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

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Type: Motorcycle

Vendor:

Sku: 58123

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

Product variants

Description

This manual covers 125, 144, 150, and 200 models produced between 1999 and 2010. These Austrian-engineered machines are recognized for their performance-oriented design, often derived from competitive off-road platforms. Featuring potent two-stroke, liquid-cooled single-cylinder engines and robust chassis components, these motorcycles offer an engaging riding experience. Common engine variants include those utilizing Mikuni or Keihin carburetors, and they are equipped with 6-speed constant mesh transmissions and wet multi-plate clutches. Known for their agility and power, models from this period are celebrated in their respective classes for their competitive edge. This comprehensive service repair workshop manual provides detailed guidance for owners, independent repair shops, and technicians. It covers a wide array of systems, including engine overhaul, transmission repair, drivetrain maintenance, fuel and electrical systems, suspension, brakes, and steering. The manual offers step-by-step instructions for routine maintenance, component rebuilds, and troubleshooting common issues, alongside essential specifications and wiring diagrams. Its vehicle-specific content ensures accuracy, empowering users to maintain and repair their motorcycles effectively, thus facilitating significant cost savings on service and repairs.

🏷️ Basic Information

Identification

Make:

Model:

125, 144, 150, 200

Production Years:

1999-2010

Codes

Engine Codes:

Varies by specific model (e.g., LC2, SX, EXC variants)

👋 Introduction

Market Position

Target Audience:

KTM owners, independent repair shops, and technicians seeking detailed repair and maintenance information.

Competitive Analysis

Value Proposition:

Provides dealership-level repair information, enabling significant cost savings on maintenance and repairs.

Key Features

Content Style:

Step-by-step instructions, diagrams, illustrations, wiring schematics, specifications.

Accuracy:

Vehicle-specific, not generic, ensuring accurate repair procedures.

📋 Manual Details

Coverage Areas

Covered Models:

KTM 125, 144, 150, 200

Covered Years:

1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010

Page Count

Estimated Page Count:

Varies significantly based on specific model year and engine size, but comprehensive manuals typically exceed 400 pages.

Manual Type

Type:

Service Repair Workshop Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Complete overhaul, top-end and bottom-end rebuilds, carburetor tuning, ignition system, cooling system.

Transmission:

Gearbox inspection, repair, clutch service, shift mechanism.

Drive Train:

Drive chain maintenance, sprocket inspection and replacement, rear hub and wheel assembly.

Fuel System:

Fuel tank, fuel lines, carburetor (Mikuni, Keihin models common), fuel pump (if applicable).

Electrical System:

Wiring diagrams, lighting system, ignition coil, stator, CDI unit, battery maintenance, starter system (if electric start equipped).

Suspension:

Front fork service (WP Suspension common), rear shock absorber service and adjustments, linkage maintenance.

Brakes:

Hydraulic brake system service (front and rear calipers, master cylinders), brake fluid replacement, pad inspection and replacement, rotor inspection.

Steering System:

Steering head bearing inspection and adjustment, handlebar and control assembly.

Bodywork:

Fairing removal and installation, seat, fenders, plastics.

Intake Exhaust:

Airbox, air filter, exhaust pipe, silencer.

Procedures Included

Routine Maintenance:

Oil changes, air filter cleaning/replacement, chain lubrication and adjustment, spark plug checks, coolant checks.

Troubleshooting:

Diagnostic procedures for common starting issues, engine performance problems, electrical faults.

Repair Procedures:

Step-by-step instructions for component disassembly, cleaning, inspection, and reassembly.

Component Rebuilds:

Engine top-end (piston, rings, cylinder, head), gearbox rebuilds, carburetor overhauls.

Wiring Diagrams:

Detailed electrical schematics for all systems.

Specifications Data:

Torque values, clearances, fluid capacities, performance data.

Technical Depth

Depth:

Comprehensive, from basic maintenance to full engine and chassis rebuilds, suitable for professional mechanics and experienced DIYers.

📊 Manual Specifications

File Format

Format:

Print Quality

Printability:

High quality, printable pages

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper Type:

N/A (Digital PDF)

Compatibility

Operating Systems:

Windows and Mac compatible

Requirements

Software Requirements:

Adobe PDF Reader

⚙️ Engine Specifications

Primary Engine

Engine Type:

2-stroke, liquid-cooled single-cylinder

Performance

125 Approx Hp:

~35-40 HP (varies by year and specific model variant)

150 Approx Hp:

~40-45 HP (varies by year and specific model variant)

200 Approx Hp:

~45-50 HP (varies by year and specific model variant)

Fuel System

Carburetor Models:

Mikuni VM series, Keihin PWK series common depending on year and model.

Fuel Type:

Unleaded gasoline with 2-stroke oil mixture (premix or oil injection systems vary).

🔧 Transmission

Standard

Gearbox Type:

6-speed constant mesh

Features

Clutch Type:

Wet multi-plate clutch

📐 Dimensions

Weights

Dry Weight Approx:

85-105 kg (highly dependent on specific model and year)

Wet Weight Approx:

95-115 kg (highly dependent on specific model and year)

🛡️ Safety Features

Active Features

Braking System:

Hydraulic disc brakes front and rear (Brembo calipers common on many models).

💡 Technology Features

Infotainment

Features:

Basic instrumentation (speedometer, tachometer, odometer, engine hour meter) common for this era and segment.

Driver Assistance

Features:

N/A (Focus on rider input and mechanical feedback)

🔧 Maintenance

Service Intervals

Oil Change Interval:

Refer to manual for specific recommendations based on usage (e.g., every 10-20 hours of off-road riding, or as per kilometers for street use).

Top End Rebuild Interval:

Highly variable based on riding style and maintenance. Typically 50-150 hours for performance engines.

Fluid Specifications

Engine Oil Type:

2-stroke specific engine oil, pre-mix ratio specified in manual (e.g., 1:40, 1:50) or specific oil for oil injection systems.

Coolant Type:

Ethylene glycol based coolant, typically a 50/50 mix with distilled water.

Brake Fluid Type:

DOT 4

Known Issues

Common Wear Items:

Piston rings, clutch plates, spark plugs, wheel bearings, steering head bearings, chain and sprockets.

Carburetor Tuning Sensitivity:

Susceptible to changes in altitude and temperature, requiring proper jetting and adjustment.

📚 Vehicle History

Brand Heritage

Manufacturer Origin:

Austria

Model Evolution

Development Focus:

Performance-oriented off-road and motocross-derived platforms adapted for street legality (where applicable).

🏆 Awards & Recognition

Recognitions

Performance Reputation:

KTM models from this era are renowned for their competitive performance in their respective classes (e.g., motocross, enduro).