Model:
125 SX, 125 MXC, 125 EXC, 200 SX, 200 MXC, 200 EXC
Model Years Covered:
1999, 2000, 2001, 2002, 2003
Product Type:
Repair Service Manual
Segment:
Performance Off-Road Motorcycles (Motocross and Enduro)
Brand Focus:
KTM, known for its 'Ready to Race' philosophy and strong off-road heritage.
Key Competitors:
Yamaha YZ125, Honda CR125R, Suzuki RM125, Kawasaki KX125, Husqvarna WR125.
Vehicle Focus:
High-performance, lightweight, agile off-road machines designed for competitive use.
Manual Value Proposition:
Provides essential technical data and procedures for owners and mechanics to maintain and repair these specialized off-road motorcycles.
Primary Coverage:
Repair, Maintenance, Troubleshooting, Specifications
Model Specific Coverage:
KTM 125 SX, 125 MXC, 125 EXC, 200 SX, 200 MXC, 200 EXC
Estimated Page Count:
Variable (PDFs can vary, but comprehensive service manuals for this era typically exceed 200 pages)
Type:
Service/Repair Manual
Language:
English (standard for most imported service manuals of this era)
Engine:
Detailed disassembly, assembly, inspection, and repair of the 125cc and 200cc two-stroke engines, including top-end, bottom-end, lubrication, cooling, and fuel/ignition systems.
Transmission:
Service and repair of the gearbox, clutch assembly, shifting mechanisms, and associated components.
Suspension:
Front fork (WP Suspension) and rear shock absorber (WP Suspension) service, including seal replacement, oil changes, and tuning adjustments. Cover both standard and potentially adjustable models.
Brakes:
Front and rear brake system service, including hydraulic caliper overhaul, master cylinder service, brake pad replacement, fluid bleeding, and disc inspection.
Electrical System:
Wiring diagrams, component testing (ignition, lighting, charging system), troubleshooting of electrical faults, and component identification.
Fuel System:
Carburetor disassembly, cleaning, adjustment, and troubleshooting (likely Keihin or Mikuni depending on specific model variant). Fuel tank and petcock service.
Cooling System:
Radiator maintenance, coolant replacement, hose inspection, and thermostat (if applicable) service.
Exhaust System:
Inspection and maintenance of the expansion chamber and silencer.
Frame And Bodywork:
Inspection, maintenance, and repair of the frame, subframe, plastics, seat, and handlebars.
Routine Maintenance:
Oil changes, filter replacements, spark plug service, chain adjustment, tire pressure checks, and general inspection points.
Engine Rebuild:
Complete engine disassembly and reassembly, piston and cylinder replacement, crankshaft bearing service, seal replacement.
Troubleshooting Guides:
Diagnostic procedures for common performance issues, starting problems, and system failures.
Torque Specifications:
Detailed torque values for all critical fasteners throughout the vehicle.
Special Tools:
Identification and usage of specialized tools required for specific repair procedures.
Depth Level:
Comprehensive, covering from basic owner maintenance to complex engine and chassis overhauls.
Diagnostic Capability:
Advanced diagnostic information for identifying and resolving mechanical and electrical faults.
Repair Procedures:
Step-by-step instructions for component removal, repair, and installation.
Engine Type:
Two-Stroke, Single Cylinder
Displacement 125:
Approximately 124-125cc
Displacement 200:
Approximately 193-200cc
Bore X Stroke 125:
Varies slightly by year and model, e.g., 54 x 54.5 mm (typical for 125cc)
Bore X Stroke 200:
Varies slightly by year and model, e.g., 62.5 x 65 mm (typical for 200cc)
Cooling System:
Liquid-Cooled
Ignition System:
Digital CDI (Capacitor Discharge Ignition)
Carburetor Type:
Keihin PWK (e.g., 36mm) or Mikuni TMX (depending on specific model and market)
Power Delivery:
Aggressive, 'on-the-pipe' powerband characteristic of high-performance two-strokes.
Horsepower 125:
Approx. 35-38 HP (stock)
Horsepower 200:
Approx. 40-43 HP (stock)
Fuel Type:
Unleaded gasoline with two-stroke oil premix (typically 50:1 ratio, check manual for specifics).
Fuel Capacity:
Typically 7-9 liters (approx. 1.8-2.4 US gallons)
Frame Type:
Chromoly Steel Trellis Frame
Front Suspension:
WP Upside-Down (USD) Conventional Fork (e.g., 43mm or 48mm diameter depending on model year/variant)
Rear Suspension:
WP PDS (Progressive Damping System) Monoshock with Linkage
Front Brake:
Hydraulic Disc (e.g., 260mm)
Rear Brake:
Hydraulic Disc (e.g., 220mm)
Front Tire Size:
80/100-21 (typical for off-road)
Rear Tire Size:
100/90-18 or 110/90-18 (typical for off-road)
Dry Weight 125:
Approx. 90-95 kg (198-210 lbs)
Dry Weight 200:
Approx. 95-100 kg (210-220 lbs)
Safety Ratings:
N/A (Off-road motorcycles are not subject to DOT or NHTSA safety ratings in the same way as street vehicles).
Active Safety:
Powerful brakes, agile handling, good rider ergonomics for control.
Passive Safety:
Sturdy frame construction, durable components, rider protection equipment (helmet, gear) is essential and assumed.
Oil Change Engine:
Every 10-15 hours of riding or as recommended in the manual for transmission/clutch lubrication.
Air Filter Cleaning:
After every few rides, especially in dusty conditions. Detailed cleaning and re-oiling procedure in manual.
Spark Plug Replacement:
Every 30-50 hours of riding, or as needed based on performance checks.
Piston Ring Replacement:
Every 50-100 hours of riding, or based on compression testing and manual recommendations for top-end rebuilds.
Suspension Service:
Fork oil change every 20-40 hours, fork seal replacement as needed based on leakage. Rear shock service per manual recommendations.
Coolant:
Mixture of distilled water and ethylene glycol-based antifreeze (50/50 mix typically), specific type detailed in manual.
Brake Fluid:
DOT 4 hydraulic brake fluid (check manual for precise type).
Transmission Oil:
SAE 80 or SAE 10W/40 gear oil suitable for wet clutches (refer to manual for exact viscosity and specification).
Common Wear Items:
Clutch plates, piston rings, fork seals, wheel bearings, chain and sprockets.
Engine Specific Concerns:
Proper jetting is critical for two-stroke performance and longevity. Overheating can occur if cooling system is not maintained. Crankshaft seal failures can lead to air leaks.
Suspension Specific Concerns:
WP PDS system can be sensitive to proper setup and maintenance. Fork internals may require specialized knowledge for complex rebuilds.
Off Road Focus:
KTM has a long and successful history in off-road racing, including motocross, enduro, and Dakar Rally.
Era Significance:
This generation of KTM 125/200 models represented a significant step in performance and chassis design for the brand in the late 90s and early 2000s.
Key Changes:
Improvements in engine power delivery, chassis stiffness, suspension performance (WP components), and weight reduction compared to previous generations.
Manufacturing Location:
Austria
Production Period:
1999-2003
