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Introduction
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Market Position
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Vehicle Category:
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Off-road motorcycles (Enduro/Cross-Country)
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Target Audience:
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Enthusiasts, amateur racers, professional mechanics, owners seeking to perform their own maintenance and repairs.
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Competitive Analysis
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Competitive Set:
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Other 125cc and 200cc off-road motorcycles from brands like Yamaha (YZ125, WR250F), Honda (CRF250X), Husqvarna, Sherco.
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Key Features
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Performance Orientation:
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KTM is renowned for its high-performance off-road capabilities, lightweight construction, and potent engines.
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Model Variant Focus:
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The manual covers both EXC (Enduro) and XC-W (Cross-Country) variants, which share many components but may have minor differences in tuning or features for their intended disciplines.
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Manual Coverage
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Systems Covered
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Engine Service:
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Complete engine overhaul, top end, bottom end, cooling system, lubrication system, fuel injection system.
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Transmission Service:
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Gearbox disassembly, inspection, repair, clutch service, lubrication.
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Chassis Service:
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Frame inspection, suspension (forks, shock absorber), steering system, swingarm.
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Electrical System:
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Wiring diagrams, lighting, ignition system, battery, charging system, ECU, sensors.
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Braking System:
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Hydraulic brake system (front and rear calipers, master cylinders, lines), brake pad replacement, bleeding procedures.
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Fuel System:
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Fuel tank, fuel pump, fuel lines, injector servicing.
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Cooling System:
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Radiator, coolant hoses, water pump, thermostat, coolant specifications.
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Procedures Included
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Routine Maintenance:
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Oil change intervals, filter replacement, chain adjustment, spark plug inspection/replacement, air filter cleaning/replacement.
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Troubleshooting:
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Diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides.
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Component Overhaul:
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Detailed instructions for disassembling, inspecting, repairing, and reassembling all major components.
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Rebuilds:
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Complete engine and transmission rebuild procedures with torque specifications and clearances.
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Wiring Schematics:
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Comprehensive electrical system diagrams for troubleshooting and repair.
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Technical Depth
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Depth Of Coverage:
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Complete factory-level service information, including detailed disassembly, assembly, torque values, and technical notes.
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Diagnostic Capabilities:
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Advanced diagnostic information for fuel injection and ignition systems, sensor testing.
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Engine Specifications
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Primary Engine 125
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Engine Type:
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2-stroke, single-cylinder
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Displacement Cc:
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125
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Bore X Stroke Mm:
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54 x 54.5
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Carburetor:
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Keihin PWK 38 AG (likely, specific carb may vary)
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Ignition:
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Kokusan digital CDI
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Cooling System:
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Liquid-cooled
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Primary Engine 200
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Engine Type:
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2-stroke, single-cylinder
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Displacement Cc:
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200
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Bore X Stroke Mm:
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64 x 62.4
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Carburetor:
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Keihin PWK 38 AG (likely, specific carb may vary)
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Ignition:
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Kokusan digital CDI
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Cooling System:
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Liquid-cooled
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Performance
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Horsepower Approx 125:
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Approx. 35-40 HP (varies by tune and region)
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Horsepower Approx 200:
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Approx. 40-45 HP (varies by tune and region)
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Fuel System
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Fuel Type:
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Unleaded gasoline (minimum 95 octane recommended), mixed with 2-stroke oil.
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Oil Mixture Ratio:
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Typically 60:1 for modern KTM 2-strokes (verify with manual).
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Maintenance
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Service Intervals
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Engine Oil Change:
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Every 10-15 hours of riding or annually (refer to manual for precise hours/miles).
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Air Filter Cleaning:
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Every 5-10 hours of riding or as needed, depending on conditions.
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Spark Plug Inspection:
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Every 20-30 hours of riding.
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Piston Ring Replacement:
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Typically between 50-100 hours for performance-oriented 2-strokes (manual will specify).
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Fluid Specifications
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Engine Oil Type:
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High-quality 2-stroke synthetic oil, pre-mix.
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Transmission Oil Type:
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KTM recommends specific transmission oil, often Motorex Top Speed 75W or equivalent.
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Coolant Type:
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Ethylene glycol-based coolant with corrosion inhibitors (e.g., Motorex Coolant M3.0).
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Brake Fluid Type:
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DOT 4 brake fluid.
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Known Issues
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Power Valve Sticking:
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Common in 2-strokes; requires regular cleaning and lubrication as per manual instructions.
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Clutch Wear:
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Can occur with aggressive riding; the manual details inspection and replacement procedures.
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Suspension Seals:
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Fork and shock seals can leak; manual provides fork seal replacement procedures.
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