🏷️ Basic Information

Make:

KTM

Model:

125 SX, 200 SX, 125 MXC, 200 MXC, 125 EXC, 200 EXC

Year:

2002

Engine Code 125Cc:

Likely based on a 125cc two-stroke single-cylinder, specific internal codes vary by chassis and sub-model

Engine Code 200Cc:

Likely based on a 200cc two-stroke single-cylinder, specific internal codes vary by chassis and sub-model

👋 Introduction

Category:

Off-road motorcycles (Motocross, Enduro/Cross Country)

Target Audience:

KTM owners, DIY mechanics, performance tuners, workshops specializing in off-road motorcycles.

Competitors 2002:

Yamaha YZ125/YZ250, Honda CR125R/CR250R, Suzuki RM125/RM250, Kawasaki KX125/KX250 (Motocross); Husqvarna, Beta, GasGas (Enduro)

Vehicle Strengths:

Lightweight, agile, powerful two-stroke engines, potent suspension, robust chassis, strong performance for their respective categories (SX for racing, EXC for off-road endurance).

Value Proposition:

Provides the essential technical information to keep these high-performance KTMs in peak condition, reducing reliance on expensive dealership service and enabling owners to perform their own maintenance and repairs.

📋 Manual Details

Coverage:

Comprehensive service, repair, and maintenance for KTM 125 SX, 200 SX, 125 MXC, 200 MXC, 125 EXC, 200 EXC models

Estimated Pages:

Likely 300-500 pages, typical for a full service repair manual of this era and scope

Type:

Full Service Repair Manual

Language:

English (assumed based on common availability for this market)

Format:

PDF Download

📖 Manual Coverage

Engine:

Top-end rebuild (cylinder, piston, rings, head), bottom-end rebuild (crankshaft, bearings, seals), carburetor tuning and overhaul, ignition system, cooling system (if applicable for EXC models), exhaust system.

Transmission:

Clutch operation and adjustment, gearshift mechanism, transmission disassembly and reassembly, lubrication and fluid specifications.

Chassis:

Frame inspection and repair, suspension (forks, shock absorber) service and rebuild, wheel and hub maintenance, steering system overhaul, brake system (hydraulic front and rear), controls (handlebars, levers, cables).

Electrical:

Wiring diagrams, lighting system, ignition coil, stator, regulator/rectifier (if equipped), battery maintenance, troubleshooting common electrical faults.

Bodywork:

Plastic panel removal and installation, seat, fuel tank, fenders, graphics.

Maintenance:

Routine inspections, oil changes (transmission), filter cleaning/replacement, chain and sprocket adjustment and lubrication, spark plug replacement, valve clearance (if applicable for specific EXC variants, though unlikely for 2-strokes).

Repair:

Engine rebuilds, suspension overhaul, brake caliper and master cylinder repair, carburetor jetting and cleaning, electrical component replacement.

Troubleshooting:

Step-by-step diagnostic procedures for common performance issues, starting problems, electrical faults, and mechanical noises.

Specifications:

Torque specifications for all fasteners, engine build specifications, tolerances, fluid types and capacities, electrical system voltages.

Depth:

Advanced diagnostic and repair procedures, full engine and transmission rebuilds, suspension servicing beyond basic maintenance.

📊 Manual Specifications

File Type:

Portable Document Format (PDF)

Searchability:

Typically text-searchable PDF, allowing for quick access to specific topics.

Quality:

High resolution scans of original factory service manual pages, suitable for printing.

Binding:

N/A (Digital Download)

Paper:

N/A (Digital Download)

⚙️ Engine Specifications

Type 125Cc:

Liquid-cooled, two-stroke, single-cylinder with Reed Valve Induction and KTM's Power Jet carburetor system.

Type 200Cc:

Liquid-cooled, two-stroke, single-cylinder with Reed Valve Induction and KTM's Power Jet carburetor system.

Bore Stroke 125Cc Approx:

Approx. 54mm x 54.5mm

Bore Stroke 200Cc Approx:

Approx. 62.5mm x 65mm

Displacement 125Cc:

124.8 cc

Displacement 200Cc:

196.1 cc

Horsepower 125Cc Approx:

30-35 HP (stock, depending on model variant)

Horsepower 200Cc Approx:

38-42 HP (stock, depending on model variant)

Torque 125Cc Approx:

17-19 lb-ft (stock)

Torque 200Cc Approx:

24-26 lb-ft (stock)

Carburetor Type:

Keihin PWK (likely 38mm for 200cc, 36mm for 125cc) with Power Jet system.

Fuel Type:

Unleaded gasoline with appropriate two-stroke oil pre-mix (typically 32:1 or 40:1 ratio, consult manual for specific recommendation).

Ignition System:

Digital CDI with dual spark plugs (on some variants for improved combustion).

🔧 Transmission

Type:

6-speed constant mesh, claw-shifted.

Optional Gearbox:

N/A (All models share a similar 6-speed gearbox configuration)

Clutch:

Hydraulic multi-plate wet clutch.

Transmission Oil:

Specific KTM gearbox oil or equivalent (e.g., Motorex Gear Oil 80W/85W). Consult manual for exact specifications and capacity.

📐 Dimensions

Wheelbase Approx:

57-58 inches (1450-1475 mm)

Seat Height Approx:

37-38 inches (940-965 mm)

Dry Weight 125Cc Approx:

205-215 lbs (93-98 kg)

Dry Weight 200Cc Approx:

215-225 lbs (98-102 kg)

Fuel Tank Capacity:

Approx. 7-8 liters (1.8-2.1 gallons)

🛡️ Safety Features

Safety Certification:

N/A (Off-road vehicles are typically not crash-tested or rated by consumer safety organizations like NHTSA or Euro NCAP in the same way as street vehicles).

Braking System:

Hydraulic disc brakes front and rear (Brembo components often used).

Suspension Damping:

Adjustable compression and rebound damping on front forks and rear shock for optimized handling and control.

Handlebars:

Fat-bar handlebars with protective grips for rider control.

Footpegs:

Wide, serrated footpegs for enhanced grip and stability.

💡 Technology Features

Infotainment System:

N/A (Dedicated off-road competition motorcycles typically do not feature infotainment systems).

Rider Aids:

N/A (No electronic rider aids such as ABS or traction control on these models).

Connectivity Features:

N/A (No onboard connectivity features).

Engine Control:

Mechanical carburetor with integrated CDI ignition control. Power valve operation is typically mechanical or vacuum-assisted, controlled by engine RPM.

🔧 Maintenance

Engine Oil Change:

Every 10-15 hours of riding or annually for transmission oil.

Air Filter Cleaning:

After every few rides, or more frequently in dusty conditions.

Chain Lubrication:

Every ride or after washing.

Spark Plug Replacement:

As needed, typically every 25-50 hours or if fouled.

Top End Rebuild:

Recommended every 40-60 hours for competitive use (piston, rings); crankshaft bearings and seals may last longer.

Transmission Oil Type:

KTM recommends specific gearbox oil or a high-quality 80W/85W motorcycle gear oil. Example: Motorex Gear Oil 80W/85W.

Coolant Type:

Ethylene glycol based antifreeze coolant with corrosion inhibitors. Refer to manual for specific type and mix ratio (typically 50/50 with distilled water).

Brake Fluid Type:

DOT 4 hydraulic brake fluid.

2-Stroke Oil Mix:

High-quality synthetic 2-stroke oil. Typical mix ratio: 32:1 or 40:1. Consult manual for specific recommendation for the lubrication system (Autolube or Pre-mix).

Common Wear Items:

Piston and rings, clutch plates, wheel bearings, steering head bearings, swingarm and linkage bearings, exhaust packing, air filter, spark plug.

Carburetor Tuning:

These models can be sensitive to jetting changes with altitude, temperature, and exhaust modifications. Proper tuning is crucial for optimal performance and engine longevity.

Suspension Seals:

Fork seals and shock seals can wear over time, leading to fluid leaks, requiring timely replacement.

Power Valve:

The automatic power valve mechanism can accumulate carbon deposits, potentially affecting engine performance. Regular cleaning is recommended.

📚 Vehicle History

Ktm Origins:

Founded in Austria in 1934, KTM initially produced tractors and later motorcycles, gaining a strong reputation in off-road racing (motocross, enduro) from the 1970s onwards.

Sx Lineage:

The SX line represents KTM's dedicated motocross competition bikes, known for their race-ready performance and aggressive styling.

Exc Lineage:

The EXC line represents KTM's enduro and cross-country competition bikes, typically featuring lighting, slightly wider gear ratios, and larger fuel tanks compared to SX models, with a focus on extended off-road capability.

Model Generation 2002:

These models are part of KTM's generation of lightweight, agile two-stroke off-road bikes that cemented the brand's dominance in various racing disciplines.

Manufacturing Location:

Austria (KTM headquarters)

🏆 Awards & Recognition

Motocross Awards:

KTM's two-stroke SX models consistently received accolades and dominated racing categories throughout the late 90s and early 2000s for their performance, handling, and build quality.

Enduro Awards:

KTM EXC models were highly regarded in enduro and cross-country racing for their ruggedness and ability to handle demanding terrain.

Magazine Reviews:

Contemporary motorcycle publications often praised these KTMs for their potent engines, advanced suspension (WP Suspension), and excellent chassis dynamics, frequently placing them at the top of their respective classes.