This manual covers the 125 SX, 125 MXC, 125 EXC, 200 SX, 200 MXC, and 200 EXC models produced between 1999 and 2003. The brand is renowned for its off-road motorcycle expertise, and these models represent a strong offering in the 125cc and 200cc categories, building upon their competitive heritage. These liquid-cooled, 2-stroke motorcycles are engineered for performance and durability in demanding off-road conditions.
This comprehensive workshop repair service manual provides detailed, step-by-step procedures for all aspects of maintenance, repair, and troubleshooting. It includes in-depth coverage of the engine top end, fuel and cooling systems, clutch, lubrication, crankshaft and transmission, wheels, tires, final drive, brakes, suspension, steering, frame, and electrical system, complete with wiring diagrams. The manual is designed to empower owners and technicians with the knowledge to maintain vehicle reliability and performance, offering significant savings on repair costs.
Model:
125 SX, 125 MXC, 125 EXC, 200 SX, 200 MXC, 200 EXC
Model Years Covered:
1999, 2000, 2001, 2002, 2003
Engine Variants Covered:
125cc, 200cc (specific displacements not detailed in provided info, but implied by model names)
Platform Codes:
Not specified in product information
Generation Designation:
Third Generation (for SX/MXC models), Pre-Generation 3 for EXC models (as per typical KTM nomenclature for this era)
Target Audience:
KTM owners seeking DIY maintenance and repair, independent workshops
Advantages:
Comprehensive coverage, official manufacturer data, digital convenience, cost savings potential
Benefit 1:
Save significant repair costs
Benefit 2:
Maintain vehicle reliability and performance
Benefit 3:
Empower users with professional-level diagnostic and repair knowledge
Format Advantage:
Print specific sections as needed, keeping digital copy clean
Primary Coverage:
All Models/Engines/Trim/Transmissions Types
Specific Models:
KTM 125 SX, 125 MXC, 125 EXC, 200 SX, 200 MXC, 200 EXC
Estimated Page Count:
Hundreds of pages (as stated in description)
Type:
Workshop Repair Service Manual
Source:
Original Manufacturer (KTM)
Delivery Method:
Instant Download
Requirements:
Adobe PDF Reader, WinZip
Compatibility:
All Versions of Windows & Mac
Lubrication System:
Included
Crankshaft Transmission:
Included
Electrical System:
Included (with wiring diagrams)
General Information:
Included
Maintenance:
Included (detailed)
Troubleshooting:
Included
Repair Procedures:
Included (step-by-step, detailed substeps)
Diagnostics:
Included (comprehensive)
Electrical Service:
Included (combined with wiring diagrams)
Depth:
Complete Professional Technician Level
Content Quality:
Top Quality, Complete, Intact
Printability:
Full Printable
Zoom Functionality:
Zoom IN/OUT capability
Binding:
N/A (Digital Download)
Paper Quality:
N/A (Digital Download)
Illustrations:
Detailed diagrams, drawings, and photos
Instructions:
Numbered, step-by-step, easy-to-follow
Critical Information:
Notes, cautions, warnings
Identification Aid:
Bold figure numbers to match illustrations
Part Identification:
Enlarged inset views for detailed part examination
Navigation:
Numbered table of contents for fast information retrieval
Engine Type:
2-stroke, single-cylinder (typical for this era and models)
Bore Stroke 125:
Specific values not provided in product description. Likely around 54mm x 54.5mm based on historical data for 125cc KTM 2-strokes.
Bore Stroke 200:
Specific values not provided in product description. Likely around 62.5mm x 65mm based on historical data for 200cc KTM 2-strokes.
Cooling System:
Liquid-cooled
Horsepower 125:
Estimated 30-35 HP (varies by model variant - SX, EXC, MXC), specific figures not in description.
Horsepower 200:
Estimated 35-40 HP (varies by model variant), specific figures not in description.
Carburetor Type:
Keihin PWK (common for this era, specific size not listed)
Fuel Type:
Unleaded gasoline with 2-stroke oil pre-mix (specified in manual)
Ignition System:
CDI (Capacitor Discharge Ignition)
Transmission Type:
6-speed constant mesh
Clutch Type:
Hydraulically operated, multi-disc wet clutch
Gear Ratios:
Specific ratios not provided, but detailed within the manual.
Transmission Fluid Type:
Manual will specify SAE 10W/30 or 10W/40 transmission oil (specific OEM or aftermarket recommendations to be found in manual).
Wheelbase:
Varies by model (SX/MXC/EXC), specific figures not provided.
Dry Weight:
Approximately 90-100 kg (varies by model), specific figures not provided.
Infotainment System:
N/A (These are performance off-road motorcycles with minimal rider-focused technology beyond essential functions).
Driver Assistance Features:
N/A
Connectivity Features:
N/A
Oil Change Interval:
Intervals for engine oil and gearbox oil will be specified in the manual, typically requiring frequent checks and changes for performance off-road bikes.
Spark Plug Replacement:
Specific intervals will be detailed, dependent on usage and spark plug type.
Air Filter Cleaning:
Frequent cleaning and re-oiling are critical for off-road applications, with specific intervals provided.
Coolant Type:
Manual will specify appropriate coolant mixture (e.g., distilled water and ethylene glycol-based antifreeze).
Brake Fluid Type:
Manual will specify DOT 3 or DOT 4 brake fluid, depending on caliper and master cylinder specifications.
Common Wear Items:
Piston, piston rings, clutch plates, wheel bearings, fork seals are common wear items for bikes of this age and type, covered extensively in the manual.
Powervalve Maintenance:
Crucial for 2-stroke performance, the powervalve system requires regular cleaning and adjustment, which is detailed in the manual.
Brand Focus:
KTM is renowned for its off-road motorcycle expertise, particularly in motocross, enduro, and rally racing.
Era Significance:
These models represent KTM's robust offering in the 125cc and 200cc off-road categories during the late 90s and early 2000s, building on their success in competition.
Manufacturing Location:
Austria (KTM's primary manufacturing base)
Brand Reputation:
KTM models from this era were often lauded for their competitive performance and robust build in their respective classes.
Performance Ratings:
While specific awards are not detailed for these individual model years, KTM's off-road lineup consistently received positive reviews from motorcycle publications for their handling and power delivery.
