🏷️ Basic Information

Make:

KTM

Model:

125 SX / 200 SX / 125 MXC / 200 MXC / 125 EXC / 200 EXC (EXE)

Engine Codes:

LC2 125, LC2 200 (Specific engine codes would vary by exact year and sub-model, refer to manual for precise identification)

👋 Introduction

Market Segment:

Performance Off-Road Motorcycles (Motocross, Enduro)

Key Competitors:

Yamaha YZ125/250, Suzuki RM125/250, Honda CR125R/250R, Kawasaki KX125/250 (for the 125 class); often compete in similar displacement classes or against larger bikes in specific disciplines.

Vehicle Strengths:

KTM's reputation for powerful two-stroke engines, lightweight chassis, advanced suspension (WP), and aggressive styling. The 125/200 models are known for their agility and strong performance in their respective classes.

Manual Value Proposition:

Provides owners and technicians with the exact same information used by KTM factory mechanics, enabling accurate diagnosis, repair, and maintenance for optimal performance and longevity. Instant download format offers immediate access.

📋 Manual Details

Applicable Models:

KTM 125 SX, 200 SX, 125 MXC, 200 MXC, 125 EXC, 200 EXC, (EXE models as applicable to the 125/200cc range)

Applicable Years:

Specific years are not explicitly stated but the manual covers the general 125/200 SX, MXC, EXC platforms, implying coverage for production years within those model lines. Crucial for users to verify within the manual for their specific model year.

Estimated Page Count:

Estimated 400-600 pages (Typical for a comprehensive factory service manual covering multiple models and engine variants)

Manual Type:

Official Factory Service / Repair / Workshop Manual

Language:

Likely English (Factory manuals are typically in the primary market language of distribution. Specific regional versions may exist.)

Delivery Format:

PDF Download

📖 Manual Coverage

Engine Mechanical:

Complete engine overhaul, disassembly, assembly, inspection, and repair of cylinder head, cylinder, piston, rings, connecting rod, crankshaft, bearings, valve train (camshaft, valves, springs, guides), oil pump, cooling system (radiator, fan, oil cooler), and lubrication system.

Fuel System:

Carburetor (disassembly, cleaning, adjustment, jetting), intake system, fuel pump (if applicable), fuel lines, fuel filter.

Ignition System:

Spark plugs, ignition coil, CDI unit, wiring, timing specifications, troubleshooting.

Transmission Drivetrain:

Gearbox disassembly, inspection, repair, clutch (operation, adjustment, replacement), chain and sprockets maintenance, output shaft, internal gear components.

Suspension:

Front fork (disassembly, oil change, seal replacement, spring inspection), rear shock absorber (inspection, rebuild procedures), linkage system maintenance.

Brakes:

Brake system service (hydraulic lines, master cylinders, calipers, brake pads, brake discs), bleeding procedure, troubleshooting.

Electrical System:

Wiring diagrams, component testing (sensors, relays, lighting), battery maintenance, troubleshooting electrical faults.

Chassis Bodywork:

Frame inspection, body panel removal/installation, seat, handlebars, footpegs, general chassis maintenance.

Routine Maintenance:

Oil change, filter replacement, chain adjustment, air filter cleaning/replacement, spark plug replacement, brake fluid flush, coolant check/replacement.

Diagnostic Procedures:

Troubleshooting guides for common issues, symptom-based diagnostics, electrical system testing.

Repair Procedures:

Step-by-step instructions for a wide range of repairs, from minor adjustments to complete engine rebuilds and component replacements.

Specifications Data:

Torque specifications, fluid capacities, wear limits, electrical component resistances, timing settings.

Depth Of Coverage:

Comprehensive: Covers everything from basic maintenance to complete engine and chassis rebuilds, including detailed diagnostic procedures.

📊 Manual Specifications

File Format:

PDF

Zoom Functionality:

Yes (Allows for detailed inspection of diagrams and text)

Printability:

Yes (Enables users to print specific sections or the entire manual)

Manual Quality:

Factory (Indicates original manufacturer documentation, ensuring accuracy and authenticity)

Binding Type:

N/A (Digital PDF format)

Paper Type:

N/A (Digital PDF format)

⚙️ Engine Specifications

Engine Type:

Liquid-cooled, two-stroke, single-cylinder (LC2 engine family)

Bore X Stroke 125:

Approximately 54 mm x 54.5 mm (Actual specifications vary by exact model year and engine variant)

Bore X Stroke 200:

Approximately 62.5 mm x 65 mm (Actual specifications vary by exact model year and engine variant)

Displacement 125:

124.8 cc (Approximate)

Displacement 200:

196 cc (Approximate)

Horsepower 125:

Approx. 35-40 hp (At crankshaft, varies by tune and model year)

Horsepower 200:

Approx. 40-45 hp (At crankshaft, varies by tune and model year)

Torque:

Specific torque figures are less commonly published for these performance-oriented bikes but are substantial for their displacement.

Carburetor Type:

Dell'Orto PHBH or similar high-performance 2-stroke carburetor (Specific model varies by year and engine)

Fuel Type:

Unleaded gasoline with a specified octane rating (e.g., 95 RON or higher), and 2-stroke engine oil premixed or via injection system (check manual for specific ratio/system).

Cooling Method:

Liquid-cooled

Lubrication System:

Premix or separate oil injection system (depending on year/model).

🔧 Transmission

Transmission Type:

6-speed manual claw-shifted gearbox

Optional Transmissions:

N/A (These models are exclusively manual transmission)

Clutch Type:

Wet multi-plate clutch

Gear Ratios:

Specific gear ratios are detailed within the manual, crucial for performance tuning and diagnostics.

Final Drive:

Chain drive

📐 Dimensions

Seat Height:

Ranging from approximately 900-950 mm (Highly model and year dependent, refer to manual for exact specification)

Dry Weight 125:

Approx. 85-90 kg (Without fuel, varies by model configuration)

Dry Weight 200:

Approx. 88-93 kg (Without fuel, varies by model configuration)

Fuel Tank Capacity:

Approx. 7-9 Liters (Varies by model and year)

🛡️ Safety Features

Safety Ratings:

N/A (Off-road motorcycles are not typically subjected to the same safety rating systems as street vehicles.)

Active Safety Features:

Powerful disc brakes (front and rear), responsive suspension for stability, effective rider control ergonomics.

Passive Safety Features:

Robust frame construction, durable body panels, appropriate lighting for visibility (where applicable for dual-sport variants like EXC).

💡 Technology Features

Infotainment Features:

N/A (These are performance-focused off-road motorcycles, not equipped with infotainment systems.)

Driver Assistance Features:

N/A (No electronic rider aids like traction control or ABS are typically found on these competition models, though some EXC models might have dual-sport features.)

Connectivity Features:

N/A

🔧 Maintenance

Oil Change Interval:

Refer to manual, but typically every 10-20 hours of riding for aggressive use. Transmissions may have separate oil change intervals.

Top End Rebuild Interval:

Highly dependent on usage, but for competitive use, piston and ring replacement might be recommended every 40-80 hours, with cylinder inspection for wear.

Chain Maintenance:

Regular cleaning, lubrication, and tension adjustment are critical for performance and longevity.

Engine Oil Type:

Specific 2-stroke oil (premix or injection) as per KTM recommendation. Transmission oil type will be specified separately (e.g., Motorex Gear Oil).

Coolant Type:

Ethylene glycol-based coolant with corrosion inhibitors, as specified by KTM (likely a specific Motorex coolant).

Brake Fluid Type:

DOT 4 or DOT 5.1 brake fluid (as specified by KTM)

Common Wear Items:

Piston rings, clutch plates, wheel bearings, steering head bearings, brake pads, fork seals are common wear items due to the demanding nature of off-road riding.

Carburetor Tuning Challenges:

Proper jetting and carburetor adjustment are critical for optimal performance and can be sensitive to altitude, temperature, and fuel quality.

📚 Vehicle History

Brand Focus:

KTM is renowned globally for its off-road racing heritage and 'Ready to Race' philosophy, excelling in Motocross, Enduro, and Rally-raid disciplines.

Model Line History:

The SX, MXC, and EXC lines represent KTM's dedication to competitive off-road motorcycles. The 125 and 200cc displacements cater to riders looking for lightweight, agile, and potent machines for competition or spirited riding.

Manufacturing Origin:

Austria (Primary manufacturing for KTM motorcycles)

🏆 Awards & Recognition

Racing Success:

KTM motorcycles, including models in the 125/200cc classes, have a long history of success in professional motocross and enduro racing championships worldwide.

Expert Reviews:

Generally praised by motorcycle publications for their performance, handling, and build quality within their respective off-road categories.

Certification:

Certified to meet emissions and safety standards of the region for which they were originally manufactured.