Model:
125 SX, 200 SX, 125 EXC, 200 EXC
Vehicle Platform Code:
Not specified in product information, but typically derived from VIN structure
Engine Codes:
Not specified in product information, but KTM typically uses internal engine designations
Motorcycle Segment:
Off-road competition motorcycles (Motocross and Enduro).
Target Audience:
Enthusiast owners, independent repair shops, and professional technicians working on 1999 KTM 125/200 SX/EXC models.
Competitors 1999:
Yamaha YZ125, Honda CR125R, Suzuki RM125, Kawasaki KX125 (Motocross); Yamaha WR250 (Enduro segment often competed with larger engines, but 125/200s occupied a niche).
Manual Advantage:
Provides dealership-level technical information, ensuring accuracy and completeness for all repair and maintenance tasks.
Model Significance:
The 125/200 SX/EXC models were crucial for KTM's growth in the smaller displacement off-road market, known for their performance and agility.
Primary Coverage:
Complete service and repair for 1999 KTM 125 SX, 200 SX, 125 EXC, and 200 EXC models.
Secondary Coverage:
Includes maintenance, troubleshooting, diagnostics, and specific repair procedures.
Page Count:
Not specified in product information, but typical comprehensive service manuals are 300-600 pages.
Manual Type:
Service Repair Manual
Language:
English (presumed, standard for downloadable service manuals)
Engine:
Complete engine overhaul, internal components (pistons, rings, valves, crankshaft, bearings), cylinder head, cooling system (if applicable to these models), lubrication system.
Transmission:
Gearbox overhaul, clutch assembly, shifting mechanisms, lubrication, troubleshooting of transmission issues.
Chassis:
Frame inspection and repair, suspension (forks, shock absorber), steering system, wheel bearings, swingarm, linkage systems.
Electrical System:
Ignition system, lighting, wiring diagrams, battery, charging system, troubleshooting of electrical faults.
Fuel System:
Carburetor overhaul and adjustment (specific to Keihin or similar), fuel tank, fuel lines, fuel petcock.
Braking System:
Front and rear brake systems (hydraulic), caliper overhaul, brake fluid replacement, disc inspection, lever and pedal adjustments.
Cooling System:
Radiator, coolant hoses, thermostat (if equipped), coolant fluid specifications and replacement.
Exhaust System:
Exhaust pipe and silencer inspection, mounting, and replacement.
Maintenance:
Routine checks, oil changes, filter replacements, chain adjustment, spark plug service, valve clearance checks (if applicable).
Troubleshooting:
Systematic diagnostic procedures for common and uncommon issues, fault finding guides.
Repair:
Step-by-step instructions for component removal, disassembly, repair, reassembly, and installation.
Overhaul:
Complete engine, transmission, and suspension component overhaul procedures.
Adjustments:
Carburetor synchronization and adjustment, clutch lever free play, brake lever free play, chain slack, suspension sag.
Depth:
Comprehensive, covering all aspects from basic maintenance to complete engine and chassis rebuilds. Specifically stated as not generic, but exact for the models.
Diagnostic Capability:
Advanced diagnostics for electrical and mechanical systems, with troubleshooting trees.
Rebuild Procedures:
Detailed step-by-step instructions for engine and gearbox rebuilding, including torque specifications and clearances.
Engine Type:
2-stroke, single-cylinder, liquid-cooled
Displacement 125:
Approximately 125cc (exact figure varies slightly by source, often 124.8 cc)
Displacement 200:
Approximately 200cc (exact figure varies slightly by source, often 193 cc)
Bore Stroke 125:
e.g., 54 mm x 54.5 mm (typical for this era, exact manual will confirm)
Bore Stroke 200:
e.g., 62.5 mm x 65 mm (typical for this era, exact manual will confirm)
Compression Ratio:
Not specified in product information, but typically around 8.5:1 to 9.5:1 for these models. Manual will provide precise figures.
Horsepower 125:
Around 30-35 HP (at crankshaft, estimated). Manual will provide exact figures.
Horsepower 200:
Around 35-40 HP (at crankshaft, estimated). Manual will provide exact figures.
Torque:
Not specified in product information. Manual will provide figures.
Carburetor Type:
Keihin PWK (typically 35mm or 38mm, specific sizes for 125/200 models will be in manual).
Fuel Type:
Unleaded gasoline (91 octane or higher recommended).
Fuel Mixture:
2-stroke oil premix. Manual will specify the recommended oil and mixing ratio (e.g., 50:1 or 40:1).
Engine Oil Type:
2-stroke engine oil (for premix). Manual will specify KTM-approved oils and specifications.
Transmission Oil Type:
Manual will specify SAE 10W/40 or similar transmission oil, likely with JASO MA rating.
Wheelbase:
Not specified in product information. Manual will provide exact dimensions.
Seat Height:
Not specified in product information. Manual will provide exact dimensions.
Dry Weight 125:
Approximately 93-95 kg (205-209 lbs) for SX models, slightly more for EXC. Manual will confirm.
Dry Weight 200:
Approximately 95-98 kg (209-216 lbs) for SX models, slightly more for EXC. Manual will confirm.
Fuel Tank Capacity:
Typically 7.5-9.5 liters (2.0-2.5 US gallons) for SX and EXC models. Manual will specify exact capacity.
Safety Certifications:
N/A (Competition motorcycles are not typically subject to automotive safety certification standards like crash tests).
Braking System Type:
Hydraulic disc brakes front and rear. Specific brake caliper and disc sizes will be in the manual.
Suspension Features:
Adjustable front forks (e.g., WP USD) and rear monoshock suspension, allowing for tuning of ride height and damping characteristics.
Frame Construction:
Chromoly steel perimeter frame, known for strength and rigidity.
Tire Sizes:
Standard off-road sizes, e.g., 80/100-21 front, 100/90-19 or 110/90-19 rear. Manual will confirm specific fitments.
Infotainment System:
N/A (Basic off-road motorcycles of this era do not feature infotainment systems).
Driver Assistance Features:
N/A (No electronic driver assistance systems like ABS or traction control).
Connectivity Features:
N/A (No digital connectivity features).
Lighting System:
Basic headlight and taillight (on EXC models, potentially optional or absent on SX). Manual will detail electrical system components.
Oil Change Interval:
Manual will specify interval for transmission oil changes, typically every 15-20 hours of operation or annually. Engine oil is part of the 2-stroke mix.
Air Filter Cleaning:
Frequent cleaning/replacement recommended, especially in dusty conditions. Interval specified in manual.
Spark Plug Replacement:
Interval specified in manual, typically based on hours or mileage.
Piston Ring Replacement:
KTM's 2-stroke engines often require piston and ring inspection/replacement based on engine hours or performance degradation. Manual will provide guidance.
Transmission Oil Spec:
Manual will specify the exact API service classification and viscosity grade (e.g., API GL-4, SAE 10W/40).
Brake Fluid Spec:
DOT 4 brake fluid is standard for most hydraulic systems of this era. Manual will confirm.
Coolant Spec:
Manual will specify type of coolant (e.g., ethylene glycol based) and recommended mixture ratio with distilled water.
Common Wear Items:
Clutch plates, piston rings, wheel bearings, swingarm bushings, fork seals, and chain/sprockets are common wear items on performance off-road bikes.
Engine Specific Concerns:
Proper pre-mix ratio and quality 2-stroke oil are critical. Overheating due to coolant issues or lean jetting can cause piston seizure. The manual will detail how to prevent and diagnose these.
Carburetor Tuning:
Carburation can be sensitive to altitude and temperature. The manual will provide jetting charts and adjustment procedures.
Ktm Off Road Legacy:
KTM has a long and successful history in off-road racing, particularly in motocross and enduro, dating back to the 1960s. This manual supports that heritage.
Sx Vs Exc Difference:
SX (Motocross) models are typically tuned for closed-course racing with specific suspension and gearing. EXC (Enduro) models are street-legal (in many markets) or designed for off-road endurance, often with features like headlights, tail lights, and slightly different engine tuning or suspension settings.
1999 Updates:
The 1999 models likely featured refinements from previous years, such as improved suspension components, chassis updates, or engine tuning modifications. The manual will detail specific changes for this year.
Manufacturing Location:
Austria (KTM headquarters and primary manufacturing)
