Tank Capacity:
Approximately 7.0 liters (specific to model variant)
Safety Ratings:
N/A for off-road motorcycles in the same vein as cars. Focus is on rider control and mechanical integrity.
Brakes:
High-performance hydraulic disc brakes front and rear (Brembo components are standard on KTM).
Suspension:
Advanced WP Suspension components (USD front forks, monoshock rear) for optimal handling and control.
Frame Construction:
Chromoly steel central double-cradle frame for strength and rigidity.
Oil Change Interval:
Refer to manual for specific mileage or hours; typically every 10-15 engine hours or 1000-1500 km for transmission/clutch oil.
Air Filter Cleaning:
Frequent checks and cleaning recommended, especially in dusty conditions, as per manual.
Spark Plug Replacement:
Refer to manual for recommended replacement intervals.
Chain Adjustment Lubrication:
Regular checks and adjustment/lubrication are critical for longevity.
Coolant Type:
Ethylene glycol-based coolant, typically 50% mixture with distilled water. Specific type detailed in manual.
Brake Fluid Type:
DOT 4 hydraulic brake fluid.
Common Wear Items:
Clutch plates, piston rings, chain and sprockets, wheel bearings, fork seals are common wear items in aggressive off-road use.
Carburetor Tuning:
Carburetor jetting may require adjustment based on altitude, temperature, and modifications, a common topic in service manuals.
Brand Origin:
KTM is an Austrian manufacturer renowned for its off-road racing pedigree.
Exc Lineage:
The EXC (Enduro Cross) line represents KTM's commitment to producing highly competitive off-road machines for competition and recreational riding.
Xc-W Lineage:
The XC-W (Cross-Country) models are typically optimized for off-road competition, often with slightly different suspension settings or componentry compared to EXC models.
Manufacturing Location:
Primarily Austria (Mattighofen) and potentially other global facilities depending on model year and specific assembly.
Brand Reputation:
KTM consistently receives accolades in off-road racing disciplines, which reflects the capability and design of their production models.
Magazine Reviews:
Contemporary reviews from motorcycle publications of the era would likely praise their performance, handling, and robust build for their intended purpose.
Certification Standards:
Manufactured to meet relevant national and international motorcycle safety and emissions standards for their category.
