Model:
125 XC, 200 XC, 125 XC-W, 200 XC-W
Year:
1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006
Engine Variants:
125cc, 200cc (Specific engine codes not provided in product description, but generally single-cylinder, liquid-cooled, 2-stroke for this era and model designation.)
Chassis Codes:
XC and XC-W designations typically indicate off-road, cross-country competition models. Specific chassis codes (e.g., EXC variants from which these might be derived) are not detailed but would be covered within the manual.
Engine Mechanical:
Complete engine disassembly, assembly, inspection, and repair for 125cc and 200cc 2-stroke engines. Includes cylinder head, piston, connecting rod, crankshaft, seals, gaskets, lubrication system, cooling system (radiator, water pump).
Engine Tuning:
Carburetor tuning, jetting recommendations, ignition timing adjustments (where applicable), exhaust system considerations.
Fuel System:
Fuel tank, fuel lines, fuel pump (if applicable), fuel filter, carburetor service and overhaul (e.g., Mikuni VM series common on these models).
Ignition System:
CDI unit, stator, ignition coil, spark plug, wiring diagrams related to ignition.
Transmission Drivetrain:
Clutch assembly (operation, adjustment, overhaul), gearbox (gear selection, shifting mechanism, bearings, seals), final drive (chain, sprockets, adjustment).
Suspension Front:
Front fork (telescopic), oil seals, bushings, spring rates, damping adjustments, service and rebuild procedures, fork stanchion condition.
Suspension Rear:
Monoshock rear suspension, linkage system (if applicable), shock absorber service and rebuild, spring adjustment, bearing checks.
Brakes Front:
Hydraulic disc brakes, caliper overhaul, master cylinder service, brake pads, brake lines, bleeding procedures, rotor specifications.
Brakes Rear:
Hydraulic disc brakes, caliper overhaul, master cylinder service, brake pads, brake lines, bleeding procedures, rotor specifications.
Electrical System:
Wiring diagrams, battery maintenance, lighting (headlight, taillight, brake light), horn, fuses, switches, starter system (if electric start equipped).
Cooling System:
Radiator, coolant hoses, thermostat (if applicable), coolant type and capacity, bleeding procedures.
Frame Chassis:
Frame inspection, steering head bearings, swingarm pivot bearings, wheel bearings, general chassis integrity checks.
Bodywork:
Seat removal, fuel tank removal/installation, fender removal/installation, plastics, graphics.
Preventative Maintenance:
Routine checks, lubrication points, air filter cleaning/replacement, spark plug inspection, chain adjustment and lubrication.
Troubleshooting:
Diagnostic guides for common starting problems, engine performance issues, electrical faults, braking issues, suspension behavior.
Engine Rebuild:
Step-by-step instructions for complete engine teardown, cleaning, inspection of components (e.g., piston ring gap, cylinder wear), and reassembly.
Suspension Overhaul:
Detailed guidance on replacing fork seals, bushings, and rebuilding rear shock absorbers.
Brake System Maintenance:
Pad replacement, caliper servicing, master cylinder rebuild, fluid flush and bleeding.
Electrical Diagnostics:
Testing of charging system, ignition components, and lighting circuits using multimeters and diagnostic procedures outlined in the manual.
Carburetor Adjustment:
Idle speed, air-fuel mixture, jetting changes for altitude or modifications.
Torque Specifications:
Precise torque values for critical fasteners throughout the motorcycle, crucial for safe and reliable assembly.
Depth:
Comprehensive coverage suitable for DIY enthusiasts and professional mechanics. Includes detailed schematics, diagnostic flowcharts, and precise measurements for wear limits and adjustments.
Type:
Liquid-cooled, 2-stroke, single-cylinder
Bore X Stroke 125:
Approx. 54mm x 54.5mm (Varies slightly by specific model year and variant, detailed in manual)
Bore X Stroke 200:
Approx. 62.5mm x 65mm (Varies slightly by specific model year and variant, detailed in manual)
Displacement 125:
124.8 cc (Approximate, detailed in manual)
Displacement 200:
195.6 cc (Approximate, detailed in manual)
Power Delivery:
Known for strong mid-range to top-end power, typical of performance 2-stroke motocross/enduro engines.
Horsepower 125:
Estimated 30-35+ HP (Stock, varies by specific model year/tune, detailed in manual)
Horsepower 200:
Estimated 38-42+ HP (Stock, varies by specific model year/tune, detailed in manual)
Carburetor:
Typically Mikuni TM series (e.g., TM34-1) or similar, precise model specified in manual.
Fuel Type:
Unleaded gasoline with appropriate 2-stroke oil premix (specified ratio in manual).
Premix Ratio:
Typically 1:30 to 1:50, consult manual for exact specification and recommended oil type.
Oil Change 2Stroke:
Not applicable for total loss 2-stroke oil injection systems; focus on premix quality. Gearbox oil changes at regular intervals (e.g., every 10-15 hours of riding or annually).
Air Filter Cleaning:
Frequent cleaning or replacement recommended based on riding conditions (e.g., every 5-10 hours).
Spark Plug Inspection:
Regular inspection and gap adjustment/replacement (e.g., every 15-20 hours).
Piston Ring Replacement:
Recommended overhaul interval for piston and rings typically between 30-60 hours, depending on usage and maintenance. Manual will specify.
Gearbox Oil Type:
API GL-4 or GL-5 SAE 80W/90 transmission oil (Specific KTM-recommended oil or equivalent detailed in manual).
Coolant Type:
Ethylene glycol-based coolant with corrosion inhibitors (Specific mix ratio and type in manual).
Brake Fluid Type:
DOT 4 hydraulic brake fluid (Specific DOT rating in manual).
Clutch Wear:
Clutch plates can wear over time, especially with aggressive riding. Manual covers inspection and replacement.
Power Valve Maintenance:
The 2-stroke power valve mechanism requires regular cleaning and inspection to ensure proper operation and prevent seizing. Manual details this critical maintenance.
Suspension Seals:
Fork seals and rear shock seals are prone to wear and leaks in off-road environments. Manual provides replacement procedures.
