Model:
125 SX, 200 SX, 125 MXC, 200 MXC, 125 EXC, 200 EXC
Model Variant:
SX (Motocross), MXC (Cross-Country), EXC (Enduro)
Generation:
Pre-KTM PowerParts era, pre-4-stroke dominance for these classes
Engine Codes:
KTM often uses internal chassis and engine codes, but for general reference, 125cc and 200cc 2-stroke engines from this era.
Market Segment:
Performance off-road motorcycles (motocross, cross-country, enduro), targeting young riders and competition enthusiasts.
Competitors:
Yamaha YZ125/250, Honda CR125R/250R, Suzuki RM125/250, Kawasaki KX125/250, Husqvarna CR125/WR250, TM Racing MX/EN 125/250.
Key Features:
Lightweight chassis, potent 2-stroke engines, advanced WP suspension (on many models), competition-focused design.
Manual Value Proposition:
Essential for owners and mechanics to maintain, diagnose, and repair these specialized off-road machines, preserving performance and longevity.
Coverage Years:
1999, 2000, 2001, 2002, 2003
Estimated Page Count:
Estimating 400-600 pages based on typical full service repair manuals for this complexity and year range.
Manual Type:
Full Service Repair Manual / Workshop Manual
Language:
English (presumed based on typical market for this product)
Engine:
Complete engine disassembly, assembly, tuning, carburetor settings, ignition system, cooling system (liquid-cooled), lubrication.
Transmission:
Clutch operation, gearbox inspection and repair, shift mechanism, final drive (chain).
Chassis:
Frame inspection and repair, subframe, suspension (forks and rear shock), steering head bearings, swingarm.
Brakes:
Hydraulic brake system (front and rear calipers, master cylinders, brake lines, pads, rotors), bleeding procedures.
Electrical:
Wiring diagrams, lighting system, ignition coil, stator, CDI unit, battery maintenance, fuse replacement, troubleshooting electrical faults.
Fuel System:
Carburetor types (likely Mikuni or Keihin), cleaning, rebuilding, jetting, fuel tank, fuel lines.
Exhaust System:
Exhaust pipe and silencer maintenance, repacking (if applicable).
Bodywork:
Plastic panel removal and installation, seat, fenders, graphics.
Maintenance:
Scheduled maintenance, oil changes, filter replacement, chain adjustment, spark plug checks, tire pressure, brake pad inspection.
Troubleshooting:
Diagnostic charts for common performance issues, starting problems, electrical faults, suspension noise.
Repair:
Detailed step-by-step instructions for engine rebuilds, transmission overhauls, suspension servicing, brake caliper rebuilding.
Adjustment:
Carburetor tuning, ignition timing, clutch lever free play, throttle cable slack, suspension sag.
Installation:
Replacement of wear items such as wheel bearings, steering head bearings, linkage bearings.
Technical Depth:
Comprehensive, covering everything from routine maintenance to full engine and gearbox rebuilds, including diagnostic procedures.
File Format:
PDF (Portable Document Format)
Print Quality:
High resolution scans, suitable for printing individual pages or the entire manual. May include vector graphics for diagrams.
Binding Type:
N/A (Digital Download - PDF)
Paper Type:
N/A (Digital Download - PDF)
Searchable Text:
Likely includes searchable text (OCR'd) for quick access to specific topics.
Engine Type:
2-stroke, single-cylinder, liquid-cooled
Bore X Stroke 125:
Approximately 54mm x 54.5mm (KTM specific, subject to minor variations by year/model)
Bore X Stroke 200:
Approximately 64mm x 60mm (KTM specific, subject to minor variations by year/model)
Displacement 125:
124.9 cc
Displacement 200:
193 cc (approximate, often cited as 193.5cc)
Power Delivery:
Aggressive, peaky powerband characteristic of 2-stroke motocross engines.
Compression Ratio:
Typically in the range of 8.0:1 to 9.5:1, depending on specific model and tune.
Ignition System:
Digital CDI (Capacitor Discharge Ignition)
Horsepower 125:
Estimated 35-40 HP at peak RPM (varies by model and tune)
Horsepower 200:
Estimated 40-45 HP at peak RPM (varies by model and tune)
Carburetor Size:
Likely 36mm or 38mm Mikuni TMX or Keihin PWK
Fuel Type:
Unleaded gasoline, minimum 91 octane (RON+MON)/2, with 2-stroke oil premix.
Oil Mixing Ratio:
Typically 40:1 or 50:1 with high-quality 2-stroke synthetic oil.
Transmission Type:
6-speed, constant mesh
Optional Transmissions:
N/A (standard configuration for these models)
Clutch Type:
Hydraulic actuated, multi-plate wet clutch
Gear Ratios:
Specific ratios vary by model (SX, MXC, EXC) and year, detailed in the manual.
Final Drive:
Chain drive, with standard sprockets sized for respective disciplines.
Frame Type:
Chromoly steel tubular frame
Wheelbase:
Approximately 1440-1470 mm (varies by model)
Seat Height:
Approximately 940-970 mm (varies by model)
Dry Weight 125:
Around 94-97 kg (approximate, varies by model)
Dry Weight 200:
Around 98-102 kg (approximate, varies by model)
Fuel Capacity:
Approximately 7-9 liters (varies by model)
Oil Change Interval:
Every 10-15 hours of riding, or annually. Transmission oil change every 20-30 hours.
Air Filter Cleaning:
Regularly, ideally after every 2-5 hours of riding, depending on conditions.
Piston Ring Replacement:
Recommended every 50-75 hours for aggressive use, or 100-150 hours for casual use.
Top End Rebuild:
Recommended every 100-150 hours (piston, rings, potentially cylinder hone).
Engine Oil Type:
KTM recommends specific 2-stroke synthetic racing oils. Common alternatives include Motorex, Bel-Ray, Castrol TTS. Refer to manual for precise grade (e.g., SAE 10W-40 for gearbox).
Transmission Oil Type:
KTM Motorex Gear Oil 10W/40 or equivalent API GL-4 specification.
Coolant Type:
Ethylene glycol based coolant with anti-corrosion additives. KTM recommends Motorex Coolant M3.0.
Common Wear Items:
Clutch plates, chain and sprockets, wheel bearings, steering head bearings, swingarm and linkage bearings, piston and rings due to high-performance nature.
Carburetion Issues:
Can be sensitive to jetting changes with altitude and temperature; requires regular cleaning and adjustment.
Suspension Seals:
Fork and shock seals can wear over time, requiring replacement to prevent oil leaks.
