Model:
125 SX, 125 MXC, 125 EXC, 200 SX, 200 MXC, 200 EXC
Product Type:
Service Repair Manual
Engine Codes Implied:
LC2 125, LC2 200 (specific codes depend on sub-model and exact year, typically an internal KTM designation)
Chassis Codes Implied:
SX (Motocross), MXC (Cross-Country/Enduro), EXC (Enduro) - specific chassis codes (e.g., EXC-F, SXS) may vary and are not explicitly detailed in the product name but are covered by the broad model designations.
Target Audience:
KTM owners, independent motorcycle repair shops, enthusiasts performing their own maintenance and repairs.
Competitive Advantage Manual:
Provides official, factory-level detail for a specific range of KTM off-road models, crucial for maintaining performance and longevity.
Competitors To Manual:
Haynes, Clymer manuals (often less detailed or based on general knowledge rather than factory data).
Key Manual Features:
Comprehensive engine rebuild procedures, detailed electrical diagrams, specific torque values, troubleshooting guides.
Production Years Covered:
1999, 2000, 2001, 2002, 2003
Model Variants Covered:
125 SX, 125 MXC, 125 EXC, 200 SX, 200 MXC, 200 EXC
Geographic Coverage:
Global (assuming standard European/North American specifications for these models)
Estimated Page Count:
Estimated 300-500 pages (typical for comprehensive service manuals of this era)
Manual Type:
Official Factory Service Repair Manual
Language:
English (Standard for most downloadable manuals, though original may have had multiple languages)
Engine Mechanical:
Complete engine teardown, assembly, rebuild, including cylinder, piston, crankshaft, connecting rod, bearings, seals, gaskets, valves (if applicable, though these are typically 2-stroke), lubrication system.
Fuel System:
Carburetor overhaul (Mikuni VM Series common), jetting, fuel lines, fuel tank.
Ignition System:
CDI ignition, stator, coil, spark plug specifications, timing.
Exhaust System:
Expansion chamber, muffler maintenance, mounting.
Cooling System:
Liquid cooling system maintenance (radiator, hoses, water pump, coolant specifications).
Transmission:
Gearbox disassembly and assembly, clutch operation (wet multi-plate), gear ratios, shift mechanism, transmission fluid type and capacity.
Chassis Components:
Frame inspection and repair, suspension (front forks - WPUSD/USD types common, rear shock - WP PDS common), steering system, swingarm, wheel bearings, linkage (if applicable).
Brakes:
Hydraulic disc brakes (front and rear), brake caliper service, master cylinder overhaul, brake fluid type (DOT 4 common), bleeding procedures.
Electrical System:
Wiring diagrams, battery maintenance, lighting, switches, fuses (if applicable to engine start/kill circuits).
Routine Maintenance:
Oil changes (gearbox), chain adjustment, air filter cleaning/replacement, spark plug checks, brake fluid checks, coolant level checks.
Disassembly Assembly:
Step-by-step instructions for complete engine and chassis component removal and installation.
Troubleshooting:
Diagnostic procedures for common performance issues, starting problems, and mechanical failures.
Rebuilding:
Detailed instructions for engine top-end and bottom-end rebuilds, carburetor rebuilds, suspension fork rebuilds.
Torque Specifications:
All critical fasteners and component torque values specified for proper assembly.
Diagnostic Capability:
Advanced diagnostics, including component testing and performance issue root cause analysis.
Rebuild Depth:
Complete motorcycle rebuild, from engine internals to chassis and suspension overhauls.
Detail Level:
Detailed exploded views, diagrams, and step-by-step instructions with specifications.
Engine Type 125:
Liquid-cooled, 2-stroke, single-cylinder (2-stroke power valve system typical)
Bore Stroke 125:
Approx. 54 mm x 54.5 mm (verify for specific model year variant within manual)
Displacement 125:
125 cc (approximate, actual may vary slightly)
Engine Type 200:
Liquid-cooled, 2-stroke, single-cylinder (2-stroke power valve system typical)
Bore Stroke 200:
Approx. 64 mm x 62.5 mm (verify for specific model year variant within manual)
Displacement 200:
200 cc (approximate, actual may vary slightly)
Horsepower 125:
Approx. 30-35 HP (stock, varies by model variant and tuning)
Horsepower 200:
Approx. 35-40 HP (stock, varies by model variant and tuning)
Carburetor Type:
Mikuni VM Series (e.g., VM28/29 or similar, size varies by model)
Fuel Type:
Unleaded gasoline, typically 95-98 RON (octane rating), with 2-stroke oil pre-mix (ratio specified in manual, typically 1:40 or 1:50).
Ignition Type:
CDI (Capacitor Discharge Ignition)
Transmission Type:
6-speed constant mesh sequential gearbox
Clutch Type:
Wet multi-plate clutch
Gear Ratios:
Specific gear ratios for each model and year will be detailed within the manual.
Transmission Fluid Type:
Motorcycle-specific gear oil (e.g., SAE 75W/80W or 10W-40 motorcycle oil, as specified by KTM).
Transmission Fluid Capacity:
Approximately 0.6 - 0.8 liters (verify in manual).
Engine Oil Change Interval:
Typically every 10-15 hours of operation or annually, as per KTM recommendations. Manual provides precise intervals.
Air Filter Cleaning:
Recommended before every ride or after dusty conditions. Manual will specify detailed cleaning/oiling procedure.
Spark Plug Check Interval:
Inspect every 10-15 hours, replace as needed. Manual specifies plug type and gap.
Chain Lubrication Adjustment:
Lubricate every 500-800 km, adjust tension regularly (check before each ride for off-road use). Manual provides specifications.
Coolant Type:
Antifreeze/coolant mixture (typically 50% distilled water and 50% ethylene glycol based coolant). Manual specifies type and concentration.
Common Wear Items:
Piston rings, piston, clutch plates, wheel bearings, swingarm bearings, fork seals.
Potential Issues 125 200 2 Stroke:
Carburetor jetting sensitivity, power valve sticking if not maintained, premature wear on piston/rings with improper lubrication or usage.
Suspension Maintenance Need:
WP suspension components (common on KTMs of this era) require regular service (oil changes, seal replacement) to maintain performance.
Brand Focus:
KTM AG is an Austrian manufacturer renowned for its off-road racing motorcycles, often nicknamed 'Ready to Race'.
Evolution 125 200 Range:
These models represent KTM's successful entry and refinement of smaller displacement off-road bikes in the late 90s and early 2000s, evolving from earlier designs with improved suspension, engines, and chassis.
Production Era:
These specific years (1999-2003) cover a significant period for these displacement classes in KTM's lineup, before major redesigns occurred.
Manufacturing Location:
Austria (primary production for KTM)
