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2016 KTM 125 -200 EXC XC-W Service Repair Manual
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Basic Information Identification Make: KTM Model: 125 EXC, 200 EXC, 125 XC-W, 200 XC-W Year: 2016 Codes Vin Designation: Refer to specific model year VIN decoder for precise engine/chassis identification....
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Type: Motorcycle
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Sku: 87144
Tags:
125 EXC
200 EXC
2016
KTM
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Motorcycle
Motorcycles
XC-W
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| Basic Information | |
| Identification | |
| Make: | KTM |
| Model: | 125 EXC, 200 EXC, 125 XC-W, 200 XC-W |
| Year: | 2016 |
| Codes | |
| Vin Designation: | Refer to specific model year VIN decoder for precise engine/chassis identification. |
| Introduction | |
| Market Position | |
| Segment: | Performance Off-Road/Enduro Motorcycles. |
| Target Audience: | Enthusiast riders, amateur racers, and professional mechanics seeking in-depth repair and maintenance information. |
| Competitive Analysis | |
| Alternatives: | Competes with other European manufacturers in the lightweight off-road segment, emphasizing performance and advanced engineering. |
| Key Features | |
| Brand Philosophy: | KTM is known for its 'Ready to Race' philosophy, focusing on lightweight, powerful, and technologically advanced off-road motorcycles. |
| Model Focus: | The 125/200 EXC and XC-W models are designed for agility, maneuverability, and competitive performance in enduro and cross-country riding. |
| Manual Details | |
| Coverage Areas | |
| Coverage: | All models and all repairs A-Z for the 2016 KTM 125 EXC, 200 EXC, 125 XC-W, and 200 XC-W. |
| Page Count | |
| Estimated Pages: | Approximately 400-600 pages (typical for comprehensive service manuals of this era and type). |
| Manual Type | |
| Type: | Service Repair Manual |
| Language | |
| Language: | English |
| Format | |
| Format: | PDF Download |
| Manual Coverage | |
| Systems Covered | |
| Engine Mechanical: | Complete engine disassembly, inspection, repair, and reassembly for 125cc and 200cc engines. Includes cylinder, piston, crankshaft, connecting rod, valve train (camshafts, valves, springs, retainers), timing, lubrication system, cooling system (radiator, coolant, water pump). |
| Fuel System: | Fuel injection system (throttle body, injectors, fuel pump, pressure regulator), fuel tank, fuel lines, fuel filter, carburetor specifications (if applicable to specific sub-models, though 2016 typically FI). |
| Ignition System: | Ignition coil, spark plug, CDI unit, stator, wiring diagrams for ignition system, timing procedures. |
| Transmission: | Gearbox inspection, maintenance, and repair. Clutch operation, assembly, and adjustment. Gear shifting mechanism, lubrication requirements. |
| Chassis Frame: | Frame inspection, repair considerations, subframe mounting, steering head bearing maintenance and replacement. |
| Suspension: | Front fork (WP Suspension components) disassembly, servicing, oil levels, valving specifications, seals, and bushings. Rear shock absorber servicing, damping adjustments, spring preload, seal replacement. |
| Brakes: | Hydraulic brake system for front and rear. Brake caliper disassembly and service, brake pads, brake discs, master cylinders, brake fluid specifications, bleeding procedures, hose inspection. |
| Electrical System: | Complete wiring diagrams, component identification (ECU, sensors, lighting, battery, starter motor, charging system), troubleshooting electrical faults, fuse specifications, battery maintenance. |
| Cooling System: | Radiator inspection and repair, coolant types and capacities, water pump servicing, thermostat operation, fan operation (if equipped). |
| Bodywork Trim: | Fairing removal and installation, seat, fuel tank removal, fenders, graphics, general trim components. |
| Procedures Included | |
| Scheduled Maintenance: | Detailed maintenance schedules for routine servicing, including oil changes, filter replacements, chain adjustment, brake inspections, and valve clearance checks. |
| Engine Overhaul: | Step-by-step instructions for complete engine teardown, inspection of critical wear components (pistons, rings, cylinder bore, bearings), and reassembly with torque specifications. |
| Suspension Rebuild: | Comprehensive guides for servicing and rebuilding both front and rear suspension units, including seal and bushing replacement, oil viscosity and volume, and shim stack configurations. |
| Brake Bleeding: | Correct procedures for bleeding the hydraulic brake system to ensure optimal performance and safety. |
| Electrical Troubleshooting: | Diagnostic procedures for identifying and rectifying electrical system faults using wiring diagrams and specified test procedures. |
| Clutch Adjustment: | Specific instructions for adjusting the clutch lever free play and ensuring proper clutch engagement and disengagement. |
| Wheel Bearing Service: | Guidance on inspecting, repacking, or replacing wheel bearings for both front and rear wheels. |
| Tire Mounting: | Information on proper tire mounting and balancing procedures, including bead seating and pressures. |
| Technical Depth | |
| Depth: | Comprehensive and specific, covering everything from basic fluid changes and adjustments to complete engine and gearbox rebuilds, suspension overhauls, and detailed electrical diagnostics. |
| Accuracy: | Designed for technicians, providing exact specifications, tolerances, and procedures, not generic advice. |
| Diagnostic Focus: | Includes sections on common faults and troubleshooting guides to help diagnose and repair issues efficiently. |
| Manual Specifications | |
| File Format | |
| File Type: | |
| Searchable: | Typically, PDF manuals are text-searchable, allowing users to quickly find specific topics or components. |
| Print Quality | |
| Image Resolution: | High-resolution images, diagrams, and schematics for clear viewing and accurate component identification. |
| Binding Type | |
| Binding: | N/A (Digital PDF format) |
| Paper Type | |
| Paper Type: | N/A (Digital PDF format) |
| Engine Specifications | |
| Primary Engine | |
| Type: | Single-cylinder, 4-stroke, liquid-cooled (for 200cc), potentially 2-stroke (for 125cc, though 2016 EXC is typically 4-stroke. Clarify if 2-stroke variant is covered). |
| Displacement: | Approximately 125cc and 200cc variants. |
| Bore X Stroke: | Specific to each 125 and 200cc variant; manual will contain exact dimensions. |
| Performance | |
| Horsepower: | Detailed horsepower figures for each model variant will be in the manual, typically in the 15-30 HP range depending on displacement and tuning. |
| Torque: | Detailed torque figures for each model variant will be in the manual. |
| Fuel System | |
| Injection Type: | Electronic Fuel Injection (EFI) with Keihin throttle body typically. |
| Fuel Type: | Unleaded gasoline, octane rating as specified by KTM. |
| Lubrication | |
| Oil Type: | High-quality synthetic motorcycle engine oil meeting API SG, JASO MA/MA2 standards. Manual will specify viscosity (e.g., 10W/50) and capacity. |
| Transmission | |
| Standard | |
| Type: | 6-speed constant mesh gearbox. |
| Optional | |
| Options: | N/A (Typically single transmission configuration for these models). |
| Features | |
| Clutch Type: | Hydraulic, multi-disc wet clutch. |
| Gear Ratios: | Specific gear ratios for each of the 6 gears will be detailed in the manual. |
| Final Drive: | Chain drive. Manual will specify chain type, pitch, and adjustment procedure, as well as sprocket ratios. |
| Dimensions | |
| Exterior | |
| Wheelbase: | Approximately 1470 - 1480 mm (Varies slightly between 125/200 and EXC/XC-W). |
| Seat Height: | Approximately 950 - 960 mm (unladen). |
| Weights | |
| Dry Weight: | Approximately 95 - 100 kg (Varies between 125/200 and EXC/XC-W). |
| Fuel Capacity: | Approximately 7-9 Liters (depending on specific model). |
| Safety Features | |
| Ratings | |
| Safety Certifications: | Designed for off-road use, not typically subject to road-legal safety ratings like cars. Compliance with relevant off-road racing standards. |
| Active Features | |
| Braking System: | High-performance hydraulic disc brakes (front and rear) with quality calipers and rotors. Manual details maintenance for optimal performance. |
| Passive Features | |
| Frame Construction: | Chromium-Molybdenum steel trellis frame for rigidity and impact resistance. |
| Ergonomics: | Designed for rider control and maneuverability in challenging off-road conditions. |
| Technology Features | |
| Infotainment | |
| Infotainment System: | N/A - These are performance off-road motorcycles with minimal electronics focused on engine management and rider control, not infotainment. |
| Driver Assistance | |
| Rider Aids: | May include basic handlebar-mounted controls for ignition/fuel mapping modes on some advanced versions, but no electronic rider aids like ABS or traction control typically found on street bikes. |
| Connectivity | |
| Connectivity Features: | N/A |
| Diagnostics | |
| Diagnostic Port: | Likely equipped with a diagnostic connector for use with KTM-specific diagnostic tools (e.g., diagnostic plug for reading error codes and live data). Manual will cover its use. |
| Maintenance | |
| Service Intervals | |
| Oil Change Interval: | Typically every 10-15 hours of riding or annually. Manual will specify exact interval based on usage. |
| Air Filter Cleaning: | Frequent cleaning recommended, especially in dusty conditions. Manual will detail procedure and frequency. |
| Valve Clearance Check: | Typically every 50-100 hours of riding. Manual provides specific checks and adjustment procedures. |
| Chain Maintenance: | Regular cleaning, lubrication, and tension adjustment. Manual details acceptable slack and adjustment method. |
| Fluid Specifications | |
| Coolant Type: | Ethylene glycol-based antifreeze/coolant, typically a 50/50 mix with distilled water. Manual specifies exact type and capacity. |
| Brake Fluid Type: | DOT 4 hydraulic brake fluid. |
| Fork Oil Type: | Specific WP suspension oil (e.g., WP Suspension Fluid 5W or equivalent). Manual specifies viscosity and volume per leg. |
| Known Issues | |
| Common Wear Items: | Piston rings, valve stem seals, fork seals, chain and sprockets, wheel bearings, brake pads are common wear items requiring regular inspection and replacement. |
| Service Tips: | Proper cleaning and maintenance are critical for longevity. Adherence to specified torque values and fluid levels is paramount. |
| Vehicle History | |
| Brand Heritage | |
| Heritage: | KTM has a long and successful history in off-road motorcycle racing, particularly in enduro and motocross, dating back to the 1950s. |
| Model Evolution | |
| Exc Series: | The EXC series has been a staple in KTM's lineup, evolving with fuel injection, advanced suspension (WP), and lighter chassis designs over the years. |
| Production | |
| Manufacturing Location: | Primarily manufactured in Austria by KTM Sportmotorcycle AG. |
| Awards & Recognition | |
| Recognitions | |
| Industry Acclaim: | KTM models consistently receive accolades in off-road riding publications for their performance, handling, and innovation. |
| Ratings | |
| Performance Rankings: | These models are highly regarded for their performance capabilities in their respective classes, often winning shootouts and comparisons. |
| Certifications | |
| Manufacturing Standards: | Manufactured to ISO 9001 quality management standards. |