Model:
125 SX, 200 SX, 125 MXC, 200 MXC, 125 EXC, 200 EXC
Chassis Code:
Likely to vary by specific model (e.g., 125 EXC may have a different chassis code than 125 SX). Manual would detail these.
Engine Code:
Likely to vary by specific model. Manual would detail specific engine designations.
Segment:
Off-road, Motocross (SX), Enduro (EXC), Dual-sport/Cross-Country (MXC) competition and recreational motorcycles.
Competitors:
Yamaha YZ125, Honda CR125R, Suzuki RM125, Kawasaki KX125; Yamaha WR200, Honda XR200R, Kawasaki KDX200.
Vehicle Type:
High-performance off-road motorcycles known for their potent two-stroke engines and aggressive styling.
Brand Philosophy:
KTM's 'Ready to Race' philosophy, emphasizing performance, lightweight design, and advanced off-road capabilities.
Utility:
Essential resource for owners and technicians to perform all levels of maintenance, repair, and diagnosis.
Primary Models Covered:
KTM 125 SX, KTM 200 SX, KTM 125 MXC, KTM 200 MXC, KTM 125 EXC, KTM 200 EXC
Model Year Coverage:
2000
Estimated Page Count:
Likely 300-500+ pages, typical for a full service repair manual.
Type:
Full Service Repair Manual
Language:
English (standard for most international markets and aftermarket manuals unless specified otherwise).
Engine:
Top-end overhaul, bottom-end assembly, cylinder head, piston, crankshaft, connecting rod, lubrication system, cooling system, fuel system (carburetor details).
Transmission:
Clutch operation and adjustment, gearbox inspection and repair, shift mechanism, transmission fluid.
Suspension:
Front fork (WP USD - Upside Down) disassembly, service, and tuning; rear shock absorber service and adjustment.
Brakes:
Front and rear brake system inspection, service (pad replacement, caliper service, master cylinder service), hydraulic fluid specifications and bleeding.
Electrical:
Ignition system, lighting system, charging system (stator, regulator/rectifier if applicable), wiring diagrams, troubleshooting common electrical faults.
Fuel System:
Carburetor model identification (likely Keihin or Mikuni), jetting specifications, float bowl service, fuel lines, fuel tank inspection.
Exhaust System:
Exhaust pipe and silencer inspection, maintenance, and potential repair.
Frame And Bodywork:
Frame inspection, body panel removal and installation, seat, fuel tank, handlebars, footpegs.
Maintenance:
Oil changes, filter replacements, chain adjustment and lubrication, spark plug inspection/replacement, air filter cleaning/replacement, valve clearance checks (if applicable to the specific engine variant).
Troubleshooting:
Diagnostic procedures for common performance issues, starting problems, electrical faults, and handling issues.
Repair:
Step-by-step instructions for engine rebuilds, transmission overhauls, suspension servicing, brake caliper rebuilding, electrical component replacement.
Rebuilds:
Comprehensive guides for complete engine and gearbox rebuilds.
Refurbishment:
Guidance on restoring components and the overall motorcycle.
Depth:
Comprehensive, covering everything from basic maintenance to full engine and transmission rebuilds, including detailed technical specifications and troubleshooting.
Engine Type:
Liquid-cooled, 2-stroke, single-cylinder
Bore X Stroke 125:
54 mm x 54.5 mm (approximate, to be confirmed by manual)
Bore X Stroke 200:
62.5 mm x 65 mm (approximate, to be confirmed by manual)
Displacement 125:
125 cc (cubic centimeters)
Displacement 200:
196 cc (cubic centimeters)
Exhaust Port Power Valve:
Yes, typically KTM's patented electronically controlled power valve (ECP) system.
Horsepower 125:
Approx. 35-40 HP (at crankshaft, varies by model variant and tuning)
Horsepower 200:
Approx. 40-45 HP (at crankshaft, varies by model variant and tuning)
Carburetor Type 125:
Keihin PWK 38mm or Mikuni TM 38mm (common for this era)
Carburetor Type 200:
Keihin PWK 39mm or Mikuni TM 39mm (common for this era)
Fuel Type:
Unleaded gasoline, minimum 95 octane (RON+MON)/2)/91 AKI
2-Stroke Oil Mix Ratio:
Typically 1:30 or 1:40 (manual will specify recommended oil and ratio)
Fuel Tank Capacity:
Approx. 7-9 liters (1.8-2.4 gallons), depending on model variant.
Engine Oil Change:
Every 5-10 hours of riding, or as specified in the manual based on usage.
Air Filter Cleaning:
Every 2-5 hours of riding, critical for 2-stroke performance.
Spark Plug Inspection:
Every 10-15 hours of riding.
Chain Lubrication Adjustment:
Every 5-10 hours of riding or after wet/muddy conditions.
Top End Rebuild:
Every 40-80 hours of riding, depending on severity of use and engine condition. Manual will provide specific guidance.
Engine Oil Type:
High-quality 2-stroke synthetic or semi-synthetic oil. Manual will specify recommended brands and viscosity (e.g., Motorex).
Gearbox Oil Type:
SAE 10W/30 or 10W/40 motorcycle gear oil. Manual will specify.
Coolant Type:
Ethylene glycol-based antifreeze mixture. Manual will specify mixture ratio and type.
Brake Fluid Type:
DOT 4 hydraulic brake fluid.
Common Wear Items:
Piston rings, cylinder wear, crankshaft bearings, clutch plates, suspension seals, swingarm bearings, wheel bearings.
Power Valve Sticking:
Carbon buildup can cause the exhaust power valve to stick, affecting performance. Requires regular cleaning and lubrication as per manual.
Carburetor Tuning Sensitivity:
2-stroke carburetors can be sensitive to altitude, temperature, and humidity changes; proper jetting is crucial. Manual provides baseline settings.
Cooling System Maintenance:
Importance of maintaining proper coolant level and condition to prevent overheating, especially in demanding off-road use.
Motorsport Success:
KTM 125 and 200cc models of this era were highly competitive in national and international motocross and enduro championships, reflecting their performance capabilities.
Editorial Reviews:
Contemporary reviews often praised their powerful engines, nimble handling, and robust chassis.
Emissions:
Not applicable to competition off-road vehicles in most markets; designed for closed-course competition.
